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
Safety
11/04

WARNING
This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair
procedures are performed only by qualified person. Read and understand this manual before operating this equipment.
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.

WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,
loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or
death.

READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating
this equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could
cause serious personal injury, loss of life, or damage to this equipment.

ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the
electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from
the electrode, work clamp, and connected work pieces.

ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the
fuse box before working on this equipment. Ground this equipment in accordance with local electrical
regulations.

ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp
cables. If any insulation damage exists replace the cable immediately. Do not place the electrode
holder directly on the welding table or any other surface in contact with the work clamp to avoid the
risk of accidental arc ignition.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any
conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some
pacemakers, and welders having a pacemaker shall consult their physician before operating this
equipment.
CE COMPLIANCE: This equipment complies with the European Community Directives.

FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use
enough ventilation or exhaust to keep fumes and gases away from the breathing zone.

ARC RAYS CAN BURN: Use a shield with the proper filter and cover plates to protect your eyes from
sparks and the rays of the arc when welding or observing. Use suitable clothing made from durable
flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel
with suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to
the arc.
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding
area and have a fire extinguisher readily available. Welding sparks and hot materials from the welding
process can easily go through small cracks and openings to adjacent areas. Do not weld on any
tanks, drums, containers, or material until the proper steps have been taken to insure that no
flammable or toxic vapors will be present. Never operate this equipment when flammable gases,
vapors or liquid combustibles are present.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and
materials in work area can cause serious burns. Use gloves and pliers when touching or moving
materials in the work area.

SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in
an environment with increased hazard of electric shock.

2
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. Do not allow the electrode,
electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders
must be located away from areas where they may be subjected to physical damage or the welding
process including sparks and heat sources.

3
Electromagnetic Compatibility (EMC)
11/04
This machine has been designed in accordance with all relevant directives and standards. However, it may still generate
electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or
other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand
this section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.
This machine has been designed to operate in an industrial area. To operate in a domestic area it is
necessary to observe particular precautions to eliminate possible electromagnetic disturbances. The
operator must install and operate this equipment as described in this manual. If any electromagnetic
disturbances are detected the operator must put in place corrective actions to eliminate these disturbances
with, if necessary, assistance from Lincoln Electric.

Before installing the machine, the operator must check the work area for any devices that may malfunction because of
electromagnetic disturbances. Consider the following.
• Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the
machine.
• Radio and/or television transmitters and receivers. Computers or computer controlled equipment.
• Safety and control equipment for industrial processes. Equipment for calibration and measurement.
• Personal medical devices like pacemakers and hearing aids.
• Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure
that all equipment in the area is compatible. This may require additional protection measures.
• The dimensions of the work area to consider will depend on the construction of the area and other activities that are
taking place.

Consider the following guidelines to reduce electromagnetic emissions from the machine.
• Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take
additional precautions such as filtering the input supply.
• The output cables should be kept as short as possible and should be positioned together. If possible connect the
work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting
the work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.
• Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special
applications.

4
 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 34

Electrical Diagram … ………………………………………………………………………………36

Electrical Diagram reference 37

5
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)
Single Phase 4.4 kW @ 35% Duty Cycle
RATED OUTPUT
Duty Cycle Output Current Output Voltage
(Based on a 10 min. period @ 40°C)
100% 105 A 24.2 Vdc
35% 145 A 25.8 Vdc

(Based on a 10 min. period @ 20°C)

100% 120 A 24.8 Vdc
60% 145 A 25.8 Vdc
OUTPUT RANGE
Maximum Open Circuit Voltage
Welding Current Range 75 Vdc (CE model)
5 -145 Amps 12 Vdc (CE 12V model)
12 Vdc (AUSTRALIA model)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Type of Plug
Fuse (delayed) or
SCHUKO 16 A / 250 V or Input Power Cable
Circuit Breaker (“D” characteristic) Size 2
AUSTRALIAN 15 A / 250 V 3 Conductor, 2.5 mm
16 A
(Included with Machine)
PHYSICAL DIMENSIONS
Weight
Height Width Length
5.9 kg
288 mm 158 mm 392 mm
6.4 kg (CE 12V model)
Operating Temperature Storage Temperature
-10°C to +40°C -25°C to +55°C

