Lincoln Invertec V145S Instrukcja serwisowa i Prezentacja techniczna
®
INVERTEC V145-S
SERVICE MANUAL
LINCOLN ELECTRIC ITALIA S.r.l
Via Fratelli Canepa 8, 16010 Serrà Riccò (GE), Italia
www.lincolnelectriceurope.com
12/2005
Rev. 01
Safety
11/04
WARNING
This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair
procedures are performed only by qualified person. Read and understand this manual before operating this equipment.
Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this
equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible
for damages caused by improper installation, improper care or abnormal operation.
WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,
loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or
death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating
this equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could
cause serious personal injury, loss of life, or damage to this equipment.
ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the
electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from
the electrode, work clamp, and connected work pieces.
ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the
fuse box before working on this equipment. Ground this equipment in accordance with local electrical
regulations.
ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp
cables. If any insulation damage exists replace the cable immediately. Do not place the electrode
holder directly on the welding table or any other surface in contact with the work clamp to avoid the
risk of accidental arc ignition.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any
conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some
pacemakers, and welders having a pacemaker shall consult their physician before operating this
equipment.
CE COMPLIANCE: This equipment complies with the European Community Directives.
FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use
enough ventilation or exhaust to keep fumes and gases away from the breathing zone.
ARC RAYS CAN BURN: 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. Use suitable clothing made from durable
flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel
with suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to
the arc.
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding
area and have a fire extinguisher readily available. Welding sparks and hot materials from the welding
process can easily go through small cracks and openings to adjacent areas. Do not weld on any
tanks, drums, containers, or material until the proper steps have been taken to insure that no
flammable or toxic vapors will be present. Never operate this equipment when flammable gases,
vapors or liquid combustibles are present.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and
materials in work area can cause serious burns. Use gloves and pliers when touching or moving
materials in the work area.
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in
an environment with increased hazard of electric shock.
2
CYLINDER MAY EXPLODE IF DAMAGED: 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. Always keep cylinders in an upright position securely chained to a fixed support. Do
not move or transport gas cylinders with the protection cap removed. Do not allow the electrode,
electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders
must be located away from areas where they may be subjected to physical damage or the welding
process including sparks and heat sources.
3
Electromagnetic Compatibility (EMC)
11/04
This machine has been designed in accordance with all relevant directives and standards. However, it may still generate
electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or
other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand
this section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.
This machine has been designed to operate in an industrial area. To operate in a domestic area it is
necessary to observe particular precautions to eliminate possible electromagnetic disturbances. The
operator must install and operate this equipment as described in this manual. If any electromagnetic
disturbances are detected the operator must put in place corrective actions to eliminate these disturbances
with, if necessary, assistance from Lincoln Electric.
Before installing the machine, the operator must check the work area for any devices that may malfunction because of
electromagnetic disturbances. Consider the following.
•
Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the
machine.
•
Radio and/or television transmitters and receivers. Computers or computer controlled equipment.
•
Safety and control equipment for industrial processes. Equipment for calibration and measurement.
•
Personal medical devices like pacemakers and hearing aids.
•
Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure
that all equipment in the area is compatible. This may require additional protection measures.
•
The dimensions of the work area to consider will depend on the construction of the area and other activities that are
taking place.
Consider the following guidelines to reduce electromagnetic emissions from the machine.
•
Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take
additional precautions such as filtering the input supply.
•
The output cables should be kept as short as possible and should be positioned together. If possible connect the
work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting
the work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.
•
Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special
applications.
