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Lincoln Electric INVERTEC SVM129-B User's Manual

1. ITEM REQ D PART NO IDENTIFICATION 3 516666 11 1 50 2592217 2 157 7 456 o00pF 1000 CAPACI TOR 23 6 12 0515 3 S 13490 92 3300 50 e o 210 1 513490 94 33 200 Lr RENNES EET EXC ETE 6 5 16668 5 022 50 515 O FA 8 4 STT DARLINGTON DRIVE DE pm AAi D1 D2 D3 D4 4 T12705 45 DI ODE 8 EX G2718 ka m 5 1 2199 144004 ole n T m ms 06 07 08 09 D10 D11 D12 8 T12705 14 DI ODE cjs uL D12 gt 13 515 gt lt Re R14 HH HA H k 11 D11 gt lt 2 EMG lt M 041 DZ3 2 2 02 45 IN4746A i 25 R13 2 72 2702 19 1N47426 a a ps M gt lt T C9 gt lt R10 12 S 18248 HEADER XXX PS 13 518248 6 HEADER Mus gt lt 25 OCT 1 515000 26 OPTOCOUPLER LOGIC QUT ets SED E 35 R9 5 S18105 7 MOSFET HEAT SINK ASSEMBLY 9 24 02 2704 80 46 100V MOSFET S9 Pe gt E 4 E TE a PONI O Ni R1 2300 81 5 WATT 0 5 1 OHM RESISTOR LA K d R2 R3 2 519400 1501 5K 1 4W R4 S 19400 3921 3 92K 1 4W o z R5 519400 2670 267 1 4W 16 R7 2 519400 1080 0 1 4W
2. olo eg S8 Ole 2 gt olo ITEM PART NO IDENTIFICATION C1 1 513490 92 3300 50 5 8 C2 C7 C11 C 14 4 516668 5 022 50 1 T11577 2 150 50 C5 1 513490 64 39uF 20VDC C6 1 S 13490 19 1 8 20 C8 C9 2 16668 11 1 50 C10 1 T11577 49 500 50 Gir 9 01 02 03 04 05 08 09 010 11 12199 1 IN4004 Fw Ix D11 D12 013 dE i CRI 10 all S 06 07 D 15 016 4 12705 23 IN58 18 fies rabi dee ic 2d im Be 014 1 12705 34 1N4936 l mi e J pao B EB ES m 021 1 T12702 29 1 447444 ole ul icq 451 45 d Ps n fani n c DZ4 DZ5 2 T12702 19 1 474204 z E um 8 Ll qur aad N UU 2 026 1 T12702 40 1N4735 218 rg u 05 of opt EERE c m J6 1 S 18248 10 HEADER 1 1 pea pr FTT mz 7 1 5 18248 8 2 2 0 S iz LES NS J14 1 518248 4 HEADER Pn HE i N OCI 1 1 15000 10 ISOLATOR BRE 5 ELEME 05 1 T12704 65 3 54 60V MOSFET SS als 9 i 040 1 T12704 68 2N4401 2 2 R1 1 T13165 16 1 0 OHM 5W RESISTOR 9 R2 1 519400 2671 2 67 1 4W R3 1 5 19400 2430 243 1 4W R4 1 519400 1501 1 5 1 4W R5 R6 R 10 R22 4 S 19400 1003 100K 1 4W R7 R8 R
3. c POWER 825 5461 f PINCH BREAKPOINT b 5 CONTROL D401 10K START RESET e pi e nos 427 5 ra TOK SHEET R428 d REMOTE POTS 2 POTS A419 3 32K PINGH COMMAND 2231 LOCAL POTS ANALOG LOGIC CURRENT enm 1 ERROR E35 1 1 R459 458 EN ISOLATED CIRCUIT BOOST COMMAND 330p E 100v PB_SCALED L 1200 BOOST RAMP IN D402 HOT_START 4 2 V PBooST i E TS J2 500K INCREASE TAILOUT p TAIL OUT DURING HOT START X24 cw J2 OR 500K POT 15 Poca Pots 0414 REMOTE PB POT LOCAL PB POT PWM OUTPUT T
4. sessed 2 8 General 9 B 3 Recommended EquipImmeht occi itis i tes ices ced Ce Ue bad B 3 Operating Controls RET B 3 nae B 3 Welding Capability M B 3 rf B 3 Operational Features and Controls 4 Welding 5 Welding Parameters and B 6 Recommended Settings for nennen entente nnns B 7 Return to Master TOC o E Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 2 Return to Section TOC Return to Master TOC o 5 OPERATION OPERATING INSTRUCTIONS Read and understand entire section before operating machine GENERAL WARNINGS SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or
5. v UNLESS OTHERWISE SPECIFIED TOLERANCE H EQUIP 77 77 TT THE LINCOLN ELECTRIC Wt REMOTE PROTECTION BOARD IS 02 ON 3 PLACE DECIMALS IS 002 CHASSIS ON ALL ANGLES IS 5 OF A DEGREE CLEVELAND OHIO U S A SUBJECT SCHEMATIC MATERIAL TOLERANCE TO AGREE SCALE NONE E S WITH PUBLISHED STANDARDS MLD DATE 04 20 94 cH sPSDG NO DR Return to Section TOC Return to Master TOC M 17609 IB fo NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided STT amp STT ELECTRIC for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of design and may result in danger to the Machine Operator Technician Improper PC board repairs could result in damage to the machine G 29 ELECTRICAL DIAGRAMS 29 PC Board Assembly Remote Protection Codes 19657 6 19961 ENGINEERING CONTROLLED CHANGE DETAIL NEW ITEM QTY PART NUMBER DESCRIPTION MANUFACTURER No 1 ___________ SEE BLANK PCBOARDBLANK 2 4 REFER TO ELECTRONIC COM
6. R473 Le CR FUSE x19 VDD R314 475K vss SET 2 KEEP IN BOOST _ 140138 STARTS R322 O 475K lt 4 CURRENT FEEDBACK 1V 100A 33 2K H A100 m vaso START RESET Bm L DGABLE LOCAL PB TIME NAND HE OPTION ENABLED PB START SIGNAL PB_START 184936 ries 1 NO OPTION TO FE SHEET 2 po 1 is 5 FOR ENERGY ENERGY CONTROL OPTION T E CONTROL OPTION ENABLE SHEET 2 OVERCURRENT HP2231 TRIP TIMING ARC START 4 18 5 0421 5 1N4936
7. LESS THAN 1VDC PULSE TRANSFORMER SIGNAL CONTROL BOARD PEAK WIRE TAILOUT BACK BACK CURRENT GROUND 7 GROUND ca METER METER CONTROL CONTROL CONTROL SWITCH SWITCH RECEPTACLE REMOTE CONTROL RECEPTACLE r z0 0 lt 20 WIRE FEEDER RECEPTACLE zO dOomadouu maosmzm CURRENT FEEDBACK IGBT DRIVER BOARD VOLTAGE FEEDBACK 10VAC AND 6VAC GENERAL DESCRIPTION The Invertec STT is a 225 ampere inverter based arc welding power supply specifically designed for the Surface Tension Transfer STT welding process cannot be classified as either a constant current CC or a constant voltage CV machine The STT pro duces current of a desired waveform to reduce spatter and fumes The STT process is optimized for short circuit GMAW welding only 42 INPUT VOLTAGE The Invertec STT can be connected for a variety of three phase voltages The initial input power is applied to the STT through a line switch located on the front of the machine The AC input voltage is applied to the input rectifier and the T1 auxiliary transformer The T1 transformer develops the appropriate AC voltages to operate the cooling fan the power and control boards The T1 transformer also supplies primary voltage to the T4 auxiliary transformer as well as 42 VAC to an exter nal wire feede
8. 6 25 Capacitor Balance 29 SWitch Board cL F 33 Snubber Resistors F 37 Power Board TeSt 41 Protection Board acer F 45 Trigger Circuit TeSt M PR F 49 Replacement Procedures endian thawed led ced denen 53 IGBT Module Removal and F 53 Switch Board Replacement ti e erede xke en Ea RR nn F 59 Capacitor Removal and Replacement Procedure F 65 Output Rectifier Removal and F 73 alude n F 77 INVERTEC STT LINCOLN 5 Section F 1 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F 2 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE A 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 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 Gui