6
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.
This machine can operate in harsh environments. • RMS voltage of the AC waveform: 230Vac ± 15%.
However, it is important that simple preventative
measures are followed to assure long life and reliable It is important to check these conditions because many
operation: engine driven generators produce high voltage spikes.
Operation of this machine with engine driven generators
• Do not place or operate this machine on a surface not conforming to these conditions is not recommended
with an incline greater than 15° from horizontal. and may damage the machine.
• Do not use this machine for pipe thawing.
• This machine must be located where there is free Output Connections
TM
circulation of clean air without restrictions for air A quick disconnect system using Twist-Mate cable
movement to and from the air vents. Do not cover plugs is used for the welding cable connections. Refer
the machine with paper, cloth or rags when to the following sections for more information on
switched on. connecting the machine for operation of stick welding
• Dirt and dust that can be drawn into the machine (MMA) or TIG welding.
should be kept to a minimum.
• This machine has a protection rating of IP23. Keep Stick Welding (MMA)
it dry when possible and do not place it on wet First determine the proper electrode polarity for the
ground or in puddles. electrode to be used. Consult the electrode data for this
• Locate the machine away from radio controlled information. Then connect the output cables to the
machinery. Normal operation may adversely affect output terminals of the machine for the selected polarity.
the operation of nearby radio controlled machinery, Shown here is the connection method for DC(+) welding.
which may result in injury or equipment damage.
Read the section on electromagnetic compatibility in Connect the electrode
this manual. cable to the (+) terminal
• Do not operate in areas with an ambient and the work clamp to the
temperature greater than 40°C. (-) terminal. Insert the
connector with the key
Duty Cycle lining up with the keyway
and rotate approximately ¼
The duty cycle of a welding machine is the percentage of
turn clockwise. Do not over
time in a 10 minute cycle at which the welder can
tighten.
operate the machine at rated welding current.
For DC(-) welding, switch the cable connections at the
Example: 35% duty cycle:
machine so that the electrode cable is connected to (-)
and the work clamp is connected to (+).

TIG Welding
This machine does not include a TIG torch necessary for
TIG welding, but one may be purchased separately.
Welding for 3.5 minutes. Break for 6.5 minutes.
Refer to the accessories section for more information.
Most TIG welding is done with DC(-) polarity shown
Refer to the Technical Specification section for more here. If DC(+) polarity is necessary switch the cable
information about the machine rated duty cycles. connections at the machine.

Input Supply Connection Connect the torch cable to

Check the input voltage, phase, and frequency supplied the (-) terminal of the
to this machine before turning it on. The allowable input machine and the work
voltage is indicated in the technical specification section clamp to the (+) terminal.
of this manual and on the rating plate of the machine. Insert the connector with
Be sure that the machine is grounded. the key lining up with the
keyway and rotate
Make sure the amount of power available from the input approximately ¼ turn
connection is adequate for normal operation of the clockwise. Do not over
machine. The fuse rating and cable sizes are both tighten. Finally, connect
indicated in the technical specification section of this the gas hose to the gas regulator on the cylinder of gas
manual. to be used.

This machine is designed to operate on engine driven VRD: Voltage Reduction Device
generators as long as the 230Vac auxiliary can supply This machine is provided by an internal VRD (Voltage
adequate power as indicated in the technical Reduction Device) circuitry: this device reduces the
specification section of this manual. The auxiliary supply voltage at the output leads. The VRD is automatically

7
enabled / disabled by the machine. The factory default Controls and Operational Features
voltage is: A. 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. 145A.