4
INDEX
Technical specification…………………………………………………………………………………………6
Installation and Operator Instructions………………………………………………………………………..7
Accessories…………………………………………………………………………………………………… 9
Maintenance……………………………………………………………………………………………………10
Major Component Location.…………………………………………………………………………………..12
Theory of Operation……………………………………………………………………………………………13
Troubleshooting and Repair…………………………………………………………………………………..20
Spare Parts
Electrical Diagram
34
… ………………………………………………………………………………36
Electrical Diagram reference
37
5
Technical Specifications - V145S
INPUT
Input Power at Rated Output
3.0 kW @ 100% Duty Cycle
4.4 kW @ 35% Duty Cycle
RATED OUTPUT
Output Current
Input Voltage
230 V ± 15%
Single Phase
Duty Cycle
Frequency
50/60 Hertz (Hz)
Output Voltage
(Based on a 10 min. period @ 40°C)
100%
35%
105 A
145 A
24.2 Vdc
25.8 Vdc
120 A
145 A
OUTPUT RANGE
24.8 Vdc
25.8 Vdc
(Based on a 10 min. period @ 20°C)
100%
60%
Maximum Open Circuit Voltage
75 Vdc (CE model)
12 Vdc (CE 12V model)
12 Vdc (AUSTRALIA model)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Type of Plug
Fuse (delayed) or
Input Power Cable
SCHUKO 16 A / 250 V or
Circuit Breaker (“D” characteristic) Size
2
3 Conductor, 2.5 mm
AUSTRALIAN 15 A / 250 V
16 A
Welding Current Range
5 -145 Amps
(Included with Machine)
PHYSICAL DIMENSIONS
Height
288 mm
Width
158 mm
Length
392 mm
Operating Temperature
-10°C to +40°C
6
Weight
5.9 kg
6.4 kg (CE 12V model)
Storage Temperature
-25°C to +55°C
Installation and Operator Instructions
of the generator must also meet the following conditions:
Read this entire section before installation or operation
of the machine.
•
•
•
Location and Environment
This machine can operate in harsh environments.
However, it is important that simple preventative
measures are followed to assure long life and reliable
operation:
•
•
•
•
•
•
•
Vac peak voltage: below 410V.
Vac frequency: in the range of 50 and 60 Hertz.
RMS voltage of the AC waveform: 230Vac ± 15%.
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.
Do not place or operate this machine on a surface
with an incline greater than 15° from horizontal.
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.
Output Connections
TM
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
(MMA) or TIG welding.
Stick Welding (MMA)
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.
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 ¼
turn clockwise. Do not over
tighten.
Duty Cycle
The duty cycle of a welding machine is the percentage of
time in a 10 minute cycle at which the welder can
operate the machine at rated welding current.
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 (+).
Example: 35% duty cycle:
TIG Welding
Welding for 3.5 minutes.
This machine does not include a TIG torch necessary for
TIG welding, but one may be purchased separately.
Refer to the accessories section for more information.
Most TIG welding is done with DC(-) polarity shown
here. If DC(+) polarity is necessary switch the cable
connections at the machine.
Break for 6.5 minutes.
Refer to the Technical Specification section for more
information about the machine rated duty cycles.
Input Supply Connection
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 ¼ turn
clockwise. Do not over
tighten. Finally, connect
the gas hose to the gas regulator on the cylinder of gas
to be used.
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 amount of power available from 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.
This machine is designed to operate on engine driven
generators as long as the 230Vac auxiliary can supply
adequate power as indicated in the technical
specification section of this manual. The auxiliary supply
VRD: Voltage Reduction Device
This machine is provided by an internal VRD (Voltage
Reduction Device) circuitry: this device reduces the
voltage at the output leads. The VRD is automatically
7
enabled / disabled by the machine. The factory default
voltage is:
V145-S CE:
V145-S CE (12V):
V145-S AUSTRALIA:
Controls and Operational Features
A.
Output Current
Knob:
Potentiometer used
to set the output
current used during
welding, from 5A to
145A.
B.
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.
75 Vdc
12 Vdc
12 Vdc
Refer to the section below for more details.
Auto Adaptive Arc Force (with MMA
welding)
During MMA welding is activated the function Auto
Adaptive Arc Force that increases temporary the output
current, used to clear intermittent connections between
the electrode and the weld puddle that 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 it is calculated in real time by the
microprocessor where are also mapped the Arc Force
levels. The control measure in each instant the output
voltage, compare with the mapped levels and it
determines the amount of the peak of current to apply;
that value is enough to breaks the metal drop that is
being transferred from the electrode to the workpiece as
to guarantee the arc stability, but not too high to avoid
spatters around the welding puddle. That means:
•
Electrode / workpiece sticking prevention, also with
low current values.
•
Spatters reduction.
•
Soft Stick: For a welding with a low spatter
presence.
•
Crisp Stick: For an aggressive welding, 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.
•
C.
The welding operations are simplified and the welded
joins looks better, also if not brushed after the welding.
This feature is available in the Soft Stick and Crisp
Stick operating modes and can be selected by the
operator and it allows to weld with the characteristics
more suitable at the electrode type and welding
conditions. The Crisp Stick feature also increases the
Hot Start action, facilitating the arc striking.
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.
D.
Power On/Off & VRD (Voltage Reduction Device)
LEDs: These LEDs (one green and one red)
operates as described in the table below:
LED status
Function
Green
Red
ON
OFF
The machine is turned ON.