9. R514 e R521 68 1K 33 2K j lt H 5 4 Return to Master Return to Section TOC m R10 vio 0422 150K om 518 LLIA 1002 ornon ps mue ENERGY CONTROL OPTION L LOCAL PB TIME WIRE SUE SELECT dires n P BOOST TIME SHEET 2 H OPTION PB TIME lt 035 DIA WIRE wes sema ya 4 25 EK E gt 045 DIA WIRE 10 Tm Sw PAS OUTPUT WIRE TYPE SELECT SS_WIRE 10K 5 oute PWM_SYNC E MILD He Q Q 200 2 e lt 3 5 SAWTOOTH m WIRE TYPE POSITION 414 0 WAVEFORM RT 6 TO FE SHEET 2 STAINLESS GENERATOR FOR ENERGY CONTROL 10 VDC 2 E DEADTINE R457 A COMMAND L OPTIONPB TME HOTSTART a je INCH COMM PINCH FAST RAMP ENABLE t
10. 5 CURRENT SENSOR R 39 FET p y zE R VOLTAGE J PRE SENSING LINE INPUT 1 CHARGE M RECEPTACLE SWITCH RECTIFIER Hi R 5 ar CR1 R T o 1 REMOTE 0 A TRANS v B CONTROL N v s Y RECEPTACLE N TR E S R A E D 1 D R R N N D T A PRE i CHARGE ges 1 rer RECEPTACLE gt N R FET p LESS THAN 1 PULSE TRANSFORMER SIGNAL SUN TRIGGER CONTROL BOARD TAILOUT GROUND Pl WIRE WIRE Er x y gir Hn tio VOLTAGE FEEDBACK 10VAC AND 6 SWITCH BOARDS There are two switch boards in the Invertec STT each containing an input filter capacitor The capacitors are connected in parallel when the machine is connected for low input voltage The capacitors are connected in series when the reconnect switch is configured for high input voltage When the capacitors are fully charged they act as power supplies for the switch boards The switch boards contain the Field Effect Transistors FETs which when switched on supply the main transformer primary windings with DC current discussion and diagrams See Figure E 4 NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INVERTEC STT LINCOLN 5 Return to Section Return to Master TOC
11. IN v 519400 1000 100 1 4W R402 R504 R5 12 519400 7520 75 1 4W R408 19400 1782 17 8K 1 4W R411 R494 19400 6811 6 81K 1 4W 509 pz2o 8342 2 sr 8218 Ri6 204 I R206 F 0208 021 022 DZ 10 DZ 11 DZ 15 02 16 DZ 17 DZ 18 DZ 19 T12702 19 1N4742A R413 19400 2000 200 1 4W R421 19400 4753 475K 1 4W 023 078 02 12 12702 29 1447444 R422 R497 R523 R524 519400 1503 150 1 4W 024 025 112702 37 1 4755 026 12702 53 1 472 R426 19400 3321 3 32K 1 44 079 0720 12702 27 134740 R439 519400 1502 15K 1 4W 18248 4 HEADER R443 8560 519400 8252 82 5K 1 4W 518248 16 HEADER R454 R456 519400 3011 3 01K 1 4W 518248 6 HEADER R458 19400 4750 475 1 4W 518248 12 HEADER R467 518380 4 THERMI STOR 518248 8 CONNECTOR R479 19400 5620 562 1 4W 518248 10 HEADER
12. Section 2 Wiring Diagram Entire Machine Codes 10151 10153 G2773 G 2 Wiring Diagram Entire Machine Codes 10381 10383 03136 G 3 Wiring Diagram Entire Machine Codes 11090 11092 G4500 G 4 Wiring Diagram Entire Machine Codes 11115 11116 G4557 G 5 Schematic Control PC Board Codes 10151 11092 G2781 Sheet 1 G 6 Schematic Control PC Board Codes 10151 11092 02781 Sheet 2 G 7 B PC Board Assembly Control Codes 10151 11092 2782 G 8 Schematic Control PC Board Codes 11115 11116 G4649 Sheet 1 G 9 Schematic Control PC Board Codes 11115 11116 24649 Sheet 2 G 10 3 PC Board Assembly Control Codes 11115 11116 04648 G 11 Schematic Power PC Board All Codes M16018 G 12 2 PC Board Assembly Power All Codes 18033 G 13 Schematic Darlington Drive Board Codes 10151 10383 M17581 G 14 PC Board Assembly Darlington Drive Codes 10151 10383 02778 G 15 Schematic IGBT Drive Board Codes 11090 11116 L12144 G 16 PC Board Assembly IGBT Drive Codes 11090 11116 112145 G 17 Schematic Switch Board All Codes 18440 G 18 PC Board Assembly Switch All
13. He OPTION ENABLED Le NO OPTION ARC_START DISABLE OPTION TO START HOT START Ls OPTION PB TIME PWM SYNC 1 H ET 3 92 z R457 EH i d cio f START RESET 1 i 231 lye y d C422 42 2047 Im T 4 8 ait gH LA V OPTION PB TIME LOCAL PB TIME EN GUTPUT 1 15V REM WIRE TYPE POSITION TO FE SHEET 2 FOR ENERGY CONTI OPTION ISOLATED CURRENT ERROR R532 RITA P BOOS COMMAND 4 1 9K R444 np HOT START 79 417 BACKGROUND COMMAND aly 2700p s 3443 Sev 2714 825 OUT 12 8K 432 R445 SHORT OR BOOK POT 15 514 7 50v Le 8435 Pr ccs 044 19k 12 1000 J2 Lox NJ 127 lt lt 0415 X30 0 8549 R548 R547 R495 of tT cw y ZEK 267K 267K 267K css Ta 8 M 10 57 REMOTE Unused Devices 128 s 2128 128 4 E m 02 0088 NOTES NUMBER 1 2248 HOT START SINCE COMPONENTS OR CIRCUITRY A PRINTED CIRCUIT B
14. HCPL220 __ 1 R OJO 400V is NE Fle cls ON IGBT ON 2 OFF IGBT OFF ds os 4 15k 3 NECI eee GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 MFD 022 50V UNLESS OTHERWISE SPECIFIED V RESISTORS Ohma 1 4W UNLESS OTHERWISE SPECIFIED LABELS Olo DIODES 1A400V UNLESS OTHERWISE SPECIFIED Ew SUPPLY VOLTAGE NET o 12 POWER SUPPLY SOURCE POINT 2 2 WITHOUT AFFECTING THE NTERCHANGEABILIFY OF A COMPLETE BOARD THIS DIAGRAM MAY CONECTION 2 9 9 G NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMOM CODE NUMBER mt EARTH GROUND CONNECTION o 01 7 50 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION DWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED olg HCPL2201 CAVITY NUMBERING SEQUENCE Em PROPRIETARY amp CONFIDENTIAL TG GER PANES ON USED ANY PURPOSE WITHOUT THE EXPRESS WATT TEN PERMISSION OF LINCOLN GLOBAL INC i GU NIE COMPONENT SUE OF BOARD R SPRINTED CREU BORA MAY wereece EQUIPMENT TYPE STT I WELDERS PAGE 01 OF 1 5 2 WITHOUT AFFEC INTERCHANGE DRAWN fi DOCUMENT DOCUMENT i ABILITY Ge A COLETE Son TS SUBJECT _ STT I 1887 DRIVE SCHEMATIC Gs COMPONENTS OR CIRCUITRY OF CONTROLS MATERIAL APPROVAL PROJECT
15. G 11 8 9 ENGINEERING CONTROLLED eM REQD PARTNO fem REQD PART NO IDENTIFICATION 1 c s cto ROOD ROMS RARA TAN _ 1 15154576 R432 R436 R532 102 103 105 301 472 5 516668 3 100pF7100 156 R423R490 3 9194002673 267K 1 4 ols 73 srs RTSLRYAZRTS RTT RIS 19400 1002 106 TAW 106 205 303 305 306 516668 8 330 100 vale E anon x IR320 R324 R325 R330 R331 ARS PER PANEL SEE ELEC 333 8403 8412 8414 8431 MAKES 2 BOARDS PER PANEL SEE ELECTRONIC FILE C204 211 307 C306 c FOR ADDITIONAL INFORMATION CA 3 CA 4 C425 C 426 C427 IR478 R509 R510 R527 R528 5 gt 428 429 0430 432 433 IR529 R536 R539 R540 R551 R561 R563 R564 R138 R406 R495 R508 R541 15 19400 2677 2 67K 1 4W a R542 R543 R544 R545 R546 IR547 R548 R549 C108 C419 2 51340019 1820 R139 R157 R387 _____ 519400 2
