SVM183-A All manuals and user guides at all-guides.com July, 2008 ® INVERTEC V155-S For use with machines having Code Numbers: 11326; 11327 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...
Page 2
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.
SAFETY All manuals and user guides at all-guides.com ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
Page 4
All manuals and user guides at all-guides.com i i i i i i WELDING and CUTTING S S A A F F E E T T Y Y CYLINDER may explode i i i i i i SPARKS can if damaged. cause fire or explosion.
Page 5
SAFETY All manuals and user guides at all-guides.com PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
Page 6
(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.
Page 7
All manuals and user guides at all-guides.com SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturerʼs recommen-...
Page 8
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS - All manuals and user guides at all-guides.com RETURN TO MAIN INDEX Page Safety ................i-iv Installation .
Page 9
TABLE OF CONTENTS - INSTALLATION SECTION All manuals and user guides at all-guides.com Installation ................A-1 Technical Specifications .
Page 10
INSTALLATION All manuals and user guides at all-guides.com INPUT - SINGLE PHASE ONLY Input Voltages / 50 /60 Hz. Max. Input Current at rated Output Input Power at Rated Output 100% 100% 120Vac ± 10% 34 A 2.2kw 3.0kw 230Vac ± 10% 33 A 3.0kw 5.0kw...
INSTALLATION All manuals and user guides at all-guides.com TILTING Read entire installation section before starting Place the machine directly on a secure, level surface. installation. Do not place or operate this machine on a surface with an incline greater than 15° from horizontal. The SAFETY PRECAUTIONS machine may topple over if this procedure is not fol- lowed.
INSTALLATION All manuals and user guides at all-guides.com INPUT POWER CONNECTION WARNING Check the input voltage, phase, and frequency sup- plied to this machine before turning it on. • Failure to wire as instructed may cause personal The allowable input voltage is indicated in the techni- injury or damage to equipment.
All manuals and user guides at all-guides.com INSTALLATION ARFU (Auto-Restore Fuse) FIGURE A.1 The dual input voltage machine is provided with the ARFU device. It operates only when the input is con- nected to the 120Vac mains and protects from input overcurrent.
Page 14
All manuals and user guides at all-guides.com INSTALLATION REPLACEMENT QUICK DISCONNECT PLUG (FOR STICK ELECTRODE CABLE) The INVERTEC® V155-S comes with a factory assem- bled stick electrode holder, cable and Twist-Mate™ adapter plug. If a replacement cable is ever needed a K852-25 Twist-Mate™...
Page 15
TABLE OF CONTENTS - OPERATION SECTION All manuals and user guides at all-guides.com Operation ................B-1 Safety Precautions .
Page 16
THEORY OF OPERATION All manuals and user guides at all-guides.com GENERAL DESCRIPTION Read and understand this entire section before operating your machine. SAFETY INSTRUCTIONS The INVERTEC® V155-S is an industrial 155 amp arc welding power source which utilizes single phase input power, to produce constant current output.
THEORY OF OPERATION All manuals and user guides at all-guides.com CONTROLS AND OPERATIONAL If the Yellow LED illuminates, and the Red and Green FEATURES 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.
Page 18
THEORY OF OPERATION All manuals and user guides at all-guides.com 5. Positive Quick Disconnect: Positive output con- AUTO ADAPTIVE ARC FORCE (WITH STICK WELDING) nector for the welding circuit. 6. Negative Quick Disconnect: Negative output con- The Auto Adaptive Arc Force function is activated dur- nector for the welding circuit.
Page 19
TABLE OF CONTENTS - ACCESSORIES SECTION All manuals and user guides at all-guides.com Accessories ................C-1 Factory Installed Options .
ACCESSORIES OPTIONAL ACCESSORIES All manuals and user guides at all-guides.com CABLE PLUGS AND COMPATIBLE EQUIPMENT K852-25 - Cable Plug Kit attaches to welding cable to Factory Installed provide quick disconnect from machine. TIG Torch Parts Kits - Parts kits are available for the Electrical Holder and Cable Assembly PTA-9FV and PTA-17 TIG torch.
120VAC. If either device opens, or Lincoln Electric. Maintenance or repairs performed the Thermal LED on the front panel will turn ON. See by unauthorized service centers or personnel will null the Operarion Section or the Troubleshooting Section and void the manufacturers warranty.
MAINTENANCE All manuals and user guides at all-guides.com MAJOR COMPONENT LOCATIONS 1. Front Panel 10. Inverter P.C. Board 2. Right Case Side 11. Control P.C. Board 3. Left Case Side 12. Knob 4. Rear Panel 13. Output Connector 5. Fan 14.
Page 24
NOTES All manuals and user guides at all-guides.com INVERTEC® V155-S...