With the MMA welding are also enabled the following
features:
•
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.
OFF
ON
VRD ON condition: The machine
is at idle (no-welding time) and
the VRD device is enabled. No
current at the output leads; the
voltage has reached a value
under the VRD limit.
The machine is turned ON.
VRD OFF condition: A welding is
running and the VRD device is
disabled. Presence of current at
the output leads, the voltage
value may be over the VRD limit.
Refer to the section below for more details.
This permanent LED condition,
showed at idle (no-welding time),
indicates a machine damage.
8
OFF
OFF
ON
ON
fan will turn ON only when a weld is started and
it will continue to run whenever the machine is
welding. If the machine doesn’t weld for more
than five minutes, the fan will turn OFF.
The machine is turned OFF
and/or the input cord could be
disconnected from the mains.
ERROR condition: With the
Power Switch turned ON and the
input cord properly connected to
a “live” main supply, this LED
condition indicates a machine
damage.
ERROR condition: This LED
condition indicates a machine
damage.
Maintenance
WARNING
For any maintenance or repair operations it is
recommended to contact the nearest technical service
center or Lincoln Electric. Maintenance or repairs
performed by unauthorized service centers or personnel
will null and void the manufacturers warranty.
E.
Positive Quick Disconnect: Positive output
connector for the welding circuit.
The frequency of the maintenance operations may vary
in accordance with the working environment. Any
noticeable damage should be reported immediately.
F.
Negative Quick Disconnect: Negative output
connector for the welding circuit.
•
Check cables and connections integrity. Replace, if
necessary.
•
Keep clean the machine. Use a soft dry cloth to
clean the external case, especially the airflow inlet /
outlet louvers.
G. Power Switch: It
turns ON / OFF
the input power to
the machine.
WARNING
Do not open this machine and do not introduce anything
into its openings. Power supply must be disconnected
from the machine before each maintenance and service.
After each repair, perform proper tests to ensure safety.
H.
Input cable: This
machine is
provided with a
plugged input
cord. Connect it
to the mains.
I.
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 in different
modes, it depends by the machine type and by the
selected weld:
•
V145-S CE (STICK mode): When the machine
is turned ON the fan will turn ON. The fan will
continue to run whenever the machine is
welding. If the machine doesn’t weld for more
than five minutes, the fan will turn OFF.
•
V145-S CE (TIG mode), V145-S CE (12V) and
AUSTRALIA (STICK and TIG modes): When
the machine is turned ON the fan is OFF. The
Accessories
KIT-140A-16-3M
Welding kit cables (3m, 16mm2).
KIT-140A-25-5M
Welding kit cables (5m, 25mm2).
W0400062A
TIG torch with tap, 4m.
.
2
Carrying case with accessories: Welding kit cables (3m, 16mm ), Hammer/wire brush,
Welding mask with glasses.
W7915000A
9
MAINTENANCE
INPUT FILTER CAPACITOR
DISCHARGE PROCEDURE
WARNING
1.
2.
3.
ELECTRIC SHOCK can kill
Have an electrician install and service this equipment
Turn the input power off at the fuse box before working
on equipment
Do not touch electrically hot parts
Prior to performing preventive maintenance, perform the
following capacitor discharge procedure to avoid electric
shock
4.
5.
6.
Remove input power to V145-S machine
Remove secondary case
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.
Locate the two terminals DC+ and DC – on the input
board. See Figure 1
Use electrically insulate 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.
Check the voltage across the two terminals. Voltage
should be zero. If any voltage remains, repeat this
procedure.
Fig.1
DC -
DC +
10
ROUTINE MAINTENANCE
THERMAL PROTECTION
1.
Thermal detection device protect the machine from
excessive
operating
temperatures.
Excessive
temperatures may be caused by a lack of cooling air or
operating the machine beyond the duty cycle and output
rating. If excessive operating temperatures should
occur, the yellow LED will light and the detection device
will prevent output voltage or current.
2.
3.
Keep the welding area around the machine clean
and free of combustible materials. No debris should
be allowed to collect which could obstruct air flow to
the machine
Every 6 months the machine should be cleaned with
a low pressure and dry airstream. Keeping the
machine clean will result in cooler operation and
higher reliability.
Examine the sheet metal case for dents or
breakage. Repair the case as required. Keep the
case in good condition to insure that high voltage
parts are protected and correct spacing are
maintained. All external sheet metal screw must be
in place to ensure case strength and electrical
ground continuity.