16. Greater than None Continue 1K ohm Less than Shorted Replace both Snubber Test 100 ohms switch boards Continued NOTE K ohm ohm reading multiplied by 1000 NOTE Always make sure that switch boards are changed in matched pairs Never mix an old style different part number switch board with a new switch board new part number Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC 5 F 36 F 36 TROUBLESHOOTING amp REPAIR SWITCH BOARD TEST continued TABLE F 5 SWITCH BOARD RESISTANCE TEST continued Apply Positive Apply Negative Test Probe to Test Probe to Terminal Terminal Test Result Conclusion Repair Action Next Procedure Notes 12 401 403 Greater than OK None Continue 1K ohm Less than Shorted Replace both Snubber Test 100 ohms switch boards 401 403 Less than OK None Continue 100 ohms Greater than Replace both Snubber Test 1K ohm switch boards 402 404 Less than None Continue 100 ohms Greater than Replace both Snubber Test 1K ohm switch boards 402 404 Greater than OK None Continue 1K ohm Less than Shorted Replace both Snubber Test 100 ohms switch boards NOTE K ohm
17. ON L PWM OFF 100K R235 Le 3L A TRIGGER INTERFACE OVERCURRENTFAULT A FROM SHEET 1 J4 C R216 4 sees 8 0206 Tt AUXXFMR 221K 2AVAC Topower BOARD Duy pos 7 PWM ENABLE TO ANALOG LOGIC SHEET 1 0209 0210 ISOLATED CIRCUIT UNUSED lt lt e 0 X28 D COMPARITOR ON SHEET 1 ON TRIGGER ON OFF TRIGGER OFF SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER UNLESS OTHERWISE SPECIFIED TOLERANCE HOLES SIZES PER E 2056 2 PLAGE DECIMALS IS 02 2 PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE 77 TO AGREE WITH PUBLISHED STANDARDS FILE G2781_1D1 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS 022 50V RESISTORS Ohms DIODES 1 400V REFERENCE DESIGNATOR SERIES DEFINITIONS 100 SERIES ARC SENSE CIRCUIT SHEET 2 200 SERIES TRIGGER CIRCUIT SHEET 2 300 SERIES DIGITAL LOGIC CIRCUIT
18. 5038 230 DARLINGTON HEATSINK 0 3 lt 15 32A 22 THERMOSTAT 32c 16 328 503A e 5 14 e 5 438 o 42 42 o VAC s x e b 33D o 2 115 gt 31 o 6AMP Return to Section TOC Return to Master TOC b 303 330 lt 8 lt 338 FAN 302 J31 d av THERMOSTAT gt 304 fy 5 gt 275 224 212 35 503 210A FE 2 3 7 33 224 2 Ws 65 224A 212B 5 301 150 gt 212 4 b 211A gt gt 504 212 210 4 gt Ti AUXILIARY AUXILIARY TRANSFORMER TRANS ORMER Y lt 4 301 4 305 4 245 lt 41 48 13 19 223 lt J11 412 J14 10 13 45 47 ELECTRICAL SYMBOLS PER E1537 21A J18 J37 415 435 J34 J6 J27 J33 2120 12 1 3 1 4 1 5 COLOR CODE 210 4 246 lt BLACK 4 G GREEN 502 4 46 5 5 0 c NS 116 428 12 136 6 6 8 RED do eor _ 8 W WHITE METER PINOUT VIEWED FROM BACK Or METER Y YELLOW BACKG
19. SCALE DATE Ohms 1A 400V 40V 2N4401 D5 A 1N4936 404 FILE NO 18440 1 CLEVELAND OHIO U S A RESISTORS DIODES GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 THE LINCOLN ELECTRIC CO CAPACITORS 4 TRANSFORMER 5 PRIMARY O Return to Section TOC Return to Master TOC A2 BYT30P600 o pi INPUT 1N4936 FILTER wo e gt CAPACITOR E at 100V 5 c IRFO110 BYT30P600 Qu ca 1 TRANSFORMER 2N4403 4 9 8 PRIMARY MATERIAL TOLERANCE TO AGREE 6 2V D10 1N4936 Q10 02 03 04 06 IRFD110 e 7 lcs IRFP460 012 lt 600 S 40V 95762 59 84 55 2N4401 HOLES SIZES PER 2056 ON 2 PLACE DECIMALS 18 02 WITH PUBLISHED STANDARDS NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NUMBER ON 3 PLACE DECIMALS 15 002 ON ALL ANGLES IS 5 OF A DEGREE UNLESS OTHERWISE SPECIFIED TOLERANCE 2 D S
20. UNLESS OTHERWISE SPECIFIED TOLERANCE 4 13 95 E M 5 20 96L THE LINCOLN ELECTRIC CO TIRE INVERTEC ON ALL ANGLES IS 5 OF A DEGREE 7 B 27 06F CLEVELAND U S A SUBJECT POWER BD SCHEMATIC MATERIAL TOLERANCE t TO AGREE 10 25 96 SCALE NONE Te SHT WITH PUBLISHED STANDARDS DR __ DATE 11 10 92 CHK SUP S D G NO 16018 Return to Master TOC Return to Section TOC IB NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided STT amp STT ELECTRIC for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine G 13 ELECTRICAL DIAGRAMS G 13 PC Board Assembly Power Codes L8033
21. 10VAC AND 6VAC 42VAC RECONNECT PROTECTION BOARD RECTIFICATION AND PRECHARGE The reconnect panel allows the user to switch to low or high input voltage to match the input line voltage The AC input voltage is rectified and applied to the driver board The driver board contains precharging circuitry for safe charging of the input filter capacitors Once the capacitors are precharged the input relays are ener gized connecting full input power to the input filter capacitors The protection board monitors the capaci tors for voltage balance and or overvoltage and will de energize the input relays and precharge circuitry if either occurs The machine output will be disabled O10 OJO E AE a gt 2 2 5 5 o NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo o E olg gt 8 515 o Return to Section Return to Master TOC E 4 THEORY OF E 4 OPERATION FIGURE E 4 SWITCH BOARDS MAIN TRANSFORMER T2
22. 150 150 FROM PROTECTION BD Capacitor Pre charging Circuit FROM PROTECTION BD 6 25 93C THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A SCALE _NONE _ Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine DR LC ___ DATE 11 492 CHK 85 FILE 520799 1 EQUIP INVERTER WELDERS TYPE G 20 SCHEMATIC DRIVER BOARD SHT SUP S D G No 5 20799 idate your factory warranty Individual Printed Circuit Board Components not available from Lincoln Electric This information is provided INVERTEC STT STT Return to Section TOC Return to Master TOC Return to Section TOC olo O 515 g 2 cic 5 5 a Return to Section TOC Return to Master TOC Return to Master TOC G 21 ELECTRICAL DIAGRAMS PC Board Assembly Driver All
23. e j R3 5 X3 R13 PI R1 816 C2 9 R4 R12 C1 R8 X1 R9 R10 R11 R5 ITEM REQ D PART NO DESCRIPTION C1 C5 2 S16668 5 022 50 ui ee C2 1 S 16668 9 150pF 100 C 1 S 13490 72 50 50 LO C4 1 16668 11 1 50 J18 1 518248 4 HEADER 2 Q1 1 T12704 62 TRANSI STOR N T220 3A 100V R1 R14 2 5 19400 1501 1 5K 1 4W R2 1 T108 12 73 2K 1 2W TRI MMER R3 R4 2 S 19400 1001 IK 1 4W R5 R12 2 S 19400 1000 100 1 4W R6 1 T10812 77 20K 1 2W TRIMMER R7 1 S 19400 6811 6 81K 1 4W R11 2 S 19400 68 13 681K 1 4W J18 R9 R10 2 S 19400 1372 13 7K 1 4W R13 1 5 19400 2941 2 94K 1 4W R15 1 S 19400 10RO 10 1 4W R16 1 S 19400 1002 10K 1 4W X1 1 515 128 16 LINEAR INTEGRATED CIRCUI T 2 1 618504 1 CURRENT SENSOR x3 1 S 15 128 10 VOLTAGE REF Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine CAPACITORS MFD VOLTS INVERTEC