Auto Adaptive Arc Force (with MMA B. Welding Mode

welding) Switch: With three
During MMA welding is activated the function Auto positions, controls
Adaptive Arc Force that increases temporary the output the welding mode of
current, used to clear intermittent connections between the machine: two for
the electrode and the weld puddle that occur during stick Stick welding (Soft
welding. and Crisp) and one
for Lift TIG welding.
This is an active control feature that guarantees the best
arrangement between the arc stability and spatter • Soft Stick: For a welding with a low spatter
presence. The feature "Auto Adaptive Arc Force" has presence.
instead of a fixed or manual regulation, an automatic and • Crisp Stick: For an aggressive welding, with an
multilevel setting: its intensity depends by the output increased Arc stability.
voltage and it is calculated in real time by the • Lift TIG: When the mode switch is in the Lift TIG
microprocessor where are also mapped the Arc Force position, the stick welding functions are disabled
levels. The control measure in each instant the output and the machine is ready for Lift TIG welding. Lift
voltage, compare with the mapped levels and it TIG is a method of starting a TIG weld by first
determines the amount of the peak of current to apply; pressing the TIG torch electrode on the work piece
that value is enough to breaks the metal drop that is in order to create a low current short circuit. Then,
being transferred from the electrode to the workpiece as the electrode is lifted from the work piece to start the
to guarantee the arc stability, but not too high to avoid TIG arc.
spatters around the welding puddle. That means:
• Electrode / workpiece sticking prevention, also with C. Thermal LED: This indicator will turn on when the
low current values. machine is overheated and the output has been
• Spatters reduction. disabled. This normally occurs when the duty cycle
of the machine has been exceeded. Leave the
The welding operations are simplified and the welded machine on to allow the internal components to
joins looks better, also if not brushed after the welding. cool. When the indicator turns off, normal operation
is again possible.
This feature is available in the Soft Stick and Crisp
Stick operating modes and can be selected by the D. Power On/Off & VRD (Voltage Reduction Device)
operator and it allows to weld with the characteristics LEDs: These LEDs (one green and one red)
more suitable at the electrode type and welding operates as described in the table below:
conditions. The Crisp Stick feature also increases the LED status
Function
Hot Start action, facilitating the arc striking. Green Red
ON OFF The machine is turned ON.
With the MMA welding are also enabled the following
features: VRD ON condition: The machine
• Hot Start: This is a temporary increase in the initial is at idle (no-welding time) and
welding current. This helps ignite the arc quickly the VRD device is enabled. No
and reliably. current at the output leads; the
• Anti-Sticking: This is a function that decreases the voltage has reached a value
output current of the machine to a low level when under the VRD limit.
the operator makes an error and sticks the electrode OFF ON The machine is turned ON.
to the work piece. This decrease in current allows
the operator to remove the electrode from the VRD OFF condition: A welding is
electrode holder without creating large sparks that running and the VRD device is
can damage the electrode holder. disabled. Presence of current at
the output leads, the voltage
Refer to the section below for more details. value may be over the VRD limit.

This permanent LED condition,

showed at idle (no-welding time),
indicates a machine damage.

8
 fan will turn ON only when a weld is started and
OFF OFF The machine is turned OFF it will continue to run whenever the machine is
and/or the input cord could be welding. If the machine doesn’t weld for more
disconnected from the mains. than five minutes, the fan will turn OFF.

ERROR condition: With the Maintenance

Power Switch turned ON and the
input cord properly connected to WARNING
a “live” main supply, this LED 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
ON ON ERROR condition: This LED performed by unauthorized service centers or personnel
condition indicates a machine will null and void the manufacturers warranty.
damage.
The frequency of the maintenance operations may vary
E. Positive Quick Disconnect: Positive output in accordance with the working environment. Any
connector for the welding circuit. noticeable damage should be reported immediately.
F. Negative Quick Disconnect: Negative output • Check cables and connections integrity. Replace, if
connector for the welding circuit. necessary.
G. Power Switch: It • Keep clean the machine. Use a soft dry cloth to
turns ON / OFF clean the external case, especially the airflow inlet /
the input power to outlet louvers.
the machine.
WARNING
H. Input cable: This
Do not open this machine and do not introduce anything
machine is
into its openings. Power supply must be disconnected
provided with a
from the machine before each maintenance and service.
plugged input
After each repair, perform proper tests to ensure safety.
cord. Connect it
to the mains.

I. Fan: This
machine has a
F.A.N. (Fan As
Needed) circuitry
inside: the fan is
automatically turned ON or OFF. This feature
reduces the amount of dirt which can be drawn
inside the machine and reduces power
consumption. The F.A.N. operates in different
modes, it depends by the machine type and by the
selected weld:

• V145-S CE (STICK mode): When the machine

is turned ON the fan will turn ON. The fan will
continue to run whenever the machine is
welding. If the machine doesn’t weld for more
than five minutes, the fan will turn OFF.

• V145-S CE (TIG mode), V145-S CE (12V) and

AUSTRALIA (STICK and TIG modes): When
the machine is turned ON the fan is OFF. The

Accessories
KIT-140A-16-3M Welding kit cables (3m, 16mm2).

KIT-140A-25-5M Welding kit cables (5m, 25mm2).