These detection device are self-resetting once the
machine cools sufficiently. If the thermostat shutdown
was caused by excessive output or duty cycle and the
fan is operating normally, the power switch may be left
on and the reset should occur within a 15 minute period.
If the fan is not turning or the air intake louvers were
obstructed , then the power must be switched off and the
fan problem or air obstruction must be corrected.
11
MAJOR COMPONENTS LOCATION
ref. 03
ref. 05
ref. 09
ref. 10
ref. 11
secondary case
fan
input board
inverter board
control board
12
THEORY OF OPERATION
General description…………………………………………………………………………….14
Input Line Voltage, Auxiliary Voltage, Precharge…………………………………………….14
Inverter Board , Main Transformer, Output Rectifier and Choke……………………………..15
Control board…………………………………………………………………………….…… 16
Protection Circuits……………………………………………………………………………..17
IGBT operation……………………………………………………………………………… 18
Block diagram
13
Input Line Voltage, Auxiliary Voltage and Precharge
GENERAL DESCRIPTION
INPUT LINE VOLTAGE, AUXILIARY
VOLTAGE AND PRECHARGE
The Invertec V145-S is an inverter based welding power
sources that offers soft , crisp Stick and LIF TIG process.
The Invertec V145-S can be connected to a 230V single
phase input voltage.
This unit can be also connect to engine driven
generators but it must follow the below conditions:
•
•
•
Vac peak voltage: below 410V.
Vac frequency: in the range of 50 and 60 Hertz.
RMS voltage of the AC waveform: 230Vac ± 15%.
The initial power is applied to the Invertec V145-S trough
a line switch located on the back of the machine. The
voltage is after rectified by the input rectifier on input
board and the resultant DC voltage is applied at inverter
Pcb’s.
During the precharge time the DC input voltage is
applied to the filter capacitors ( located on the inverter
Pcb ) through a start resistance ( located on input board)
that limits the charge current. After this time the start
relays go closed and they by-pass the start resistance (
there are two start relays in parallel , RL1A and RL2A ).
The 230AC voltage is also applied to a auxiliary voltage
circuit, that gives the necessary low voltages ( + 15V
and +5V ) for the control board.
14
Inverter board , Main transformer, Output rectifier and Output Choke
INVERTER BOARDs, MAIN
TRANSFORMER, OUTPUT RECTIFIER
AND OUTPUT CHOKE
primary winding is redirected back to the filter capacitors
when the IGBTs are turned off. This is due to the
inductance of the transformer primary winding.
The secondary winding supplies the electrode-to-work
voltages and the resulting current.
The output current is regulated via Pulse Width
Modulation.
The control circuitry, on the inverter board , receives a
signal from the control board and regulates the output
current to the desired level.
The output rectifier receives the AC output from the main
transformer secondary winding and rectifies it to a DC
voltage level. Since the output choke is in series with the
positive leg of the output rectifier.
A filtered DC output is applied to the machine’s output
terminals.
When the input filter capacitors are fully charged they act
as power supplies for the IGBT switching circuit.
The IGBTs supply the main transformer winding with
80KHz current flow.
The inverter board also monitors the filter capacitors for
overvoltage. If this occurs, the appropriate error signal is
sent to the control board to disable the machines output
and to turn on the thermal/voltage Overload LED.
The IGBTs act as a switch assembly. This assembly
feeds the primary winding of the main transformer. When
current is pulsed through this primary winding, a
resultant current is produced on a secondary winding of
the main transformer. The DC current flow through the
15
Control board
This machine is provided by an internal VRD (Voltage
Reduction Device) circuitry: this device reduces the
voltage at the output leads. The VRD is automatically
enabled / disabled by the machine. The factory default
voltage is:
Control Board
The control board receives status and
analogue feedback from the inverter board,
input board and various sensor.
The control circuitry interprets these signals,
makes decisions and changes the machine
mode and output to satisfy the requirements
as defined by the circuitry.
The control board sends a signals to the
inverter boards to control the output current.
for V145-S CE:
for V145-S CE (12V):
forV145-S AUSTRALIA:
75 Vdc
12 Vdc
12 Vdc
For CE version,ONLY: After 5 minutes of inactivity
the OCV shut down from 75Vdc to around 12Vdc
On control board DIP SWITCHES are present for these
above settings, see pag.33
16
OVERLOAD PROTECTION
THERMAL PROTECTION
The Invertec V145-S is electrically protected from
producing higher than normal output currents. An
electronic protection circuit limits the current to within the
capabilities of the machine.