24. emp x HR Section E General 2 157012 ERE 2 Reconnect Protection Board Rectification and Precharge E 3 WICH 4 Main Transformer Output Rectification and E 5 Control Board IGBT Drive and emen ene E 6 POWER BOAR es rb tes E 7 Remote Protection Board tee ee et E 7 Field Effect Transistor FET E 8 Pulse Width Modulation Minimum Outputs tero eint tuii ntn eid ri Maximum OutpUl eer teste ER E Protective teer tenent NN M RUE MM EP Id Overload Protection 222 MAIN TRANSFORMER T2 is Pu 5 B CURRENT rd ET SENSOR 1 Al FET D Z Ah LL PRE LINE INPUT CHARGE 1 RECEPTACLE SWITCH RECTIFIER 1 F H H E L
25. 2 3 Return to Master TOC ojo O 0 55 E N 2 2 8 ele 2 5 8 2 2 H N 223 J5 J17 J27 J28 J2 J3 J1 4 DVL 177 s ARA NNN IPS 5 o pfe Big paese a Ph pu O olie AANA Nibley da gt p E ret MEERN o 9 E 210 5 6 Using the ohmmeter check for approximately lead 223 at the control PC board See 9198 3 5 ohms resistance from pin C of the 14 pin Figure F 21 and Figure F 22 Simplified amphenol see Figure F 20 to plug J4 pin 9 Trigger Circuit Diagram 51 3 5 c INVERTEC STT LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC olo E olg gt 8 515 Return to Master TOC F 52 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued FIGURE F 22 SIMPLIFIED TRIGGER CIRCUIT DIAGRAM POWER BOARD 3014 FROM PROTECTION BOARD OVERVOLTAGE CONTROL BOARD gt gt 8305 lt PWM OUTPUTS TO POWER BOARD STT II Only T1 AUXILIARY TRANSFORMER ll O
26. 2 CONNECTION MAIN 289A 20304 288A m in CURRENT 2 4 3 0 SENSE 2090W 4 287 Comme OUTSIDE E Return to Section TOC Return to Master TOC 3 2 0 1 9 10 5 9 12 4 11 8 INSIDE 4 53 INPUT i fis RECTIFIER 9090 4008 2 4 9 52 52 PROTECTION gt BOARD OPTIONAL REMOTE 290A INTERFACE WIRE Jag FEEDER N ELECTRODE SENSE LEAD 414 3406 21 iee OMC 81 5 2405 13 413 O 2 TRIGGER 16 3 416 lt K 42 42 8 n 15 45 1 7 apt ye Se J ECT 76 lt 06 75 503B 1 dee 2 5 48B oN 42 HEATSIN 3 5 42 9 THERMOSTAT 308 4 8 4 503A 309 2 pope 310 lt 4 2 6 3 224 6 gt 224A CB2 115 504 8 s gt _ 10 28 11 2 3 224 AJm3 N H EZA RECONNECT 9B c oS 98 1 DRIVE BOARD SWITCH BOARD RIGHT 25 25W 450V POWER LINE FILTER ASSEMBLY 371105 371A 374 gt 11 gt 374A 1 gt 240 18V 25 241 19V 3 gt 242 Return to Section TOC Return to Master TOC 330
27. DOL uonoes 0 DOL 49 49 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST A 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test includes a few quick checks to troubleshoot the machine trigger circuit The Simplified Trigger Circuit Diagram will enable the technician to view the trigger circuit in an abbreviated uncomplicated format Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver Volt ohmmeter Multimeter Wiring Diagram and board Schematics Note Component locations and disassembly procedures may vary slightly on STT models olo E 2 olg iz 8 515 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 50 50 TROUB
28. 5 INSTALLATION CASE BACK INPUT CABLE RATING PLATE ENTRY ACCESS amp CABLE STRAIN RELIEF FIGURE A 1 CASE BACK INPUT CABLE INSTALLATION AND CON NECTION 5 Connect the three phase line con ductors to the power switch termi D nals labeled U V and W Tighten A cable strain relief is provided at the supply line entry the connections to 3 0 Nm 27 in Ib torque and is designed to accommodate cable diameters of 310 1 070 in 7 9 27 2 mm On European models the strain relief is designed to accommodate cable diameters of 709 1 000 in 18 0 25 4 mm Refer to Technical Specifications at the beginning of this sec tion for the proper input cable sizes Refer to Figure A 1 and perform the following steps 6 Securely tighten the cable strain relief located on the case back of the machine GROUND CONNECTION 1 Remove the wraparound cover of the Invertec STT Il 1 Connect the ground terminal to earth QD ground per National Electrical Code 2 Feed the input cable through the input cable entry access hole at the right rear of the 2 Replace the wraparound cover of the machine Invertec STT Il 3 Route the cable through the cable hangers located along the lower right inside edge of the machine up to the power switch located on the front panel 4 Strip away 102 mm 4 in of the outer jacket Trim fillers and strip conductor jackets to connect to the power switch INVERTEC
29. N END VIEW FRONT VIEW Table B 3 90 He 7 5 Ar 2 5 Gas Shield Set for Steel Mode Plate Thickness mm Electrode size mm WFS min m min Peak Current Background Current Tailout setting Average Amperage Travel Speed min m min Gas Flow cfh L min Electrical Stickout mm Table B 4 98 Ar 2 Gas Shield Set for Stainless Steel Mode Plate Thickness mm Electrode size mm WFS min m min Peak Current Background Current Tailout setting Average Amperage Travel Speed min m min Gas Flow cfh L min Electrical Stickout mm INVERTEC STT LINCOLN 5 8 NOTES O tr 5 gt E NOL Je1Se A 0 DOL J91Se N 01 DOL 0 DOL J91Se N 01 DOL uonoes DOL uonoes DOL uonoes 0 DOL Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES 9 Section C eni ACCROSS ONG E C 2 LN 742 Wire Feeder Connection C 3 Connection 4 Return to Master Q E Return to Mast
30. DOL 41 41 TROUBLESHOOTING amp REPAIR POWER 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the power PC board is receiving the correct AC voltages and also if the correct DC voltages are being generated on the power PC board MATERIALS NEEDED 5 16 Nut driver Volt ohmmeter Multimeter Wiring diagram Return to Section TOC Return to Master TOC Note Component locations and disassembly procedures may vary slightly on STT models o 5 o 2 2 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 42 42 TROUBLESHOOTING amp REPAIR POWER BOARD TEST continued FI
31. POS FE POWER PLANE 45 UNUSED GATES lt 2 J5 14 owe P le p b Nus ie T 1466 lt lt 4 xs 7915 COMPARATOR pe 15128 12 125 n 184007 Bl s pa sT vh 15V OUT E lt lt NEG FE POWER NET FE 4 GENERAL INFORMATION LAST USED OPTION common 31 V ELECTRICAL SYMBOLS PER 1537 242 348 864 CAPACITORS MFD 822 50V UNLESS OTHERWISE SPECIFIED ZUM S RESISTORS Ohms 1 40 UNLESS OTHERWISE SPECIFIED LABELS manasis POWER SUPPLY FOR 4 SUPPLY VOLTAGE REFERENCE DESIGNATOR SERIES DEFINITIONS POWER SUPPLY SOURCE POINT 100 SERIES ARC SENSE CIRCUIT SHEET 2 COMMON CONNECTION 228 SERIES DIGITAL LOGIC CIRCUIT SHEET D 2 CONNECTION 388 SERIES ANALOG LOGIC CIRCUIT SHEET D CC EARTH GROUND CONNECTION NOTES Gr SRM EQUIP SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE PROPRIETARY amp CONFIDENTIAL THIS DOCUMENT PAGE 2 OF 2 Front End Eme 000000 rone WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY CONTAINS PROPRIETARY INFORMATION OWNED THE LINCOLN ELECTRIC CO TYPE STL end Varo 1000000 gation 1 0 and Vac NOT SHOW THE EXACT COMPONENTS O