W0400062A TIG torch with tap, 4m.

.
2
W7915000A Carrying case with accessories: Welding kit cables (3m, 16mm ), Hammer/wire brush,
Welding mask with glasses.

9
MAINTENANCE
INPUT FILTER CAPACITOR
WARNING
DISCHARGE PROCEDURE
1. Remove input power to V145-S machine
2. Remove secondary case
3. 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.
Turn the input power off at the fuse box before working 4. Locate the two terminals DC+ and DC – on the input
on equipment board. See Figure 1
Do not touch electrically hot parts 5. Use electrically insulate gloves and insulated pliers.
Prior to performing preventive maintenance, perform the Hold the body of the resistor and connect the
following capacitor discharge procedure to avoid electric resistor leads across the two terminals. Hold the
shock resistor in place for 10 seconds. DO NOT TOUCH
CAPACITOR TERMINALS WITH YOUR BARE
HANDS.
6. Check the voltage across the two terminals. Voltage
should be zero. If any voltage remains, repeat this
procedure.

Fig.1

DC -

DC +

10
ROUTINE MAINTENANCE THERMAL PROTECTION
1. 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
2. Every 6 months the machine should be cleaned with rating. If excessive operating temperatures should
a low pressure and dry airstream. Keeping the occur, the yellow LED will light and the detection device
machine clean will result in cooler operation and will prevent output voltage or current.
higher reliability.
3. Examine the sheet metal case for dents or These detection device are self-resetting once the
breakage. Repair the case as required. Keep the machine cools sufficiently. If the thermostat shutdown
case in good condition to insure that high voltage was caused by excessive output or duty cycle and the
parts are protected and correct spacing are fan is operating normally, the power switch may be left
maintained. All external sheet metal screw must be on and the reset should occur within a 15 minute period.
in place to ensure case strength and electrical If the fan is not turning or the air intake louvers were
ground continuity. obstructed , then the power must be switched off and the
fan problem or air obstruction must be corrected.

11
MAJOR COMPONENTS LOCATION

ref. 03 secondary case

ref. 05 fan
ref. 09 input board
ref. 10 inverter board
ref. 11 control board

12
 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

13
 Input Line Voltage, Auxiliary Voltage and Precharge

GENERAL DESCRIPTION INPUT LINE VOLTAGE, AUXILIARY

VOLTAGE AND PRECHARGE
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:

• Vac peak voltage: below 410V.

• Vac frequency: in the range of 50 and 60 Hertz.
• RMS voltage of the AC waveform: 230Vac ± 15%.

The initial power is applied to the Invertec V145-S trough

a line switch located on the back of the machine. The
voltage is after rectified by the input rectifier on input
board and the resultant DC voltage is applied at inverter
Pcb’s.
During the precharge time the DC input voltage is
applied to the filter capacitors ( located on the inverter
Pcb ) through a start resistance ( located on input board)
that limits the charge current. After this time the start
relays go closed and they by-pass the start resistance (
there are two start relays in parallel , RL1A and RL2A ).
The 230AC voltage is also applied to a auxiliary voltage
circuit, that gives the necessary low voltages ( + 15V
and +5V ) for the control board.

14
 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. This is due to the
The IGBTs supply the main transformer winding with inductance of the transformer primary winding.
80KHz current flow. The secondary winding supplies the electrode-to-work
The inverter board also monitors the filter capacitors for voltages and the resulting current.
overvoltage. If this occurs, the appropriate error signal is The output current is regulated via Pulse Width
sent to the control board to disable the machines output Modulation.
and to turn on the thermal/voltage Overload LED. The control circuitry, on the inverter board , receives a
The IGBTs act as a switch assembly. This assembly signal from the control board and regulates the output
feeds the primary winding of the main transformer. When current to the desired level.
current is pulsed through this primary winding, a The output rectifier receives the AC output from the main
resultant current is produced on a secondary winding of transformer secondary winding and rectifies it to a DC
voltage level. Since the output choke is in series with the
the main transformer. The DC current flow through the positive leg of the output rectifier.
A filtered DC output is applied to the machine’s output
terminals.