There are one thermal device located on the output
diodes heatsink;it protect the machine from excessive
operating temperature.
Excessive temperature may be caused by a lack of
cooling air or by operating the machine beyond the duty
cycle and output rating. If excessive operating
temperature should occur, the Thermal LED indicator on
the control board, will turn ON and the thermostat will
prevent output current.
The thermal protection device is self-resetting once the
machine cools sufficiently. If the shut down was caused
by excessive output or duty cycle and the fan is
operating normally, the power switch may be left on and
the reset should occur within about 15 minute period. If
the fan is not turning or the air intake louvers are
obstructed, the input power must be removed and the
fan problem or air obstruction must be corrected.
17
INSULATED GATE BIPOLAR
TRANSISTOR (IGBT) OPERATION
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.
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.
18
TROUBLESHOOTING AND REPAIR SECTION
How to use troubleshooting Guide……………………………………………………………. 20
Input Filter Capacitors discharge procedure………………………………………………….. 21
Troubleshooting Guide………………………………………………………………………… 22
Input Board Resistance Test………………………………………………………………….. 23
Inverter Board Resistence Test……………………………………………………………….. 25
Input Board Voltage Test……………………………………………………………………... 29
Inverter Board Voltage Test……………………………………………………………………..31
Control Board
…...………………………………………….33
19
HOW TO USE TROUBLESHOOTING GUIDE
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 and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
………………………………………………………………………………………………………………………………
This Troubleshooting Guide is provided to help
you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 3. PERFORM COMPONENT TESTS.
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.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEMS”.
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 three main categories: Output
Problems, Function Problems, and LED Function
Problems.
All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced
electrical wiring diagrams and schematics. Refer
to the Wiring Diagrams Section Table of
Contents to locate the appropriate diagram.
Step 2. PERFORM EXTERNAL TESTS.
The second column, labeled “CHECKS”, 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.
20
MAINTENANCE
INPUT FILTER CAPACITOR
DISCHARGE PROCEDURE
WARNING
1.
2.
3.
ELECTRIC SHOCK can kill
Have an electrician install and service this equipment
Turn the input power off at the fuse box before working
on equipment
Do not touch electrically hot parts
Prior to performing preventive maintenance, perform the
following capacitor discharge procedure to avoid electric
shock
4.
5.
6.
Remove input power to V145-S machine
Remove secondary case
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.
Locate the two terminals DC+ and DC – on the input
board. See Figure 1
Use electrically insulate 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.
Check the voltage across the two terminals. Voltage
should be zero. If any voltage remains, repet this
procedure.
Fig.1
DC -
DC +
21
LINCOLN ELECTRIC ITALIA s.r.l
TROUBLESHOOTING
V145-S
!! WARNING !!
BEFORE CONNECT POWER SUPPLY, MAKE A CAREFUL VISUAL INSPECTION
INSIDE THE MACHINE , CHECK ALL THE BOARDS AND HARNESS.
====
PROBLEMS / SYMPTOMS
GENERAL PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
=====
CHECK
RECOMMENDED COURSE
OF ACTION
THE LINE CIRCUIT BREAKER
TRIPS WHEN POWER
SWITCH
IS “ ON”
1) INPUT POWER BRIDGE
IS IN SHORT CIRCUIT
2) ELECTROLYTIC
CAPACITORS FAILURE
3) VARISTORE FAILURE
1) MULTIMETER CHECK
2) VISUAL INSPECTION AND
MULTIMETER CHECK
3) VISUALLY INSPECT
VARISTORE
1) REPLACE INPUT BOARD
2) REPLACE INVERTER
BOARD
3) REPLACE INPUT BOARD
THE MACHINE IS DEAD,
NO OUTPUT, NO FAN
1)
1) CHECK THE PHASE INPUT
VOLTAGE ON THE
MACHINE
2) CHECK THE POWER
SUPPLY
CABLE
3) CHECK THE LINE SWITCH
4) CHECK THE INPUT
BOARD
5) CHECK INVERTER
BOARD FOR VISIBLE
DAMAGE
1) RECONNECT THE
POWER
SUPPLY
2) REPLACE THE INPUT
POWER CABLE
3) REPLACE THE LINE
SWITCH
4) REPLACE THE INPUT
BOARD
5) REPLACE THE INVERTER
BOARD
2)
3)
4)
5)
THE PILOT LIGHT IS “ ON “
BUT THERE IS NO OUTPUT
AND OVERLOAD LIGHT IS
“ ON “
THERE IS NO POWER
SUPPLY ON LINE
THE POWER SUPPLY
CABLE IS INTERRUPTED
LINE SWITCH FAILURE
INPUT
BOARD
IS
DEFECT
THE INVERTER BOARD
IS DAMAGED
1) THERMAL PROTECTIONS
HAS TRIPPED
2) LOGIC CIRCUIT ERROR
ON CONTROL BOARD
1) CHECK FAN AND
1) REPLACE FAN
THERMAL PROTECTION 1A) REPLACE THERMAL
ON INVERTER BOARD
PROTECTIONS
2) CHECK CONTROL BOARD 2) REPLACE CONTROL
BOARD
===== WELDING PROBLEMS =====
THE MACHINE WELDS BUT
THERE IS NO OUTPUT
CONTROL
1)
POTENTIOMETER
FAILURE
2) THE SHUNT SCREWS
ARE
LOOSE
3) INVERTER BOARD
FAILURE
1) CHECK THE
POTENTIOMETER
2) CHECK THE SHUNT
SCREWS
3) ............................................
