Lincoln Electric INVERTEC 150S Service Manual
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Summary of Contents for Lincoln Electric INVERTEC 150S
- Page 1 SVM 2013A Rev.00 07-2012 ® INVERTEC 150S For use with machines having code numbers: 52067 - 52096 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 MAIN BOARD (INPUT-INVERTER-OUTPUT) .................... 11 CONTROL BOARD............................13 TROUBLESHOOTING AND REPAIR SECTION ..................15 HOW TO USE TROUBLESHOOTING GUIDE .................... -
Page 3: Technical Specifications
TECHNICAL SPECIFICATIONS INPUT Input Power at Rated Output EMC Class Input Voltage Frequency 230V ± 15% 2.5kW @ 100% Duty Cycle 150S 50/60Hz Single Phase 4.2kW @ 30% 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 C. Fan: Welding Mode Switch: With three positions, 150S: This machine has a F.A.N. (Fan As • controls the welding mode of the machine: Needed) circuitry inside. The machine two for Stick welding (Soft and Crisp) and automatically reduces the speed of the fan or one for Lift TIG welding.
- 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
7. Check the voltage across the resistor R92. machine. Voltage should be zero. If any voltage 1. Remove input power to Invertec 150S remains, repeat this procedure. machine 2. Remove the cover following the instruction available in this Service manual. -
Page 10: Routine Maintenance
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. -
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: Main Board (Input-Inverter-Output)
INPUT LINE VOLTAGE, AUXILIARY activities will starts: VOLTAGE AND PRECHARGE +24Vdc is generated by the flyback power The Invertec 150S can be connected to a 230V supply circuits single phase input voltage. +15Vdc, +5Vdc, -5Vdc are generated by This unit can be also connect to engine driven... - Page 13 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 monitor the primary current. If the primary current they act as power supplies for the IGBT switching become abnormally high, the inverter control circuit.
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Page 14: 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) and requirements as decided by the operator. These generate the proper set reference for inverter changes are relayed to the PWM circuit on the board: manages stick function (soft crisp,hot start, Inverter Board to regulate the gate signals to the... -
Page 15: Overload Protection
If excessive operating temperature should occur, the Thermal LED indicator on the control board, will turn ON Invertec 150S are electrically protected from and the thermostat will prevent output current. producing higher than normal output currents. An... -
Page 16: Troubleshooting And Repair Section
TROUBLESHOOTING AND REPAIR SECTION How to use troubleshooting Guide Troubleshooting Guide Case cover removal and capacitor discharge procedure Page15... -
Page 17: 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 18 WARNING NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature. 5. Remove the replacement PC board and ELECTRIC SHOCK can kill substitute it with the original PC board to recreate the original problem. Have an electrician install and service this •...
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Page 19: Troubleshooting
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 •... -
Page 20: 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 21 ® INVERTEC 150S - 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 (A). 4. Remove the 10 screws of the wraparound (B). 5.
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Page 22: Dc Link Capacitors Discharge Procedure
10 seconds. DO NOT TOUCH CAPACITOR machine. TERMINALS WITH YOUR BARE HANDS. 1. Remove input power to Invertec 150S 7. Check the voltage across the resistor R92. machine Voltage should be zero. If any voltage 2. -
Page 23: Main Board Resistance Test
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 your Local Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. -
Page 24: Test Procedure
MAIN BOARD RESISTANCE TEST (continued) PTC TH1 PTC TH2 PTC 1 & 2 IGBT heatsink Output diodes heatsink ACa ~ ACb ~ IGBT and Output diode heatsink DC + DC - INPUT RECTIFIER BRIDGE Figure 1 – Main Board TEST PROCEDURE ®... - Page 25 MAIN BOARD RESISTANCE TEST (continued) n° 2 Output IGBT diodes pinout D23A1&D23A2 Anodes n° 2 Output diodes D23B1&D23B2 Cathodes Output Diode pinout Anodes Figure 1 – Main Board TEST PROCEDURE (continued) 10. Check each IGBT (Q9A,Q9B,Q9C,Q9D), with multimeter in diode test mode, following the Table tests 1 below.
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Page 26: Main Board Voltage Test
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 your Local Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. - Page 27 MAIN BOARD VOLTAGE TEST (continued) WARNING DO NOT CONNECT THE SAME SCOPE GROUND BETWEEN HIGH SIDE AND LOW SIDE 0VNI +24V +15V +24VNI Figure 1A 230Vac 230Vac Figure 1B Neutral Phase Figure 1C - R92 Figure 1 TEST PROCEDURE Use always electrically insulate gloves during this test procedure ®...
- Page 28 MAIN BOARD VOLTAGE TEST (continued) Figure 1 J3 fan Connector Pin20 Pin19 Pin2 pin1 J1 connector to control board J2 connector to current sensor Secondary side circuit Primary side circuit TEST PROCEDURE (continued) Use always electrically insulate gloves during this test procedure 9.
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Page 29: 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 30 CONTROL BOARD TEST (continued) Welding modes LEDs Operative LEDs Cutting mode selection To Main Board Pin 19 Pin 20 Output current potentiometer SW2 setup for CE machines: SW2 setup for AUS machines: Pin 2 Pin 1 Figure 1 TEST PROCEDURE ®...
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Page 31: 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 32: Disassembly Operations
DISASSEMBLY OPERATIONS AIR FLOW CONVEYOR AND FAN ASSEMBLY 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:... - Page 33 DISASSEMBLY OPERATIONS 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 Take care about the arrow sense when re- assembly the hall effect...
- Page 34 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 REMOVAL PROCEDURE Necessary tool:...
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Page 35: 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. -
Page 36: Electrical Diagrams
ELECTRICAL DIAGRAMS Wiring Diagram X1039 Page35... -
Page 37: Electrical Diagrams
ELECTRICAL DIAGRAMS Main Board Schematic X1064. Page 1/4 Page36... -
Page 38: Electrical Diagrams
ELECTRICAL DIAGRAMS Main Board Schematic X1064. Page 2/4 Page37... -
Page 39: Electrical Diagrams
ELECTRICAL DIAGRAMS Main Board Schematic X1064. Page 3/4 Page38... -
Page 40: Electrical Diagrams
ELECTRICAL DIAGRAMS Main Board Schematic X1064. Page 4/4 Page39... -
Page 41: Electrical Diagrams
ELECTRICAL DIAGRAMS Control Board Schematic X1088 Page40... -
Page 42: Note
NOTE Page41...
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