Lincoln Electric INVERTEC 170S Service Manual
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Summary of Contents for Lincoln Electric INVERTEC 170S
- Page 1 SVM 2013B Rev.00 07-2012 ® INVERTEC 170S For use with machines having code numbers: 52068 - 52097 LINCOLN ELECTRIC EUROPE www.lincolnelectric.eu...
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Page 2: Table Of Contents
INDEX OF CONTENTS INDEX OF CONTENTS ..............................1 TECHNICAL SPECIFICATIONS ............................. 2 SAFETY ..................................3 INSTALLATION AND OPERATOR INSTRUCTIONS..................... 4 MAINTENANCE ................................8 THEORY OF OPERATION ............................10 GENERAL DESCRIPTION AND EMC FILTER BOARD ....................11 MAIN BOARD (INPUT-INVERTER-OUTPUT) ......................12 CONTROL BOARD ............................... -
Page 3: Technical Specifications
TECHNICAL SPECIFICATIONS INPUT Input Power at Rated Output EMC Class Input Voltage Frequency 230V ± 15% 2.9kW @ 100% Duty Cycle 170S 50/60Hz Single Phase 5.1kW @ 35% Duty Cycle RATED OUTPUT AT 40° C Duty Cycle Output Current Output Voltage (Based on a 10 min. -
Page 4: Safety
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 5: Installation And Operator Instructions
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in an environment with increased hazard of electric shock. 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. - Page 6 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.
- Page 7 Welding Mode Switch: With three positions, C. Fan: controls the welding mode of the machine: 170S: This machine has a F.A.N. (Fan As • two for Stick welding (Soft and Crisp) and Needed) circuitry inside. The machine one for Lift TIG welding. automatically reduces the speed of the fan or turns it OFF.
- Page 8 Lincoln Electric. The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system.
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Page 9: Maintenance
MAINTENANCE WARNING 1. Remove input power to Invertec 170S machine 2. Remove the cover following the instruction available in this Service manual. ELECTRIC SHOCK can kill 3. Obtain a high resistance and high wattage resistor ( 25-1000 ohms and 25 watts Have an electrician install and service this •... - Page 10 ROUTINE MAINTENANCE THERMAL PROTECTION 1. Keep the welding area around the machine Thermal detection device protect the machine clean and free of combustible materials. No from excessive operating temperatures. debris should be allowed to collect which Excessive temperatures may be caused by a lack could obstruct air flow to the machine of cooling air or operating the machine beyond 2.
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Page 11: Theory Of Operation
THEORY OF OPERATION General description Input Line Voltage, Auxiliary Voltage, Precharge Inverter Board , Main Transformer, Output Rectifier, Choke and Output Current Probe Control Board Protection Circuits and IGBTs operation BLOCK DIAGRAM Page10... -
Page 12: General Description And Emc Filter Board
GENERAL DESCRIPTION AND EMC FILTER BOARD GENERAL DESCRIPTION EMC FILTER BOARD ® The INVERTEC 170S is an industrial 160 amp Prevents noise from the machine from being arc welding power source which utilizes single transmitted along the main power line and vice phase input power, to produce constant current versa, necessary to be in accordance with all... -
Page 13: Main Board (Input-Inverter-Output)
Once the VOLTAGE AND PRECHARGE input switch is moved to ON position the 230 Vac The Invertec 170S can be connected to a 230V +/- 15% voltage is applied to the input circuits and +/- 15% single phase input voltage. - Page 14 MAIN BOARD (INPUT-INVERTER-OUTPUT) (continued) INVERTER BOARD, MAIN TRANSFORMER, OUTPUT RECTIFIER, OUTPUT CHOKE AND OUPUT CURRENT PROBE When the input filter capacitors are fully charged A thermal protector is also present, to the inverter they act as power supplies for the IGBT switching heatsink, to protect the IGBTs from overheating circuit.