1) REPLACE THE
POTENTIOMETER OR
COMPLETE CONTROL
BOARD
2) TIGHTER SCREWS
3) REPLACE THE INVERTER
BOARD
THE MACHINE DOES NOT
HAVE MAXIMUM OUTPUT
1) POWER CABLES ARE
LOOSE OR IN BAD
CONDITIONS
2) THE CONTROL BOARD IS
OUT OF CALIBRATION
1)
1)
THE MACHINE HAS HIGH
WELDING OUTPUT AND NO
CONTROL
1) POTENTIOMETER
FAILURE
2) CONTROL BOARD
DAMAGED
1) CHECK THE
POTENTIOMETER
2)
.............................................
1) REPLACE
POTENTIOMETER
2) REPLACE CONTROL
BOARD
THE VRD SYSTEM DOESN’T
WORK
1)
1)
1)
2)
WRONG SETTING ON
CONTROL BOARD
CONTROL BOARD
DEFECT
2)
2)
22
CHECK ALL THE POWER
CABLES
………………..
FOLLOW VRD SETTING
INSTRUCTION ON THIS
MANUAL
…………………………..
2)
2)
REPLACE DAMAGED
CABLES
TRY TO SET AGAIN THE
CONTROL BOARD
OTHERWISE CHANGE IT
SET THE CORRECT VRD
VALUE FROM DIPSWITCHES
REPLACE CONTROL
BOARD
INPUT BOARD RESISTANCE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs
performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory
warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions
detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you
proceed.
………………………………………………………………………………………………………………………………
DESCRIPTION
This test will determine if the input board has any copper wires burned or any faulty components.
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram W05X0509
Miscellaneous tools
This procedure takes approximately 10 minutes to perform
23
TEST PROCEDURE
1.
2.
3.
4.
5.
6.
7.
Remove main input power to the Invertec V145-S
Remove secondary plastic cover, using a star screw driver
Perform the Discharge Procedure
Viasually check for burned area on the Input Board. Solder side
Check with multimeter for continuity between “AC1” to “ Point –A-” and “AC2” to “Point –B-”
Check the input rectifier bridge “D1”
Check Start resistance “R2” for 20 Ohms
AC1
AC2
D1
Input rectifier
Bridge
Point
–B-
1
Point
–A-
2
1
R2 Start Resistor =
20 ohms
24
INVERTER BOARD RESISTANCE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs
performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory
warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions
detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you
proceed.
………………………………………………………………………………………………………………………………
DESCRIPTION
This test will determine if the inverter board has any “ shorted “ or “leaky” power diodes or Insulated Gate Bipolar
Transistore.
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram X0519
Star crew driver
4 mm nut driver
This procedure takes approximately 15 minutes to perform
25
TEST PROCEDURE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Remove main input power to the Invertec V145-S
Remove secondary plastic cover, using a star screw driver
Perform the Discharge Procedure
Remove AC1 ,AC2, DC+,DC-,and flat cable from JP1, on input board
Remove the four screws at the input board corners
Remove the ground wires from the input board metal supports
Remove the input board and the two metal supports
Remove the copper flexible power cable from the inverter board shunt
Remove the bras screw ,where is also located the little white wire, from inverter board
Remove the three star screws that fix the inverter board to the primary cover
Remove the inverter board from the primary cover
Viasually check for burned area on the Inverter Board. in both sides componet and solder side
Check the IGBTs for “shorts” using the ohmmeter in test diode position, check each IGBT from Emitter to Collector.