15
 Control board

Control Board This machine is provided by an internal VRD (Voltage

Reduction Device) circuitry: this device reduces the
The control board receives status and voltage at the output leads. The VRD is automatically
analogue feedback from the inverter board, enabled / disabled by the machine. The factory default
input board and various sensor. voltage is:
The control circuitry interprets these signals,
makes decisions and changes the machine for V145-S CE: 75 Vdc
mode and output to satisfy the requirements for V145-S CE (12V): 12 Vdc
as defined by the circuitry. forV145-S AUSTRALIA: 12 Vdc
The control board sends a signals to the
inverter boards to control the output current. For CE version,ONLY: After 5 minutes of inactivity
the OCV shut down from 75Vdc to around 12Vdc

On control board DIP SWITCHES are present for these

above settings, see pag.33

16
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.
capabilities of the machine. Excessive temperature may be caused by a lack of
cooling air or by operating the machine beyond the duty
cycle and output rating. If excessive operating
temperature should occur, the Thermal LED indicator on
the control board, will turn ON and the thermostat will
prevent output current.
The thermal protection device is self-resetting once the
machine cools sufficiently. If the shut down was caused
by excessive output or duty cycle and the fan is
operating normally, the power switch may be left on and
the reset should occur within about 15 minute period. If
the fan is not turning or the air intake louvers are
obstructed, the input power must be removed and the
fan problem or air obstruction must be corrected.

17
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. is capable of conducting current. A voltage supply
Drawing A shows an IGBT in a passive mode. There connected to the drain terminal will allow the IGBT to
is no gate signal, zero volts relative to the source, and conduct and supply current to circuit components
therefore, no current flow. The drain terminal of the coupled to the source. Current will flow through the
IGBT may be connected to a voltage supply; but since conducting IGBT to downstream components as long
there is no conduction the circuit will not supply as the positive gate signal is present. This is similar
current to components connected to the source. The to turning ON a light switch.
circuit is turned off like a light switch in the OFF
position.

18
 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

19
 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.
………………………………………………………………………………………………………………………………

This Troubleshooting Guide is provided to help Step 3. PERFORM COMPONENT TESTS.

you locate and repair possible machine The last column, labeled “RECOMMENDED
malfunctions. Simply follow the three-step COURSE OF ACTION ” lists the most likely
procedure listed below. components that may have failed in your machine.
It also specifies the appropriate test procedure to
Step 1. LOCATE PROBLEM (SYMPTOM). verify that the subject component is either good or
Look under the column labeled “PROBLEMS”. bad.
This column describes possible If there are a number of possible components,
symptoms that the machine may exhibit. Find check the components in the order listed to
the listing that best describes the symptom that eliminate one possibility at a time until you locate
the machine is exhibiting. Symptoms are the cause of your problem.
grouped into three main categories: Output
Problems, Function Problems, and LED Function
Problems. All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
Step 2. PERFORM EXTERNAL TESTS. at the end of this chapter. Refer to the
The second column, labeled “CHECKS”, lists the Troubleshooting and Repair Table of Contents to
obvious external possibilities that may contribute to locate each specific Test Procedure. All of the
the machine symptom. Perform these tests/checks referred to test points, components, terminal
in the strips, etc., can be found on the referenced
order listed. In general, these tests can be electrical wiring diagrams and schematics. Refer
conducted without removing the case to the Wiring Diagrams Section Table of
wrap-around cover. Contents to locate the appropriate diagram.

20
MAINTENANCE
INPUT FILTER CAPACITOR
WARNING
DISCHARGE PROCEDURE
1. Remove input power to V145-S machine
2. Remove secondary case
3. 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.
Turn the input power off at the fuse box before working 4. Locate the two terminals DC+ and DC – on the input
on equipment board. See Figure 1
Do not touch electrically hot parts 5. Use electrically insulate gloves and insulated pliers.
Prior to performing preventive maintenance, perform the Hold the body of the resistor and connect the
following capacitor discharge procedure to avoid electric resistor leads across the two terminals. Hold the
shock resistor in place for 10 seconds. DO NOT TOUCH
CAPACITOR TERMINALS WITH YOUR BARE
HANDS.
6. Check the voltage across the two terminals. Voltage
should be zero. If any voltage remains, repet this
procedure.