TABLE OF CONTENTS-THEORY OF OPERATION SECTION All manuals and user guides at all-guides.com Theory of Operation ..............E-1 General Description .
THEORY OF OPERATION All manuals and user guides at all-guides.com FIGURE E.2 — GENERAL DESCRIPTION GENERAL DESCRIPTION The INVERTEC® V155-S is rated at 155 amps, 16.2 The INVERTEC® V155-S is an industrial 155 amp arc volts, at 30% duty cycle on a ten minute basis. It is welding power source which utilizes single phase input capable of higher duty cycles at lower output currents.
THEORY OF OPERATION All manuals and user guides at all-guides.com FIGURE E.3 — INPUT BOARD INPUT BOARD An improper input voltage would be recognized dur- The Input Board includes the following circuits: ing this time and an input error sent to the Control Board.
THEORY OF OPERATION All manuals and user guides at all-guides.com FIGURE E.4 — MAIN INVERTER BOARD MAIN INVERTER BOARD - Output Circuit: The output diodes and the output The Inverter Board includes the following circuits: choke rectify and filter the current from the secondary of the main transformer to make it acceptable for - Inverter Circuit: Through the use of Insulated Gate welding.
THEORY OF OPERATION All manuals and user guides at all-guides.com FIGURE E.5 — CONTROL BOARD CONTROL BOARD The Weld Controler also responds to thermal and input The Control Board receives status and analogue sig- errors to shut down the machine output. The error nals from the inverter board, input board and various information is then displayed by the three LEDʼs on the sensors and feeds this information to the Weld...
THEORY OF OPERATION All manuals and user guides at all-guides.com FIGURE E.6 – IGBT OPERATION POSITIVE VOLTAGE APPLIED GATE GATE SOURCE SOURCE BODY REGION BODY REGION DRAIN DRIFT REGION DRAIN DRIFT REGION BUFFER LAYER BUFFER LAYER INJECTING LAYER INJECTING LAYER DRAIN DRAIN B.
THEORY OF OPERATION All manuals and user guides at all-guides.com Figure E-7 MINIMUM OUTPUT m/sec m/sec MAXIMUM OUTPUT m/sec m/sec PULSE WIDTH MODULATION MAXIMUM OUTPUT By holding the gate signals on for 31 microseconds The term PULSE WIDTH MODULATION is used to and allowing only 2 microseconds of off time during describe how much time is devoted to conduction in the 33 microsecond cycle, the output is maximized.
Page 32
NOTES All manuals and user guides at all-guides.com INVERTEC® V155-S...
Page 33
TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR All manuals and user guides at all-guides.com Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .
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.
Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding CAUTION bag. This will prevent further damage and allow prop- er failure analysis.
Page 36
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...
Page 37
Replace if needed. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. INVERTEC® V155-S...
Page 38
2. Check Control Board conections. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. INVERTEC® V155-S...
Page 39
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.
TROUBLESHOOTING & REPAIR All manuals and user guides at all-guides.com CASE COVER REMOVAL PROCEDURE (CONTINUED) FIGURE F.1 – CASE COVER SCREW LOCATIONS Five Screws Three Screws Ground PROCEDURE 5. Using a phillips screwdriver, remove the three 1. Disconnect power to the INVERTEC® V155-S. screws securing the Inverter board to the right side 2.
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.
Page 42
TROUBLESHOOTING & REPAIR F-10 F-10 All manuals and user guides at all-guides.com INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED) FIGURE F.2 – CAPACITOR DISCHARGE LOCATIONS CAPACITOR TERMINALS (4 places) WARNING 4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This resis- ELECTRIC SHOCK can kill.
Page 43
TROUBLESHOOTING & REPAIR F-11 F-11 All manuals and user guides at all-guides.com INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED) FIGURE F.4 – CAPACITOR DISCHARGE LOCATIONS INVERTER BOARD Black 8. Remove the right side cover per Case Cover Removal Procedure steps 5 thru 7. 9.
Page 44
NOTES F-12 F-12 All manuals and user guides at all-guides.com INVERTEC® V155-S...
Page 45
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.
TROUBLESHOOTING & REPAIR F-14 F-14 All manuals and user guides at all-guides.com INPUT BOARD RESISTANCE TEST (CONTINUED) FIGURE F.5 – INPUT BOARD TEST POINTS – PROCEDURE 1. Disconnect power to the INVERTEC® V155-S. 2. Perform the Case Cover Removal Procedure. 3.
Page 47
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.
TROUBLESHOOTING & REPAIR F-16 F-16 All manuals and user guides at all-guides.com INVERTER BOARD RESISTANCE TEST (CONTINUED) FIGURE F.6 – INVERTER BOARD TEST POINTS IGBT Collector Emitter Gate Channel A Channel A INVERTER BOARD IGBT Gate Collector Emitter channel B Channel B PROCEDURE The IGBTʼs of each channel are connected in par-...