Normal value is 0,40 Vdc in one polarity and a charging value in opposite polarity
14. Check also each device from Gate to Emitter. Normal value is 0,34 Vdc in both polarities
15. The IGBT’s of each channel are connected in parallel
NOTE: These devices will usually fail “ short” resulting in a zero or very low resistance reading. If they “open “ physical
damage should be evident
Collector
channel A
Collector
channel B
Gate
Emitter
26
Emitter
Gate
IGBT
channel A
IGBT
channel B
16. Check the Diodes D3 and D9 for “shorts” or “opens”
17. Check diode D7 but take note that some resistance ( around 27/ 28 ohms ) will be read in both polarities across
D7, because it is the snubber diode and it has connected in parallel the snubber resistors R8, R9 and R10. See the
wiring diagram X0519
D9
D7
27
D3
18. Check the output diodes for “shorts” or “opens” . Check from one central leg “Point 1” ( all the central legs of the
diodes are in connection with the heatsink ) to the big central area “ Point 2 “.
19. Check the resistence between the thermal protection terminals R24. It should be about 36 - 40 ohms
20. Check the resistance between output connections. It should be about 8,5Kohms
Output
Terminals
Point 1
( central Leg )
Point 2
R24 = PTC
28
INPUT BOARD VOLTAGE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs
performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory
warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions
detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you
proceed.
………………………………………………………………………………………………………………………………
DESCRIPTION
This test will help to 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 X0509
Screw driver
This procedure takes approximately 10 minutes to perform
29
TEST PROCEDURE
1.
2.
3.
4.
5.
6.
7.
8.
Remove main input power to the Invertec V145-S
Remove secondary plastic cover, using a star screw driver
Connect the main 230V ac to the unit and switch ON the input switch
Check with multimeter between “AC1” and “AC2” for 230Vac
Check between DC+ and DC- for 320-325 Vdc
Refer pin 8,9,15 or 16 of JP1 as a ground
Check pin 2,4 and 14 for +15Vdc
Check pin 12 for +5Vdc
AC1
AC2
DC -
DC +
JP1
Pin 17
Pin 16
Pin 1
30
Pin 2
INVERTER BOARD VOLTAGE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs
performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory
warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions
detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you
proceed.
………………………………………………………………………………………………………………………………
DESCRIPTION
This test will help to 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.
NOTE: DUE TO SAFETY REASON AND FOR PHYSICAL INVERTER POSITION IS NOT
EASY TO PERFORM THE VOLTAGE TEST,ON INVERTER BOARD FOR THIS REASON
CHECKS CAN BE DONE FROM THE INPUT BOARD JP1 CONNECTOR (see next page)
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram X0509 and X0519
Screw drivers
This procedure takes approximately 10 minutes to perform
31
TEST PROCEDURE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Remove main input power to the Invertec V145-S
Remove secondary plastic cover, using a star screw driver
Connect the main 230V ac to the unit and switch ON the input switch
Set the unit in STICK mode
Check following points on JP1 connector
Refer pin 8,16,9 or 15 as a ground
Check on pin 1 - & gt; +15Vdc means fan ON while 0(zero) Vdc means fan OFF
Check on pin 3
- & gt; 0(zero) Vdc during OCV condition
Check on pin 5 - & gt; 11,6 Vdc means the inverter is ON ( only for CE version in the first 5 minutes after activity )
while 1,5 Vdc means inverter OFF ( normal for CE 12 V version and Australia version )
Check on pin 6 - & gt; value change from 7,6 to 8,5 Vdc during reading when the inverter is ON ( only CE version ) ;
50-60 mVdc when inverter is OFF ( normal for CE12 Vdc and Australia version )
Check on pin 7 - & gt; 15 Vdc
Check on pin 11 - & gt; 5 Vdc
Check on pin 12 - & gt; 5 Vdc ( supply voltage generated on input board )
Check on pin 13 - & gt; pin not used
Check on pin 14 - & gt; 15 Vdc ( supply voltage generated on input board )
Jp1
Pin 2
Pin 1
32
CONTROL BOARD
The control board is the mind of the machine, on it there is micro processor and some other components that drive the
unit for good performances.