32. 2 TEST POINTS NORMAL VOLTAGES 2 PLUG J13 PINS 5 TO 6 6VAC PLUG J13 PINS 2 TO 3 10VAC PLUG J22 PINS 1 TO 2 18VAC LEADS 240 TO 241 olo PLUG J22 PINS 2 TO 9 18VAC LEADS 241 TO 242 PLUG 122 PINS 3 TO 4 18VAC 23 LEADS 243 244 G cle PLUG J22 PINS 12 TO 13 18VAC 5 2 LEADS 245 TO 246 13 Check the secondary AC voltages accord 15 After all tests are completed reconnect the ing to Table F 2 following 14 With the correct 115VAC applied to the pri Leads 32 32B 33B to the mary winding 32 to 33 if any or all of T4 transformer tabs the secondary voltages are missing or low Plug J13 to the IGBT drive board the T4 auxiliary transformer may be faulty Replace the T4 auxiliary transformer Plug J22 to the wiring harness Reinstall lower tray assembly using 7 16 wrench and 5 bolts Plug J1 to the control PC board Reconnect lead splice from the output choke to the IGBT module Reposition insulating sleeve olo E olg gt 8 mlt 515 16 Install the case wraparound cover Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 25 25 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER 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
33. Return to Section Return to Master TOC 24V A J7 EE 014 14936 J7 RELAY COILS __ D Q5 9 14 IRF513 FROM PROTECTION BD CONTROL id CNY17 8 14 TRIGGER J6 P6 5 4 lt lt lt OTES SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER olo O 515 2 2 cic 5 5 a GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 R 69 CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED C 14 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS Des Dg DIODES 1 400V UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION FILENAME 16018 6JA 77 FRAME CONNECTION EARTH GROUND CONNECT
34. a Return to Section TOC Return to Master TOC E 10 THEORY OF OPERATION PROTECTIVE CIRCUITS Protective circuits are designed into the Invertec machine to sense trouble and shut down the machine before the trouble damages the internal machine com ponents Both overload and thermal protection circuits are included OVERLOAD PROTECTION The machine is electrically protected from producing abnormally high output currents due to short electrode stick out or the nozzle shorting to the work Should the output current exceed 500 amps an electronic pro tection circuit will reduce the current to zero amps Five seconds after the short is removed the Invertec STT will produce normal output A protection circuit is included to monitor the voltage across input filter capacitors the event that the capacitor voltage is too high the protection circuit will prevent output The protection circuit may prevent out put if any of these circumstances occur 1 Capacitor conditioning is required Required if machine has been off for prolonged periods of time 2 Line surges over 500 VAC 3 Internal Component damage 4 Improper connections THERMAL PROTECTION Thermostats protect the machine from excessive oper ating temperatures Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating If excessive operating temperature should occur the thermos
35. 367 377 00 FOR SINGLE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE 062868 378 LI CONNECT BLACK amp WHITE LEADS TO SUPPLY CIRCUIT 35 TCW MAX WRAP RED LEAD WITH TAPE TO PROVIDE 600V INSULATION 365 04 10Kn13 HOT STARI FOR THREE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE B 2W CONTROL CONNECT BLACK RED amp WHITE LEADS TO SUPPLY CIRCUIT SO DC 366 1 FOR MACHINES NOT SUPPLIED WITH INPUT CABLE FOR SINGLE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES 367 CONNECT TERMINALS U amp W TO SUPPLY CIRCUIT m U BLUE 2 D o g hi4 FOR THREE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES 045 52 WIRE SIZE CONNECT TERMINALS U V amp W TO SUPPLY CIRCUIT 368 zh 035 N B SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING __ 367 THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER STAINLESS 53 WIRE TYPE N D PLACE A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE ___369 MILD CONNECTION SHOWN IS FOR 440 460V OPERATION N E D1 THRU D5 OUTPUT DIODES ARE A MATCHED SET D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET N F R1 R9 BLE
36. DARLINGTON 1 i 1 Kady r3 p 31 manda Ad 4 52 3 52 4 9 8 MH PROTECTION INC 120 1 57 156 RECONNECT HAE 128427 1 deck 4 gt 31 5 4 2 374 lt 4 gt 52 3 i Jig 15 314 4 1 244 2 0 5 o A SENSE LEAD c i 1425414 GND 6406 H 21 TIE O k 6 eee ee 7 DARLINGTON i Jt 5 374 J DRIVEBOARD 1 402 404 427 376 SWITCH 4 b 2w ch BOARD 8 25 1 12B 20 H I 9 25Wi50V Lj 025 e 401 403 POWE LLIL 9B I LINE 128 12 1 W q B 7 FILTER I R B 6 3719 16 371 5 240 d4 8 374 gt 13 374 503B 241 4 2 DARLINGTON 242 lt lt 4 438 42 11 24 HEATSINK 1 42 o 1 18 32 18 22 THERMOSTAT 371Aqe 8 4251 s Return to Section TOC Return to Master TOC N L g NI i _ 326 lt 1 328 1 1 74 4 yf
37. E E olg gt 8 mlt 515 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 64 NOTES O tr 5 gt E NOL Je1Se A 0 DOL J91Se N 01 DOL 0 DOL J91Se N 01 F 64 DOL uonoes DOL uonoes DOL uonoes 0 DOL 65 65 TROUBLESHOOTING amp REPAIR CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the input filter capac itors C1 and C2 MATERIALS NEEDED 5 16 Nut driver Slot head screw driver 7 16 Wrench Needle nose pliers 1 2 Wrench Return to Section TOC Re
