Lincoln Electric INVERTEC 160SX Service Manual
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Lincoln Electric INVERTEC 160SX Service Manual

Lincoln Electric INVERTEC 160SX Service Manual

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SVM 2038
Rev.00 12-2012
INVERTEC
160SX
®
For use with machines having code numbers: 52101
LINCOLN ELECTRIC EUROPE
www.lincolnelectric.

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  • Page 1 SVM 2038 Rev.00 12-2012 INVERTEC 160SX ® For use with machines having code numbers: 52101 LINCOLN ELECTRIC EUROPE www.lincolnelectric.

  • Page 2: Table Of Contents

    INDEX OF CONTENTS INDEX OF CONTENTS ..............................1 TECHNICAL SPECIFICATIONS ............................. 2 ACCESSORIES ................................2 SAFETY ..................................3 INSTALLATION AND OPERATOR INSTRUCTIONS ....................4 ELECTROMAGNETIC COMPATIBILITY (EMC) ......................7 MAINTENANCE ................................8 MAJOR COMPONENTS LOCATION ..........................9 THEORY OF OPERATION ............................10 GENERAL DESCRIPTION ............................

  • Page 3: Technical Specifications

    TECHNICAL SPECIFICATIONS INPUT Input Voltage Range Input Power at Rated Output EMC Class Frequency from 115 to 230Vac ±15% 3.07kVA @ 100% Duty Cycle 50/60Hz Single Phase 5.17kVA @ 30% Duty Cycle RATED OUTPUT AT 40°C Duty Cycle (@ Input Voltage) 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

    Consult the electrode data for this information. Then connect the output cables to the The Invertec 160SX is a wide input voltage range: before output terminals of the machine for the selected polarity. installing and turning it on, check the supplied input Shown here is the connection method for DC(+) welding.
  • Page 6 • For DC(-) welding, switch the cable connections at the Anti-Sticking: This is a function that decreases the machine so that the electrode cable is connected to (-) output current of the machine to a low level when and the work clamp is connected to (+). the operator makes an error and sticks the electrode to the work piece.
  • Page 7 Please contact the nearest 9.09 technical service center or Lincoln Electric and report the To restore the machine: 3-digit code displayed on the meter of the Front Panel. Turn OFF then ON the Mains Switch to restart the machine.

  • Page 8: Electromagnetic Compatibility (Emc)

    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.

  • Page 9: Maintenance

    MAINTENANCE WARNING INPUT FILTER CAPACITOR DISCHARGE PROCEDURE ® Remove input power to Invertec 160SX Remove the cover following the instruction ELECTRIC SHOCK can kill available in this Service manual. Obtain a high resistance and high wattage resistor Have an electrician install and service this equipment ( 500-1000 ohms and 25 watts minimum ).

  • Page 10: Major Components Location

    ROUTINE MAINTENANCE THERMAL PROTECTION Keep the welding area around the machine clean and Thermal detection device protect the machine from free of combustible materials. No debris should be excessive operating temperatures. Excessive temperatures allowed to collect which could obstruct air flow to the may be caused by a lack of cooling air or operating the machine machine beyond the duty cycle and output rating.

  • Page 11: Theory Of Operation

    THEORY OF OPERATION General description Main Input Switch, Input Rectifier, Soft/Start Input Relay, Boost and Power Factor Correction, Auxiliary Voltages Board Inverter Board, Output Section Control Board and Display Board Protection Circuits IGBT operation BLOCK DIAGRAM     Page10     ...

  • Page 12: General Description

    GENERAL DESCRIPTION GENERAL DESCRIPTION environmentally hardened to an IP23 rating for operating in difficult environments. ® The INVERTEC 160SX is an industrial arc welding power source which utilizes single phase EMC FILTER input power, to produce regulated constant current output. The welding response of this EMC filter circuit, parts of the Boost PCB, Invertec has been optimized for stick (SMAW) and prevents noise from the machine from being...

  • Page 13: Main Input Switch, Input Rectifier, Soft Start/Input Relay, Boost And Power Factor Correction, Auxiliary Voltages Board

    MAIN INPUT SWITCH, INPUT RECTIFIER, SOFT START/INPUT RELAY, BOOST AND POWER FACTOR CORRECTION, AUXILIARY VOLTAGES BOARD MAIN INPUT SWITCH, INPUT RECTIFIER, SOFT START/INPUT RELAY, BOOST AND POWER FACTOR CORRECTION, AUXILIARY VOLTAGES BOARD ® The INVERTEC 160SX can be connected from The AC input power is connected to the Boost 115Vac to a 230Vac +/- 15% single phase input Board.