Control board also drives the VRD system setted for the three different type of units ( CE / CE-12V / Australia 12V ) by
the DIP SWICH SW2 following the below table:
Dip Switch number
1
2
3
4
CE version
OFF
OFF
OFF
OFF
CE 12V version
OFF
ON
ON
OFF
Australia 12V version
ON
ON
ON
OFF
Here below the difference between CE12V version and Australia 12V version :
CE 12V version
Australia 12V version
= The inverter switch ON when the resistance between electrode and piece is less than
20Kohms
= The inverter switch ON when the resistance between electrode and piece is less than
200 ohms
SW2
33
Spare Parts
02/05
Part List reading instructions
•
•
•
Do not use this part list for a machine if its code number is not listed. Contact the Lincoln Electric Service Department for
any code number not listed.
Use the illustration of assembly page and the table below to determine where the part is located for your particular code
machine.
Use only the the parts marked " X " in the column under the heading number called for in the assembly page (# indicate a
change in this printing).
SP52018/52021/52022 Rev. 1
07/03
ASSEMBLY
PAGE NAME
CODE
NO.:
52018
52021
52022
FIGURE NO.:
V145-S CE
V145-S AUSTRALIA
V145-S CE (12V)
Machine Assembly
INVERTEC V145-S CE, V145-S AUSTRALIA
A
1
2
1
Figure A
34
Figure A: Machine Assembly
Item
1
2
3
4
5
6
7
7
8
9
10
11
12
13
14
Description
Front Panel with Front Nameplate
Primary Case (dx) with Side Nameplate (dx)
Secondary Case (sx) with Side Nameplate (sx)
Rear Panel
Fan, 120x38mm
Cable Clamp
Input Cable CE
Input Cable Australia
Input Switch
Input P.C. Board
Inverter P.C. Board
Control P.C. Board
Knob Kit
Output Dinse Connector
Carrying Strap
Part Number
W95X0521R
W95X0523R
W95X0522R
W95X0524R
W7200004R
W8460038R
W78X0248R
W78X0369R
W7516224R
W05X0509R
W05X0519R
W05X0510R
W8700022R
W7600024R
W92X0543R
35
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
X
X
X
X
X
X
X
Ÿ
X
X
X
X
X
X
X
2
X
X
X
X
X
X
Ÿ
X
X
X
X
X
X
X
X
3
4
5
6
1
W ET
IR IE
4
2
36
1
4P S
IN
4
1
2
1PS
6 IN
PBC NET RCV YN ME IN SQEC
C ONCO AIT U BR G E UNE
(V WDF O C MOETS EO P .B AD
IE E R M O P NN ID F .C OR)
R B NCBE
IB O A L
T ISE C BE
W TD AL
MCINSCD 5201 A D52022
AH E OE 8 N
BU W EM UT D
L E IR: ONE
INU INUT RNTM U TD
P T DCO : O O NE
MCINSCD 52022
AH E OE
BU W ENTM U TD
L E IR: O O NE
INU INUT RM UT D
P T DCO : ONE
230V c
a
50/60 H
z
L
N
Y
/G
O/OFS IT H
N F WC
5
BU
LE
1
5
1
6
BO N
RW
BU
LE
BA K A2A
LC C
BA K A 1
L C CA
B O N A1
RW C
BU
LE
A2
C
Y
/G
P3
E
BO N
RW
FN
A
INU INUT R
P T DCO
W 09
58X 5 9
(S HMT : X 5 9
C E AIC 0 0 )
INU B AD
P T OR
W 00
05X 5 9
PR PR PR
W2 W5 W4
Y
/G
JP
1
P
E
PR
W1
JP
1
Y
/G
(S HMT : X 5 0)
C E AIC 0 1
CNR LB AD
OT O OR
W 01
05X 5 0
D+ RD
C E
LC
DC BA K
D+
C
P
E
BA K DLC C
RD
E
JP
2
WIT
HE
RD
E
BA K
LC
(S HMT : X 5 9)
C E AIC 0 1
INE T RB AD
VRE OR
W 01
05X 5 9
JP
1
N
1
P
1
SUT
HN
-
+
Electrical Schematic
WIT
HE
RD
E
BA K
LC
Wiring Diagram Reference Number:
•
X0548
Block diagram V145-S
•
X0509
Input Board V145-S
•
X0519
Inverter Board
•
X0510
Control Board
37