38. E gt 8 JE ply 9 Return to Section TOC Return to Master TOC Return to Master TOC B 5 B 5 OPERATION 6 WIRE SIZE SELECT SWITCH This toggle switch selects between electrode diameters of 035 1 mm and smaller or 045 1 2 mm and larger The 035 1 mm position provides improved performance of smaller diameter wires at higher wire feed speeds 7 WIRE TYPE SELECT SWITCH This toggle switch selects between mild or stainless steel In the stain less position the pulse width of the Peak Current is changed from 1 to 2 ms for better performance for stainless steel welding 8 THERMAL SHUT DOWN INDICATOR This light will indicate that either the internal thermo stat s or the FET over current sensor has E actuated Machine output will return after the internal components have returned to normal operating temperature if the thermostat s opened or after about 3 7 seconds if the FET over current sensor activated 9 REMOTE RECEPTACLE This is a 10 pin MS type connector for remote control of Peak Current and Background Current Trigger switch connections are also provided The presence of the mating con nector is automatically sensed disabling the front panel Peak and Background Current controls Refer to REMOTE CON TROL CONNECTOR in the ACCESSORIES Section of this manual for more information 10 WIRE FEEDER RECEPTACLE This is 14 pin MS type connector fo
39. HAVING COMMON CODE NUMBER APPROVED DL DRAWING roni NA lOO AL 67972006 6 9 2006 CRM38136 A 8136 4 12144 2C0 IB fo NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided INVERTEC STT amp STT ELECTRIC for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine Return to Section TOC Return to Section TOC Return to Master TOC Ojo 5 8 16 gt 2 2 a Return to Section TOC Return to Master TOC Return to Master TOC G 17 PC Board Assembly IGBT Drive Codes 11090 11116 L12145 ENGINEERING CONTROLLED CHANGE DETAIL NEW MANUFACTURER No ELECTRICAL DIAGRAMS P C BOARD BLANK INFORMATION MAKE FROM 19399 MAKES 6 BOARDS PER PANEL SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION BLANK PART NUMBER L12145 C 8 DRIVE 25 308 168 IB foe NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troublesho
40. SHEET 2 57 COMMON CONNECTION 208 SERIES DIGITAL LOGIC CIRCUIT SHEET D FRAME CONNECTION 488 SERIES ANALOG LOGIC CIRCUIT SHEET 1 d EARTH GROUND CONNECTION EQUIP PAGE LOF 2 TYPE Sit SCHEMATIC CONTROL DOCUMENT REVISION APPROVAL PROJECT g DOC 8 19 2006 jpeg CRM38136 8 G 4649 289 Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine MFD 022 50 UNLESS OTHERWISE SPECIFIED 1 4W UNLESS OTHERWISE SPECIFIED LABELS SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT OTHERWISE SPECIFIED INVERTEC STT STT tacto ELECTRICAL DIAGRAMS G 10 Schematic Control PC Board Codes 11115 11116 24649 Sheet 2 of 2 5 TRIGGER CIRCUIT ARC VOLT FILTER 1 DV DT Vero PRIMARY CURRENT e R208 SAMPLE e FEEDBACK 1254 RATIO 18 0201 H ju DV DT LEVEL DETECT amp Qu m E MIR md p T TO DIGITAL LOGIC 8 SHEET 1 TR
41. V 2 DH 2 DR e K 1 v 21 v Q 24 vs CM 1 Hu MM 0 67 56906105 063 615 C4 O Eek T O O L8441 SWITCH Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided ITEM REQ D PART NO IDENTIFICATION C1 C5 C6 C7 4 816668 5 022 50 C2 C8 2 516668 4 2100pF 50 C4 2 13490 112 047 1200 D1 D2 D8 D4 D5 D6 07 08 09 010 10 112705 34 1N4936 221 DZ2 DZ12 4 112702 27 1N4740 024 027 2 1112702 29 1N4744A 026 029 2 T12702 40 1 4735 DZ5 DZ8 2 112702 53 98 3V 1W Q1 Q2 Q3 Q10 4 T12704 73 PKG MOSFET Q4 Q12 2 112704 68 2 4401 Q5 Q6 Q7 Q8 Q9 011 6 112704 69 2 4403 H1 R3 R5 R24 4 819400 1000 100 1 4W R2 R4 2 819400 2210 221 1 4W H6 R8 R9 R17 R19 R25 826 R27 R33 834 10 519400 10 0 10 1 4W R7 R30 2 519400 1501 1 5K 1 4W R10 R32 2 1519400 1502 15K 1 4W R11 R15 R22 R28 4 T14231 20 1 1 2W R12 R14 R20 R21 4 519400 1001 1 1 4W R13 R31 2 1919400 2080 20 1 4W R16 R23 2 519400 2212 22 1K 1 4W R18 R29 R37
42. WARNING NOTE If a test indicates that a switch board is defective both switch boards must be replaced ELECTRIC SHOCK can kill olo the same time In addition to replacing the switch Before continuing with the e o boards replace capacitors C1 and C2 if the fol 9 test procedure perform the 5 5 lowing conditions exist capacitor discharge proce 9 The machine was operating from 380 dure to avoid electric 0 2 or higher when the failure occurred shock 9 2 cle b Burned areas are visible on the switch 8 2 boards 4 Carefully disconnect the leads at the top of the cc 1 Turn off the Invertec STT and disconnect main switch board AC input power to the machine 5 Using the 3 16 socket wrench remove the 2 Using the 5 16 nut driver remove the case four cap screws from the switch board See wraparound cover Figure F 28 3 Perform the Input Filter Capacitor Discharge Procedure See the Maintenance jection Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 O10 E mlt 515 ply 9 ajo Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR SWITCH BOARD REPLACEMENT continued 6 Using the 7 16 wrench remove the two hex head capacitor screws located in the center of the switch board Hold the board firmly as you remove
43. 19400 1003 100K 1 4W C112 C116 C118 C120 C201 C202 C203 C206 C300 C302 C304 C312 C314 C401 C403 C405 C406 C4 15 C449 C453 C454 C455 C46 1 C463 C473 C474 516668 5 022 50 149 R430 519400 3320 332 1 44 150 10812 36 5K 1 2W R151 19400 68 10 681 1 4W R154 155 160 R16 1 R225 R226 R227 R228 R503 19400 1501 1 5K 1 4W R156 519400 1821 1 82K 1 4W C113 C114 C310 T11577 52 0047 or 005 1400 158 R339 R429 T10812 62 500 1 2W TRIMMER C115 513490 66 47 35 R 165 R482 R486 R487 R488 519400 8250 825 1 4W C117 C119 513490 93 27 35 C200 C464 13490 94 33 200 C207 513490 73 20 50 R20 1 R202 R203 R204 R205 R230 R434 R466 R483 R484 R492 R500 R501 19400 1080 10 1 4W C309 C400 C402 C404 C409 C412 C423 C446 C447 C448 C45 1 C452 C460 C462 513490 42 1 0 35 R206 R207 R208 R209 19400 26R7 26 7 1 4W R2 12 R335 R34 1 R407 R4 10 R437 8453 R550 R554 519400 1502 15K 1 4W C313 513490 97 100 20 C407 516668 10 4700 50 R2 16 R3 17 R343 R344 R4 17 R4 18 R473 19400 2211 2 21 1 4W C410 516668 2 47 100 C414 516668 6 4700pF 50V C417 C475 516668 4 2700pF 50 R2 17 R2 18 R219 R220 R221 R222 R223
44. R515 519400 1580 15 1 4W 518248 14 HEADER R521 19400 22 13 221K 1 4W 1 OCI 2 OCI 3 OCI 4 OCI 5 0 16 515000 27 OPTOCOUPLER LOGI C OUT DUAL R553 19400 2432 24 3K_1 4W W1 W2 W3 W4 18317 1 0 01 OHMS INSULATED JUMPER 0 17 5 15000 10 ISOLATOR 1 515128 15 01 02 03 04 06 08 09 010 12704 68 2N4401 x2 15128 12 VOLTAGE REGULATOR 07 112704 69 2N4403 x3 M14513 6 CMOS SAMPLE HOLD QUAD R100 R101 R102 R103 R104 R105 R106 R 107 R115 R116 R117 R118 R119 R120 R121 R122 R447 19400 1372 13 7K 1 4W x4 15128 22 1C OP AMP QUAD LO NOI SE X5 X23 X28 15128 11 14 PIN QUAD COMPARATOR X6 X11 X12 X13 X14 X15 X 16 X17 X18 X36 N w 515018 15 14 PIN 1 108 R 162 R498 519400 2002 20K 1 4W x8 518395 23 REG H S ASBLY R109 R110 R112 114 R133 R211 R215 R231 R409 R4 15 R4 19 R420 R5 19 19400 4752 47 5K 1 4W x9 X10 5150 18 9 CMOS 14538B X19 5150 18 10 14 PIN X20 X32 15018 5 16 PIN 1 NOTE R111 R113 R125 R128 R136 R159 R302 R305 R306 R318 R319 R322 R323 R334 R340 R468 R502 R537 R556 R557 519400 4751 X21 X22 X30 X31 15018 6 DIGITAL INTEGRA