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Page 15: Control Board
CONTROL BOARD Potentiometer to make decisions and change the Control Board (User Interface) machine mode and output to satisfy the Control Board takes signals (Iout, Vout, Iset), requirements as decided by the operator. These shows the proper value on the display and changes are relayed to the PWM circuit on the generate the proper set reference for inverter Inverter Board to regulate the gate signals to the... - Page 16 If excessive operating temperature should occur, the Thermal LED indicator on the control board, will turn ON Invertec 170S are electrically protected from and the thermostat will prevent output current. producing higher than normal output currents. An...
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Page 17: Troubleshooting And Repair Section
TROUBLESHOOTING AND REPAIR SECTION How to use troubleshooting Guide Troubleshooting Guide Case cover removal and capacitor discharge procedure Page16... -
Page 18: How To Use Troubleshooting Guide
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 19 WARNING 4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board. NOTE: Allow the machine to heat up so that all ELECTRIC SHOCK can kill electrical components can reach their operating temperature. Have an electrician install and service this •...
- Page 20 TROUBLESHOOTING !! WARNING !! BEFORE CONNECT POWER SUPPLY, MAKE A CAREFUL VISUAL INSPECTION INSIDE THE MACHINE , CHECK ALL THE BOARDS AND HARNESS. GENERAL PROBLEMS POSSIBLE AREAS OF RECOMMENDED COURSE PROBLEMS / SYMPTOMS CHECK MISADJUSTMENT(S) OF ACTION • INPUT POWER BRIDGE •...
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Page 21: Case Cover Removal And Dc Link Capacitor Discharge Procedure
DISCHARGE PROCEDURE WARNING Service and repair should be performed only by 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 22: Invertec ® 170S - Case Cover Removal
® INVERTEC 170S - CASE COVER REMOVAL Procedure: 1. Disconnect Input Power from the machine! 2. Turn on/off switch to off position. 3. Remove the 8 screws of the front and rear plastic handle (A). 4. Remove the 10 screws of the wraparound (B). 5. -
Page 23: Dc Link Capacitors Discharge Procedure
DC LINK CAPACITORS DISCHARGE PROCEDURE WARNING 1. Remove input power to Invertec 170S machine 2. Remove the cover following the instruction available in this Service manual. ELECTRIC SHOCK can kill 3. Obtain a high resistance and high wattage resistor ( 25-1000 ohms and 25 watts Have an electrician install and service •... -
Page 24: Emc Filter Board Resistance Test
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact your Local Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. - Page 25 EMC FILTER BOARD RESISTANCE TEST (continued) Input cable Phase To main board Input cable Neutral To main board TEST PROCEDURE ® 1. Remove main input power to the INVERTEC 170S 2. Follow the case cover removal procedure available in this Service Manual. 3.
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Page 26: Main Board Resistance Test
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact your Local Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. - Page 27 MAIN BOARD RESISTANCE TEST (continued) Thermic PTC 1 sensorTH1 ACa ~ ACb ~ IGBT heatsink DC + DC - INPUT RECTIFIER BRIDGE TEST PROCEDURE ® 1. Remove main input power to the INVERTEC 170S 2. Follow the main board disassembly operations available in this Service Manual. 3.
- Page 28 MAIN BOARD RESISTANCE TEST (continued) Note: OLD board version has 8 IGBTs in total, new board version, as shown in Figure1, has only 4 IGBTs in total IGBT Figure 3 pinout Figure 1 – Main Board Figure 2 TEST PROCEDURE (continued) 7.
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Page 29: Emc Filter Board Voltage Test
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact your Local Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. - Page 30 EMC FILTER BOARD VOLTAGE TEST (continued) Input cable Phase To main board Input cable Neutral To main board TEST PROCEDURE Use always electrically insulate gloves during this test procedure ® 1. Remove main input power to the INVERTEC 170S 2. Follow the case removal procedure available in this Service Manual ®...