Page 49
TROUBLESHOOTING & REPAIR F-17 F-17 All manuals and user guides at all-guides.com INVERTER BOARD RESISTANCE TEST (CONTINUED) FIGURE F.7 – INVERTER BOARD TEST POINTS Output Collector Terminals Channel A INVERTER BOARD Black Point 1 (center leg) R24 = PTC Collector Point 2 (solder pad) Channel B...
Page 50
NOTES F-18 F-18 All manuals and user guides at all-guides.com INVERTEC® V155-S...
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.
Page 52
TROUBLESHOOTING & REPAIR F-20 F-20 All manuals and user guides at all-guides.com INPUT BOARD VOLTAGE TEST (CONTINUED) FIGURE F.8 – INPUT BOARD TEST POINTS PIN 14 PIN 12 PIN 8 PIN 4 PIN 3 PIN 1 PIN 2 INPUT BOARD PROCEDURE 4.
Page 53
TROUBLESHOOTING & REPAIR F-21 F-21 All manuals and user guides at all-guides.com INPUT BOARD VOLTAGE TEST (CONTINUED) FIGURE F.9 – MAIN SWITCH PLUG LOCATION White from PWR 2 White from PWR4 Blue from Blue from PWR 1 PWR 3 1. Put the blue wire from PWR3 in position 2 of the main switch while the white wire from PWR4 in posi- tion 5.
Page 54
NOTES F-22 F-22 All manuals and user guides at all-guides.com INVERTEC® V155-S...
Page 55
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.
TROUBLESHOOTING & REPAIR F-24 F-24 All manuals and user guides at all-guides.com INVERTER BOARD VOLTAGE TEST (CONTINUED) FIGURE F.10 – PLUG JP1 TESTPOINTS PIN 1 PIN 2 INPUT BOARD NOTE: DUE TO SAFETY REASONS AND THE PHYS- Check pin 3-> 0VDC during OCV condition. ICAL LOCATION OF THE INVERTER, IT IS Check pin 5->...
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.
Page 58
TROUBLESHOOTING & REPAIR F-26 F-26 All manuals and user guides at all-guides.com INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.11 – SCREW AND LEAD LOCATION INPUT BOARD MOUNTING SCREWS PROCEDURE 6. Label and remove all associated leads and plugs. 1. Disconnect power to the INVERTEC® V155-S. Some leads will require a 7mm nutdriver for 2.
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.
Page 60
TROUBLESHOOTING & REPAIR F-28 F-28 All manuals and user guides at all-guides.com INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.12 – DOOR REMOVAL Five Screws Three Screws Ground PROCEDURE 1. Disconnect power to the INVERTEC® V155-S. Note: Pay attention to wiring diagram very closely. 2.
Page 61
TROUBLESHOOTING & REPAIR F-29 F-29 All manuals and user guides at all-guides.com INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.13 – INVERTER BOARD REMOVAL 10MM BOLTS OUTPUT TERMINALS 7. Using a 10mm nutdriver with extension, remove the 9. Remove the inverter board. two bolts mounting the inverter board to the positive 10.
Page 62
NOTES F-30 F-30 All manuals and user guides at all-guides.com INVERTEC® V155-S...
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.
Page 64
TROUBLESHOOTING & REPAIR F-32 F-32 All manuals and user guides at all-guides.com CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.14 CONTROL BOARD REMOVAL MOUNTING SCREWS WASHER CONTROL BOARD KNOB PROCEDURE RED CAP 8. Disconnect the JP1 connector. 1. Disconnect power to the INVERTEC® V155-S. 9.
TROUBLESHOOTING & REPAIR F-33 F-33 All manuals and user guides at all-guides.com 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.
Page 66
NOTES F-34 F-34 All manuals and user guides at all-guides.com INVERTEC® V155-S...
Page 67
TABLE OF CONTENTS - DIAGRAM SECTION All manuals and user guides at all-guides.com Electrical Diagrams ..............G-1 Wiring Diagram (W07X071) .
All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODES 11326 & 11327 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. INVERTEC®...
All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE - CODES 11326 & 11327 control output them turning on full with Power Up – – 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®...
Page 70
1st emis. date: 1st emis. date: This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not to be This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not to be This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not to be...
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.
Page 72
Thursday, June 14, 2001 Thursday, June 14, 2001 This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not...
Page 73
Friday, January 31, 2003 Friday, January 31, 2003 This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not...
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.
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.
Page 76
Wednesday, February 18, 2004 Wednesday, February 18, 2004 This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not to be This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not to be This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l.
Page 77
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.
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.
Need help?
Do you have a question about the INVERTEC V155-S and is the answer not in the manual?
Questions and answers