45. Tools which come in contact with the PC Board must be either conductive anti static or static dissipative Remove the PC Board from the static shielding bag and place it directly into the equipment Don t set the PC Board on or near paper plastic or cloth which could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag f the PC Board uses protective shorting jumpers don t remove them until installation is complete e f you return PC Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test the machine to determine if the failure symp tom has been corrected by the replacement PC board NOTE Allow the machine to heat up so that all electri cal components can reach their operating tem perature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a f the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and termi nal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was
46. V 99 310 4 H 243 7 1 b 330 2 115 7 33 1 336 lt 8 33 9 242 224 _ 6 224A 501 5 J7 244 14 J17 E 4 13 24 504 4 6 303 4 3 ER 8 1 B ido 24 212A 21 42 504 19 BACKGROUND METER er 5 877 Y 9 1 378 CASE CASE TRAY FAN CASE 210 FRONT BOTTOM SHROUD BACK 246 4 7 358 i 4 35 CW MAX 502 k 10 1 J1 J8 J11 i2 jia 306 8 ELECTRICAL SYMBOLS PER E1537 J18 J37 J15 J35 J6 J27 J33 COLOR CODE DG 2 B BLACK i i 1 i GREEN i i i i i N BROWN 374 4 X6 6 10 ORANGE J4 J17 J2 J36 RED x 4 3 W WHITE YELLOW 10K 2W R11 i i CW MAX 0103050 050 IRAE A EEES 2 METER PINOUT VIEWED FROM BACK OF METER PLATFORM CASE S 105 12 BACKGROUND 7 Ww Tp 8 gt ES UM A BACK 2b 2 CONTROL P C BOARD CONNECTOR CAVITY NUMBERING SEQUENCE NOTES Pat 5b 365 cw 1 TAILOUT 6 366 CONTRO UIEWEDAEROMGOMPONENT SIDEOF BOARD 1 FOR MACHINES SUPPLIED WITH INPUT CABLE 1
47. 100p 100V INPUT FROM VOLTAGE SENSE PANEL FRONT END ARC VOLT FILTER DV DT Vare SAMPLE DV DT x A PHASE A FROM PWM 7 PHASE B_ FROM 5 PWM 12VFE x5 12VFE D 3 920 gt 8164 SAMPLE PULSE Ria e n 47 5K 133 2231 4 1 Diis 1N9j4 NEG CLAMP Di08 14014 330p 100V FE TRIACATES DT DELAYED VEE STROBE refe iT NEW DV DT Varc SAMPLE xs B 12VFE c109 820p 50V V FE NEG CLAMP OP470 721 H LOW DV DT 10K L HIGH DV DT R144 DVIDT 10x AMPLIFIER ic OLD DVIDT FE Varc SAMPLE SHORT DETECT Varc SAMPLE
48. 4 lt lt 10 001 400 2 BOARD eR 8 i OUTSIDE 2W R3 com 5 Return to Master Return to Section TOC J38 s 3 403 BOTTOM 2 IGBT 5402 p INSIDE 4 0 B 401 2 5 Ww MODULE gt A10 lt INPUT b 310 Y 209 RECTIFIER 9 9 gt w A 3 412 D13 852 277 AME E 44 lt pef TRIGGER lt GND 1 N H fl 52 gt lt Ee fier PROTECTION lt 1 INTERF 87 BOARD 2 REMOTE RECONNECT 5 OPTIONAL 9B 1 1 L 9B 4154 dcs 2 4 FEEDER 120o lt 2 WIRE 6 4 lt 3 2219 CURRENT 5 lt TRANSFORMER p 414 gt 406 He 21 IGBT 5 lt L 82 sono DRIVE BOARD DCUM 405 ye 4 5 413 ce 2 TRIGGER RIH 416 001 400 p 408 41 f VAC acd s B xo gt zxopqe e 5407 Een lt F 76 lt 06 75 POWER LINE FILTER J22 ASSEMBLY E 371 105 371A 374 gt 1 gt 374A
49. DETECTOR 18V NORMAL 23V PINCH START HeSHORT DETECTOR ADJUSTMENT FOR INTIAL PINCH PULSE LARC Ht 23 poses ENERGY CONTROL OPTION ENABLE 0106 184936 DODEON OPTION ENABLED DIODE OFF DISABLED ENERGY CONTROL OPTION P BOOST TIME 0106 184936 DIODE ON OPTION P_BOOST TWE DIODE OFF LOCAL BOOST TIME NOT OPTION _BOOST W PINGH L NOT PINCH SHEET 1 H START PLASMA BOOST TIMING L NOT PLASMA BOOST LATED CIRCUIT 7 SHEET 1 H STAINLESS L MLD STEEL HP2231 12VFE 36 VAC XFMR 18VAC cr 0047 1400V xi 815128 15 1 Gd er 52 1 0118 1BVAC 0047 1400V E 15V OUT 184007 N4007 o e 1 _ 0120 85V 7915 815128 12 0112 ENERGY CONTROL OPTION COMMON OUT POWER SUPP FOR FRONT END 2VFE POS FE POWER PLANE FE GROUND
50. Have an electrician install and service this equipment Turn the machine OFF before working on equipment not touch electrically hot parts Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect board using standard practices to avoid static elec trical damage and electrical shock Read the warn ing inside the static resistant bag and perform the following procedures PC Board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ATTENTION rol Static Sensitive ohm resistive cord connected to a Devices grounded part of the equipment Handle only at frame Static Safe you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent sta tic build up Be sure not to touch any electrically live parts at the same time Workstations Reusable Container Do Not Destroy
51. NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INVERTEC STT LINCOLN 5 Return to Section Return to Master TOC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC Q 7 5 7 THEORY OPERATION FIGURE E 7 POWER BOARD AND REMOTE PROTECTION BOARD LINE INPUT SWITCH RECTIFIER E B x 8 B Ro Pol Jt aS R R E D o D R N mm 1 25 ia LEAD PRE ICHARGE MAIN TRANSFORMER T2 PULSE TRANSFORMER SIGNAL 2 4 ig A 1 LESS THAN 1VDC HI PWM SIGNAL 9 8 15VDC TL GUN TRIGGER CONTROL BOARD TALOUT GROUND Back WIRE A NL METER CREAT SRR Sotho SWITCH WIRE TYPE SWITCH CURRENT LI 1 1 SENSOR 1 VOLTAGE SENSING RECEPTACLE REMOTE CONTROL RECEPTACLE WIRE FEEDER RECEPTACLE 20 maosemm CURRENT FEEDBACK IGBT DRIVER 36VA BOARD VOLTAGE FEEDBACK 10VAC AND 6VAC POWER BOARD The power board creates a pulse transformer drive sig nal which is derived from t
52. Codes 10151 11092 G2782 8 N 5 eo 154 2019 LOLH AR 0018 1018 901g Solu vole olo 0010 7 Ri61 R160 125 amp 01051 e 1 1 8471 550 530 8320 os L4 82187 305 16 24 100 Or ees 1 an 5 80254 ELECTRICAL DIAGRAMS 2070 sid Seyf 9554 2098 9069 475005 leza 8516 8524 Ra gt 458 9517 R316 weu 1029 R822 8