  • Page 14: Inverter Board (Inverter-Output)

    INVERTER BOARD (INVERTER-OUTPUT) INVERTER BOARD, MAIN TRANSFORMER, OUTPUT RECTIFIER, 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.

  • Page 15: Control Board And Display Board

    CONTROL BOARD AND DISPLAY BOARD Control Board (User Interface) and Display Board Control Board takes signals (Iout, Vout, Iset), from the Mode Switch and the Control shows the proper value on the display and Potentiometer to make decisions and change the generate the proper set reference for inverter machine mode and output to satisfy the board: manages stick function (soft crisp,hot start,...
  • Page 16 the duty cycle and output rating. If excessive OVERLOAD PROTECTION operating temperature should occur, the Thermal ® LED indicator on the control board, will turn ON INVERTEC 160SX is electrically protected from and the thermostat will prevent output current. producing higher than normal output currents. An electronic protection circuit limits the current to The thermal protection devices are self-resetting within the capabilities of the machine.

  • 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. •...
  • Page 20 TROUBLESHOOTING !! WARNING !! BEFORE CONNECT POWER SUPPLY, MAKE A CAREFUL VISUAL INSPECTION INSIDE THE MACHINE , CHECK ALL THE BOARDS AND HARNESS. POSSIBLE AREAS OF RECOMMENDED COURSE PROBLEMS / SYMPTOMS CHECK MISADJUSTMENT(S) OF ACTION • INPUT POWER BRIDGE IS IN SHORT CIRCUIT THE LINE CIRCUIT BREAKER •...

  • 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 160SX - CASE COVER REMOVAL Procedure: 1. Disconnect Input Power from the machine! 2. Turn on/off switch to off position. 3. Remove the 4 screws of the front and rear plastic handle supports (A). These screws are longer compared to the rest of the screws, keep them separate and use them back to these positions.

  • Page 23: Dc Link Capacitors Discharge Procedure

    DC LINK CAPACITORS DISCHARGE PROCEDURE WARNING INPUT FILTER CAPACITOR DISCHARGE PROCEDURE ® 1. Remove input power to Invertec 160SX 2. Remove the cover following the instruction ELECTRIC SHOCK can kill available in this Service manual. 3. Obtain a high resistance and high wattage Have an electrician install and service this resistor ( 500-1000 ohms and 25 watts equipment.

  • Page 24: Boost Board Resistance Test

    BOOST 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 25 BOOST BOARD RESISTANCE TEST (continued) PTC 1 DC + DC + B1-B2 INPUT RECT. BRIDGE PTC 2 Figure 1 – Boost Board TEST PROCEDURE ® 1. Remove main input power to the INVERTEC 160SX 2. Perform the Discharge procedure 3. Follow the Boost Board disassembly operations available in this Service Manual. 4.
  • Page 26 BOOST BOARD RESISTANCE TEST (continued) Anodes Diode D8 pinout IGBT Cathode pinout Figure 1 – Boost Board TEST PROCEDURE Check diode D8, with multimeter in diode test mode, for short, following the Table tests 1. 10. Check IGBT Q5 and Q6, with multimeter in diode test mode, following the Table tests 2. Diode D8 –...

  • Page 27: Inverter 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 28 INVERTER BOARD RESISTANCE TEST (continued) IGBT and PTC 1 PTC 2 Output diode heatsink IGBT pinout Figure 1 – Inverter Board TEST PROCEDURE ® 1. Remove main input power to the INVERTEC 160SX 2. Perform the Discharge procedure 3. Follow the Inverter Board disassembly operations available in this Service Manual. 4.
  • Page 29 INVERTER BOARD RESISTANCE TEST (continued) Diode Anodes pinout Cathode Figure 1 – Inverter Board Check the output diodes D15,D16,D17,D18,D24), with multimeter in diode test mode, for short, following the Table tests 2 below (see Figure 1) Diode D15,D16,D17,D18,D24 – Table tests 2 Positive Probe (RED) Negative Probe (BLACK) Value...

  • Page 30: Boost 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 31 BOOST BOARD VOLTAGE TEST (continued) Input Voltage L & N Primary side +5Vdc GND/1 +15Vdc +24Vdc Secondary side GND +24V/1 Figure 1 – Inverter Board WARNING! TEST PROCEDURE DO NOT connect together GND/1 and GND Use always electrically insulate gloves during this test procedure ®...
  • Page 32 BOOST BOARD VOLTAGE TEST (continued) TEST PROCEDURE(continued) Use always electrically insulate gloves during this test procedure 10. Follow the below tables to perform the voltage tests on connectors J1A Pin# Description Use pin 9 as GND ref. Notes TX_B 0-5V (typical value 3,9Vdc) Serial protocol transmission Not used Not used...