Fig.1

DC -

DC +

21
 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

MISADJUSTMENT(S) OF ACTION

THE LINE CIRCUIT BREAKER 1) INPUT POWER BRIDGE 1) MULTIMETER CHECK 1) REPLACE INPUT BOARD
TRIPS WHEN POWER IS IN SHORT CIRCUIT 2) VISUAL INSPECTION AND 2) REPLACE INVERTER
SWITCH 2) ELECTROLYTIC MULTIMETER CHECK BOARD
IS “ ON” CAPACITORS FAILURE 3) VISUALLY INSPECT 3) REPLACE INPUT BOARD
3) VARISTORE FAILURE VARISTORE

THE MACHINE IS DEAD, 1) THERE IS NO POWER 1) CHECK THE PHASE INPUT 1) RECONNECT THE
NO OUTPUT, NO FAN SUPPLY ON LINE VOLTAGE ON THE POWER
2) THE POWER SUPPLY MACHINE SUPPLY
CABLE IS INTERRUPTED 2) CHECK THE POWER 2) REPLACE THE INPUT
3) LINE SWITCH FAILURE SUPPLY POWER CABLE
4) INPUT BOARD IS CABLE 3) REPLACE THE LINE
DEFECT 3) CHECK THE LINE SWITCH SWITCH
5) THE INVERTER BOARD 4) CHECK THE INPUT 4) REPLACE THE INPUT
IS DAMAGED BOARD BOARD
5) CHECK INVERTER 5) REPLACE THE INVERTER
BOARD FOR VISIBLE BOARD
DAMAGE

THE PILOT LIGHT IS “ ON “ 1) THERMAL PROTECTIONS 1) CHECK FAN AND 1) REPLACE FAN
BUT THERE IS NO OUTPUT HAS TRIPPED THERMAL PROTECTION 1A) REPLACE THERMAL
AND OVERLOAD LIGHT IS 2) LOGIC CIRCUIT ERROR ON INVERTER BOARD PROTECTIONS
“ ON “ ON CONTROL BOARD 2) CHECK CONTROL BOARD 2) REPLACE CONTROL
BOARD

===== WELDING PROBLEMS =====

THE MACHINE WELDS BUT 1) POTENTIOMETER 1) CHECK THE 1) REPLACE THE

THERE IS NO OUTPUT FAILURE POTENTIOMETER POTENTIOMETER OR
CONTROL 2) THE SHUNT SCREWS 2) CHECK THE SHUNT COMPLETE CONTROL
ARE SCREWS BOARD
LOOSE 3) ............................................ 2) TIGHTER SCREWS
3) INVERTER BOARD 3) REPLACE THE INVERTER
FAILURE BOARD

THE MACHINE DOES NOT 1) POWER CABLES ARE 1) CHECK ALL THE POWER 1) REPLACE DAMAGED
HAVE MAXIMUM OUTPUT LOOSE OR IN BAD CABLES CABLES
CONDITIONS 2) ……………….. 2) TRY TO SET AGAIN THE
2) THE CONTROL BOARD IS CONTROL BOARD
OUT OF CALIBRATION OTHERWISE CHANGE IT

THE MACHINE HAS HIGH 1) POTENTIOMETER 1) CHECK THE 1) REPLACE

WELDING OUTPUT AND NO FAILURE POTENTIOMETER POTENTIOMETER
CONTROL 2) CONTROL BOARD 2) 2) REPLACE CONTROL
DAMAGED ............................................. BOARD

THE VRD SYSTEM DOESN’T 1) WRONG SETTING ON 1) FOLLOW VRD SETTING 1) SET THE CORRECT VRD
WORK CONTROL BOARD INSTRUCTION ON THIS VALUE FROM DIP-
2) CONTROL BOARD MANUAL SWITCHES
DEFECT 2) ………………………….. 2) REPLACE CONTROL
BOARD

22
 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. If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you
proceed.
………………………………………………………………………………………………………………………………

DESCRIPTION

This test will determine if the input board has any copper wires burned or any faulty components.

MATERIALS NEEDED

Volt/Ohmmeter
Wiring Diagram W05X0509
Miscellaneous tools

This procedure takes approximately 10 minutes to perform

23
TEST PROCEDURE
1. Remove main input power to the Invertec V145-S
2. Remove secondary plastic cover, using a star screw driver
3. Perform the Discharge Procedure
4. Viasually check for burned area on the Input Board. Solder side
5. Check with multimeter for continuity between “AC1” to “ Point –A-” and “AC2” to “Point –B-”
6. Check the input rectifier bridge “D1”
7. Check Start resistance “R2” for 20 Ohms

AC1 AC2 Point Point

–B- –A-

D1 1 2
Input rectifier 1
R2 Start Resistor =
Bridge 20 ohms

24
 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. If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you
proceed.
………………………………………………………………………………………………………………………………

DESCRIPTION

This test will determine if the inverter board has any “ shorted “ or “leaky” power diodes or Insulated Gate Bipolar
Transistore.

