Related Manuals for Lincoln Electric INVERTEC V145-S
Summary of Contents for Lincoln Electric INVERTEC V145-S
- Page 1 12/2005 Rev. 01 ® INVERTEC V145-S SERVICE MANUAL LINCOLN ELECTRIC ITALIA S.r.l Via Fratelli Canepa 8, 16010 Serrà Riccò (GE), Italia www.lincolnelectriceurope.com...
- Page 2 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.
- Page 3 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.
- Page 4 Lincoln Electric. Before installing the machine, the operator must check the work area for any devices that may malfunction because of electromagnetic disturbances.
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Page 5: Table Of Contents
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 … ………………………………………………………………………………36 Electrical Diagram reference... -
Page 6: Technical Specification
Technical Specifications - V145S INPUT Input Voltage Input Power at Rated Output Frequency 230 V ± 15% 3.0 kW @ 100% Duty Cycle 50/60 Hertz (Hz) 4.4 kW @ 35% Duty Cycle Single Phase RATED OUTPUT Duty Cycle Output Current Output Voltage (Based on a 10 min. -
Page 7: Installation And Operator Instructions
Installation and Operator Instructions Read this entire section before installation or operation of the generator must also meet the following conditions: of the machine. • Vac peak voltage: below 410V. • Location and Environment Vac frequency: in the range of 50 and 60 Hertz. •... - Page 8 enabled / disabled by the machine. The factory default Controls and Operational Features voltage is: Output Current Knob: V145-S CE: 75 Vdc Potentiometer used V145-S CE (12V): 12 Vdc to set the output V145-S AUSTRALIA: 12 Vdc current used during welding, from 5A to Refer to the section below for more details.
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Page 9: Accessories
For any maintenance or repair operations it is condition indicates a machine recommended to contact the nearest technical service damage. center or Lincoln Electric. Maintenance or repairs ERROR condition: This LED performed by unauthorized service centers or personnel condition indicates a machine will null and void the manufacturers warranty. -
Page 10: Maintenance
MAINTENANCE INPUT FILTER CAPACITOR WARNING DISCHARGE PROCEDURE 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 ELECTRIC SHOCK can kill resistor is NOT supplied with the machine. NEVER USE A SHORTING STRAP FOR THIS Have an electrician install and service this equipment PROCEDURE. - Page 11 ROUTINE MAINTENANCE THERMAL PROTECTION Keep the welding area around the machine clean Thermal detection device protect the machine from and free of combustible materials. No debris should excessive operating temperatures. Excessive be allowed to collect which could obstruct air flow to temperatures may be caused by a lack of cooling air or the machine operating the machine beyond the duty cycle and output...
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Page 12: Major Component Location
MAJOR COMPONENTS LOCATION ref. 03 secondary case ref. 05 fan ref. 09 input board ref. 10 inverter board ref. 11 control board... -
Page 13: Theory Of Operation
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... -
Page 14: General Description
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: •... -
Page 15: Inverter Board , Main Transformer, Output Rectifier And Choke
Inverter board , Main transformer, Output rectifier and Output Choke INVERTER BOARDs, MAIN TRANSFORMER, OUTPUT RECTIFIER AND OUTPUT CHOKE When the input filter capacitors are fully charged they act primary winding is redirected back to the filter capacitors as power supplies for the IGBT switching circuit. when the IGBTs are turned off. -
Page 16: Control Board
Control board This machine is provided by an internal VRD (Voltage Control Board Reduction Device) circuitry: this device reduces the voltage at the output leads. The VRD is automatically The control board receives status and enabled / disabled by the machine. The factory default analogue feedback from the inverter board, voltage is: input board and various sensor. -
Page 17: Protection Circuits
OVERLOAD PROTECTION THERMAL PROTECTION The Invertec V145-S is electrically protected from There are one thermal device located on the output producing higher than normal output currents. An diodes heatsink;it protect the machine from excessive electronic protection circuit limits the current to within the operating temperature. -
Page 18: Igbt Operation
INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION Drawing B shows the IGBT in an active mode. When An IGBT is a type of transistor. IGBTs are semicon- the gate signal, a positive DC voltage relative to the ductors well suited for high frequency switching and source, is applied to the gate terminal of the IGBT, it high current applications. - Page 19 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...
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Page 20: Troubleshooting And Repair
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. -
Page 21: Input Filter Capacitors Discharge Procedure
MAINTENANCE INPUT FILTER CAPACITOR WARNING DISCHARGE PROCEDURE 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 ELECTRIC SHOCK can kill resistor is NOT supplied with the machine. NEVER USE A SHORTING STRAP FOR THIS Have an electrician install and service this equipment PROCEDURE. -
Page 22: Troubleshooting Guide
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. GENERAL PROBLEMS ==== ===== PROBLEMS / SYMPTOMS POSSIBLE AREAS OF CHECK RECOMMENDED COURSE... -
Page 23: Input Board Resistance Test
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. - Page 24 TEST PROCEDURE 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-”...
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Page 25: Inverter Board Resistence Test
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. - Page 26 TEST PROCEDURE 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...
- Page 27 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...
- Page 28 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.
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Page 29: Input Board Voltage Test
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 30 TEST PROCEDURE 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...
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Page 31: Inverter Board Voltage Test
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. - Page 32 TEST PROCEDURE 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...
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Page 33: Control Board
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 CE version... -
Page 34: 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. - Page 35 Figure A: Machine Assembly Item Description Part Number Front Panel with Front Nameplate W95X0521R Primary Case (dx) with Side Nameplate (dx) W95X0523R Secondary Case (sx) with Side Nameplate (sx) W95X0522R Rear Panel W95X0524R Fan, 120x38mm W7200004R Cable Clamp W8460038R Ÿ Input Cable CE W78X0248R Ÿ...
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Page 36: Electrical Diagram
Electrical Schematic W H IT E R E D B L A C K... -
Page 37: Electrical Diagram Reference
Wiring Diagram Reference Number: • X0548 Block diagram V145-S • X0509 Input Board V145-S • X0519 Inverter Board • X0510 Control Board...