  • Page 33: Inverter 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 34 INVERTER BOARD VOLTAGE TEST (continued) Figure 1A J21A Figure 1 TEST PROCEDURE Use always electrically insulate gloves during this test procedure ® 1. Remove main input power to the INVERTEC 160SX 2. Follow the case removal procedure available in this Service Manual 3.
  • Page 35 INVERTER BOARD VOLTAGE TEST (continued) Figure 1 TEST PROCEDURE Use always electrically insulate gloves during this test procedure 9. Follow the below tables to perform the voltage tests on connectors J25 and J22: J25: Current Sensor Pin# Description Use pin 4 as GND ref. Notes +15V +15V Power supply...

  • Page 36: 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 37 CONTROL BOARD TEST (continued) 3 digits Welding Display modes LEDs Operative Welding mode LEDs selection To inverter board Pin 20 Pin 19 Output current SW2 setup for CE machines: SW2 setup for AUS machines: potentiometer Pin 2 Pin 1 Figure 2 TEST PROCEDURE ®...

  • Page 38: Error Codes

    ERROR CODES Error condition list. If occurs, try to turn Off the machine, wait for a few seconds, then turn ON again. If the error remains, read the 3-digit code displayed on the meter of the Front Panel to identify the error condition.

  • Page 39: Disassembly Operations

    DISASSEMBLY OPERATIONS BOOST 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 REMOVAL PROCEDURE Necessary tool: Phillips screwdriver PH02...
  • Page 40 DISASSEMBLY OPERATIONS BOOST BOARD REMOVAL AND REPLACEMENT PROCEDURE (continue) 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 10.
  • Page 41 DISASSEMBLY OPERATIONS INVERTER 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 REMOVAL PROCEDURE Necessary tool: Phillips screwdriver PH02...
  • Page 42 DISASSEMBLY OPERATIONS INVERTER 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 8.
  • Page 43 DISASSEMBLY OPERATIONS HALL CURRENT 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 REMOVAL PROCEDURE Necessary tool: Phillips screwdriver PH02...
  • Page 44 DISASSEMBLY OPERATIONS CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE REMOVAL PROCEDURE Necessary tool: 6 mm Nutdriver 5,5 mm wrench ® 1. Remove input power to INVERTEC 160SX 2. Remove the cover following the instruction available in this Service Manual. Perform the Discharge procedure. 4.
  • Page 45 DISASSEMBLY OPERATIONS FAN REMOVAL AND REPLACEMENT PROCEDURE REMOVAL PROCEDURE Necessary tool: Phillips screwdriver PH02 ® 1. Remove input power to INVERTEC 160SX 2. Remove the cover following the instruction available in this Service Manual. Perform the Discharge procedure. Remove the 2 small black plastic rivets (A), to be able to pull a bit the rear panel away from the central frame and facilitate the fan removal.

  • Page 46: 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 47: Electrical Schematics

    ELECTRICAL SCHEMATICS Block Diagram     Page46     ...

  • Page 48: Electrical Schematics

    ELECTRICAL SCHEMATICS Input Boost Schematic X1281. Page 1/3     Page47     ...

  • Page 49: Electrical Schematics

    ELECTRICAL SCHEMATICS Input Boost Schematic X1281. Page 2/3     Page48     ...

  • Page 50: Electrical Schematics

    ELECTRICAL SCHEMATICS Input Boost Schematic X1281. Page 3/3     Page49     ...

  • Page 51: Electrical Schematics

    ELECTRICAL SCHEMATICS Inverter Schematic X1280. Page 1/3     Page50     ...

  • Page 52: Electrical Schematics

    ELECTRICAL SCHEMATICS Inverter Schematic X1280. Page 2/3     Page51     ...

  • Page 53: Electrical Schematics

    ELECTRICAL SCHEMATICS Inverter Schematic X1280. Page 3/3     Page52     ...

  • Page 54: Electrical Schematics

    ELECTRICAL SCHEMATICS Control Board Schematic X1319.     Page53     ...

  • Page 55: Electrical Schematics

    ELECTRICAL SCHEMATICS Display Board Schematic X1344.     Page54     ...

  • Page 56: Electrical Schematics

    ELECTRICAL SCHEMATICS Output Filter Board Schematic X1459.     Page55     ...

  • Page 57: Note

    NOTE     Page56     ...

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