MATERIALS NEEDED

Volt/Ohmmeter
Wiring Diagram X0519
Star crew driver
4 mm nut driver

This procedure takes approximately 15 minutes to perform

25
TEST PROCEDURE
1. Remove main input power to the Invertec V145-S
2. Remove secondary plastic cover, using a star screw driver
3. Perform the Discharge Procedure
4. Remove AC1 ,AC2, DC+,DC-,and flat cable from JP1, on input board
5. Remove the four screws at the input board corners
6. Remove the ground wires from the input board metal supports
7. Remove the input board and the two metal supports
8. Remove the copper flexible power cable from the inverter board shunt
9. Remove the bras screw ,where is also located the little white wire, from inverter board
10. Remove the three star screws that fix the inverter board to the primary cover
11. Remove the inverter board from the primary cover
12. Viasually check for burned area on the Inverter Board. in both sides componet and solder side
13. Check the IGBTs for “shorts” using the ohmmeter in test diode position, check each IGBT from Emitter to Collector.
Normal value is 0,40 Vdc in one polarity and a charging value in opposite polarity
14. Check also each device from Gate to Emitter. Normal value is 0,34 Vdc in both polarities
15. The IGBT’s of each channel are connected in parallel

NOTE: These devices will usually fail “ short” resulting in a zero or very low resistance reading. If they “open “ physical
damage should be evident

Collector IGBT
channel A Gate Emitter channel A

IGBT
Collector Emitter Gate channel B
channel B

26
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

D9

D7 D3

27
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. Check the resistence between the thermal protection terminals R24. It should be about 36 - 40 ohms
20. Check the resistance between output connections. It should be about 8,5Kohms

Output
Terminals

Point 1
( central Leg )

Point 2

R24 = PTC

28
 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. If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you
proceed.
………………………………………………………………………………………………………………………………

DESCRIPTION

This test will help to determine if the correct input voltage is being applied to the input board and will also determine if the
correct voltages are being processed on the input board.

MATERIALS NEEDED

Volt/Ohmmeter
Wiring Diagram X0509
Screw driver

This procedure takes approximately 10 minutes to perform

29
TEST PROCEDURE
1. Remove main input power to the Invertec V145-S
2. Remove secondary plastic cover, using a star screw driver
3. Connect the main 230V ac to the unit and switch ON the input switch
4. Check with multimeter between “AC1” and “AC2” for 230Vac
5. Check between DC+ and DC- for 320-325 Vdc
6. Refer pin 8,9,15 or 16 of JP1 as a ground
7. Check pin 2,4 and 14 for +15Vdc
8. Check pin 12 for +5Vdc

AC1 AC2

DC - DC +
JP1

Pin 17
Pin 16

Pin 1 Pin 2

30
 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. If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you
proceed.
………………………………………………………………………………………………………………………………

DESCRIPTION

This test will help to determine if the main inverter board is receiving the correct input voltages and if the correct
regulated voltages are being processed and maintained by the main inverter board.

NOTE: DUE TO SAFETY REASON AND FOR PHYSICAL INVERTER POSITION IS NOT
EASY TO PERFORM THE VOLTAGE TEST,ON INVERTER BOARD FOR THIS REASON
CHECKS CAN BE DONE FROM THE INPUT BOARD JP1 CONNECTOR (see next page)
MATERIALS NEEDED