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Page 31: Main And Control Board Voltage Test
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact your Local Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. - Page 32 MAIN AND CONTROL BOARD VOLTAGE TEST (continued) WARNING DO NOT CONNECT THE SAME SCOPE GROUND BETWEEN HIGH SIDE AND LOW SIDE Pin 19 Pin 20 Pin 2 Pin 1 Figure 2 Figure 1A TEST PROCEDURE Figure 1 Use always electrically insulate gloves during this test procedure ®...
- Page 33 MAIN BOARD VOLTAGE TEST (continued) Figure 1 TEST PROCEDURE (continued) Use always electrically insulate gloves during this test procedure J2: Current Sensor Connector Pin # Description Value (use pin 4 as 0V ref.) Notes +15Vdc Auxiliary supply -5Vdc –5Vdc ±2% Auxiliary supply From 0Vdc to 6,4Vdc ±5% IOUT...
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Page 34: Control Board Test
CONTROL BOARD 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 35 CONTROL BOARD TEST (continued) 3 digits Welding Operative Display modes LEDs LEDs Cutting mode selection To Main Board Pin 19 Pin 20 SW2 setup for CE machines: SW2 setup for AUS machines: Output current potentiometer Pin 2 Pin 1 Figure 2 TEST PROCEDURE ®...
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Page 36: Error Codes
ERROR CODES If errors condition occurs, try to turn Off the machine, wait for a few seconds, then turn ON again. If the error remains, control tests described into this manual are required. Blink Blink This occurs when an internal auxiliary undervoltage condition is detected. -
Page 37: Disassembly Operations
DISASSEMBLY OPERATIONS PLANAR TRANSFORMER AND MAIN BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL Figure 2 Figure 1... - Page 38 DISASSEMBLY OPERATIONS PLANAR TRANSFORMER AND MAIN BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL Figure 1 Figure 3...
- Page 39 DISASSEMBLY OPERATIONS OUTPUT DIODE MODULE AND THERMAL SENSOR REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL Figure 1 Output diode...
- Page 40 DISASSEMBLY OPERATIONS HALL SENSOR, OUTPUT FILTER BOARD AND EMC FILTER REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. EMC Input Output choke Only qualified persons should install, use ELECTRIC SHOCK or service this equipment.
- Page 41 DISASSEMBLY OPERATIONS FAN REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL Figure 3 Figure 1 Figure 2 REMOVAL PROCEDURE...
- Page 42 DISASSEMBLY OPERATIONS CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL Figure 1 Figure 2 REMOVAL PROCEDURE...
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Page 43: Retest After Repair
RETEST AFTER REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested. Machine input and output Input Voltage Input Current... -
Page 44: Electrical Diagrams
ELECTRICAL DIAGRAMS Wiring Diagram X1037 Page43... -
Page 45: Electrical Diagrams
ELECTRICAL DIAGRAMS Main Board Schematic X0909. Page 1/5 Note: OLD boards version have 8IGBTs in total, new boards version, as shown in Figure1, have only 4 IGBTs in total Page44... -
Page 46: Electrical Diagrams
ELECTRICAL DIAGRAMS Main Board Schematic X0909. Page 2/5 Page45... -
Page 47: Electrical Diagrams
ELECTRICAL DIAGRAMS Main Board Schematic X0909. Page 3/5 Page46... -
Page 48: Electrical Diagrams
ELECTRICAL DIAGRAMS Main Board Schematic X0909. Page 4/5 Page47... -
Page 49: Electrical Diagrams
ELECTRICAL DIAGRAMS Main Board Schematic X0909. Page 5/5 Page48... -
Page 50: Electrical Diagrams
ELECTRICAL DIAGRAMS Control Board Schematic X907 Page49... -
Page 51: Electrical Diagrams
ELECTRICAL DIAGRAMS Output Filter Board Schematic X1221 Page50... -
Page 52: Electrical Diagrams
ELECTRICAL DIAGRAMS EMC Input Filter Board Schematic X1220 Page51... -
Page 53: Note
NOTE Page52...