Volt/Ohmmeter
Wiring Diagram X0509 and X0519
Screw drivers

This procedure takes approximately 10 minutes to perform

31
TEST PROCEDURE
1. Remove main input power to the Invertec V145-S
2. Remove secondary plastic cover, using a star screw driver
3. Connect the main 230V ac to the unit and switch ON the input switch
4. Set the unit in STICK mode
5. Check following points on JP1 connector
6. Refer pin 8,16,9 or 15 as a ground
7. Check on pin 1 -> +15Vdc means fan ON while 0(zero) Vdc means fan OFF
8. Check on pin 3 -> 0(zero) Vdc during OCV condition
9. Check on pin 5 -> 11,6 Vdc means the inverter is ON ( only for CE version in the first 5 minutes after activity )
while 1,5 Vdc means inverter OFF ( normal for CE 12 V version and Australia version )
10. Check on pin 6 -> value change from 7,6 to 8,5 Vdc during reading when the inverter is ON ( only CE version ) ;
50-60 mVdc when inverter is OFF ( normal for CE12 Vdc and Australia version )
11. Check on pin 7 -> 15 Vdc
12. Check on pin 11 -> 5 Vdc
13. Check on pin 12 -> 5 Vdc ( supply voltage generated on input board )
14. Check on pin 13 -> pin not used
15. Check on pin 14 -> 15 Vdc ( supply voltage generated on input board )

Jp1

Pin 2
Pin 1

32
 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 CE 12V version Australia 12V version

1 OFF OFF ON
2 OFF ON ON
3 OFF ON ON
4 OFF OFF OFF

Here below the difference between CE12V version and Australia 12V version :

CE 12V version = The inverter switch ON when the resistance between electrode and piece is less than
20Kohms
Australia 12V version = The inverter switch ON when the resistance between electrode and piece is less than
200 ohms

SW2

33
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.
• Use only the the parts marked "X" in the column under the heading number called for in the assembly page (# indicate a
change in this printing).

SP52018/52021/52022 Rev. 1
07/03

INVERTEC V145-S CE, V145-S AUSTRALIA

Machine Assembly

ASSEMBLY
PAGE NAME

CODE
FIGURE NO.: A
NO.:
52018 V145-S CE 1
52021 V145-S AUSTRALIA 2
52022 V145-S CE (12V) 1

Figure A

34
 Figure A: Machine Assembly
Item Description Part Number QTY 1 2 3 4 5 6
1 Front Panel with Front Nameplate W95X0521R 1 X X
2 Primary Case (dx) with Side Nameplate (dx) W95X0523R 1 X X
3 Secondary Case (sx) with Side Nameplate (sx) W95X0522R 1 X X
4 Rear Panel W95X0524R 1 X X
5 Fan, 120x38mm W7200004R 1 X X
6 Cable Clamp W8460038R 1 X X
7 Input Cable CE W78X0248R 1 X Ÿ
7 Input Cable Australia W78X0369R 1 Ÿ X
8 Input Switch W7516224R 1 X X
9 Input P.C. Board W05X0509R 1 X X
10 Inverter P.C. Board W05X0519R 1 X X
11 Control P.C. Board W05X0510R 1 X X
12 Knob Kit W8700022R 1 X X
13 Output Dinse Connector W7600024R 2 X X
14 Carrying Strap W92X0543R 1 X X

35
 INPUTINDUCTOR
W58X0599
BLUE

BROWN
5 2
ON/OFFSWITCH RED DC+
4 1 BLACK DC-
BROWN
Electrical Schematic

BLUE
WIRETIE DC+ RED
L BROWN AC1 PWR2 PWR5 PWR4 PWR1
DC- BLACK INVERTERBOARD
N BLUE
AC2 W05X0519
Y/G Y/G INPUTBOARD JP1
PE3 (SCHEMATIC:X0519)
230Vac W05X0509
50/60 Hz (SCHEMATIC:X0509)

36
BLACK AC1A
MACHINESCODE52018 AND52022 FAN
BLUEWIRE:MOUNTED BLACK AC2A
Y/G
INPUTINDUCTOR:NOTMOUNTED JP1 PE P1
+
MACHINESCODE52022
BLUEWIRE:NOTMOUNTED N1
-
INPUTINDUCTOR:MOUNTED SHUNT
BLACK
WHITE
RED

TWISTEDCABLE
RIBBONCABLE RED
BLACK
JP1 JP2
PCBCONNECTORCAVITYNUMBERINGSEQUENCE WHITE
(VIEWEDFROMCOMPONENTSIDEOFP.C.BOARD) Y/G
PE CONTROLBOARD
1 4 2 16 W05X0510
(SCHEMATIC:X0510)

4PINS 1 15
16PINS
 Wiring Diagram Reference Number:

• X0548 Block diagram V145-S

• X0509 Input Board V145-S

• X0519 Inverter Board

• X0510 Control Board

37