53. RECEPTACLE B A TRANS R D ZzOo JomJomvu gt lt 2 220 0 lt 20 WIRE FEEDER RECEPTACLE rie SS CURRENT FEEDBACK PULSE TRANSFORMER SIGNAL PWM SIGNAL Return to Section TOC Return to Master TOC CONTROL BOARD BH BOARD mv R HE TAILOUT CONTROL CHERENT Shr GROUND strony CONTROL CONTROL CONTROL SWISH VOLTAGE FEEDBACK WIBE 10VAC AND 6VAC CONTROL BOARD IGBT DRIVE AND MODULE The control board monitors the directives of the various controls and compares these commands to the current and voltage feedback information received from the current sensor and voltage sensing receptacle This The control board also determines when the IGBT module should be switched OFF to reduce weld spat ter and fumes The appropriate signal is sent to the IGBT drive board which then applies or removes the data is processed and the suitable PWM signal is sent 9212 drive signal to the IGBT module When the IGBT to the power board See module is in the OFF state the welding current must discussion pass through the one ohm resistance This reduces the current and subsequently spatter and fumes O10 o Fle a gt 515 ply o
54. Return to Master TOC INVERTEC STT LINCOLN 5 67 F 67 TROUBLESHOOTING amp REPAIR CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 31 PLUG J1 DISCONNECTION Return to Section TOC Return to Master TOC J1 CURRENT SENSING PLUG OUTPUT CHOKE IGBT MODULE SPLICED CONNECTION Return to Section TOC Return to Master TOC 5 Disconnect the current sensing plug J1 from the control PC board Carefully remove plug J1 and associated leads from the control PC board compartment FIGURE F 32 PLUG J22 DISCONNECTION olo gt 2 5 ply 9 PLUG J22 6 Locate and disconnect plug J22 from the wiring harness See Figure F 32 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC E 68 68 TROUBLESHOOTING amp REPAIR CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 33 PLACED ON ITS RIGHT SIDE MOUNTING BOLTS 5 7 Carefully lift and tilt the Invertec STT machine onto its right side See Figure F 33 8 Using the 7 16 wrench remove the five bolts h
55. Return to Section TOC Return to Master TOC O10 o Fle a gt 2 2 5 5 Return to Section TOC Return to Master TOC E 5 THEORY OF OPERATION FIGURE E 5 MAIN TRANSFORMER OUTPUT RECTIFICATION AND CHOKE POSITIVE MAIN TRANSFORMER CURRENT SENSOR CHOKE VENGE NSING RECEPTACLE REMOTE RECEPTACLE WIRE 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 RECEPTACLE 1 A 20 maosmzm Ww LET 5 gt R p J e LINE INPUT CHARGE SWITCH RECTIFIER R 4 D al eni R 0 CURRENT 3r 16 A TRANS eS N A dsl E D 4 b R E LEAD PRE CR2 CHARGE T S B MES 8 WA A ER E R R Df p LESS THAN 1VDC PULSE TRANSFORMER SIGNAL PWM SIGNAL 15VDC GUN TRIGGER CONTROL BOARD die 5 WE WE EF x b a p T IGBT DRIVER BOARD CURRENT FEEDBACK VOLTAGE FEEDBACK 10VAC AND 6VAC MAIN TRANSFORMER OUTPUT RECTIFICATION AND CHOKE Each switch board works as a switch pair Each board feeds a separate oppositely wound primary winding of the main tr
56. allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout
57. ohm reading multiplied by 1000 NOTE Always make sure that switch boards are changed in matched pairs Never mix an old style different part number switch board with a new switch board new part number 8 Reconnect all wiring harness leads 401 403 1 8 9 12 4 5 402 404 to the switch board 9 Install the case wraparound cover INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC 5 37 37 TROUBLESHOOTING amp REPAIR SNUBBER RESISTORS 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 elec trical 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will determine if the snubber resistors R4 R5 R6 H7 are functioning properly MATERIALS NEEDED
58. 10 Locate and remove plug J13 from the bolts holding the lower tray assembly to the IGBT drive board See Figure F 7 case bottom PLUG J13 olo 9 FIGURE PLUG J13 LOCATION o 8 3 IGBT a DRIVE BOARD ala eic ojo eg 5 T4 AUXILIARY 15 9 TRANSFORMER 5 STT Il 3a c INVERTEC STT LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 E 5 5 Return to Section TOC Return to Master TOC F 23 F 23 TROUBLESHOOTING amp REPAIR T4 AUXILIARY TRANSFORMER TEST continued FIGURE F 8 4 TRANSFORMER LEAD CONNECTIONS LEADS T4 AUXILIARY 32A 32B 33A 33B 9 d 32A 32B 33A 33B T4 AUXILIARY TRANSFORMER 11 Locate and remove leads 732A 32B and 12 Carefully apply the 115VAC isolated supply 33A 33B from the T4 transformer tabs to the T4 transformer at the 32 and 33 See Figure F 8 tabs WARNING ELECTRIC SHOCK can kill With input power ON there are high voltages inside the machine Do not reach into machine or touch any internal part INVERTEC STT LINCOLN 5 24 24 TROUBLESHOOTING amp REPAIR O10 5 5 T4 AUXILIARY TRANSFORMER TEST continued 2 TABLE 2 T4 AUXILIARY TRANSFORMER VOLTAGES
59. 150p 50V Return to Section TOC Return to Master TOC HALL EFFECT SENSOR X1 LT1014 n olo O 5 5 2 cic 5 5 a THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO FILE 521410 GENERAL INFORMATION LABELS NCE COMPONENTS OR CIRCUITRY ON PRINTED RCUITBOARD MAY CHANGE WITHOUT AFFECTING ELECTRICAL SYMBOLS PER E1537 SUPPLY VOLTAGE 7 7 FRAME CONNECTION HE INTERCHANGEABILITY OF A COMPLETE BOARD CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED POWER SUPPLY SOURCE POINT HIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED m R CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER DIODES 1A 400V UNLESS OTHERWISE SPECIFIED COMMON CONNECTION EARTH GROUND CONNECTION UNLESS OTHERWISE SPECIFIED TOLERANCE Ch ge Sht No THE LINCOLN ELECTRIC CO 1 STT CURRENT SENSE ON HOLES SIZES PER E 2056 5 19 95 ON 2 PLACE DECIMALS IS 02 CLEVELAND
60. 18V B 8 gt gt 353 6 4 4 5 and 6 4 gt 357 350 12 245 2 354 15 2 358 326 25 3 gt 24 9 350 353 1 1 99 11 6 351 362 2 2 12 gt gt 352 X 3 PLN 1 355 2 246 18 35p 356 351 16 359 yr 10 360 357 T4 AUXILIARY TRANSFORMER 1 AUXILIARY 356 2 25 41 8 J3 J9 J11 J12 J14 410 J13 TRANSFORMER ELECTRICAL SYMBOLS PER E1537 7 361 H4 362 3 363 5 gt gt 377 3 3 BACKGROUND 5 5 gt METER 6 6 1 378 355 354 J18 J37 J15 J35 J6 J27 J33 1 3 1 5 12 ooooo o0 46 6 10 J2 J36 COLOR CODE gara BLACK CASE CASE TRAY FAN CASE G GREEN FRONT BOTTOM SHROUD BACK N BROWN ORANGE S 358 TTTTTTTTTTTT 5 CW MAX 40K PEAK 359 e ow R11 CURRENT CONTROL 55 5 RED W WHITE Y YELLOW U BLUE J4 J17 Le 6 J16 J28 90000 360 eet cw 10K 19 363 2 6 377 64 BACKGROUND CONTROL METER PINOUT VIEWED FROM BACK OF METER PLATFORM CASE t OPERE 1 FOR MACHINES SUPPLIED WITH INPUT CABLE FOR SINGLE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE CONNECT BLACK amp WHITE LEADS TO SU
61. 2 Using the 5 16 nut driver remove the case 6 Use an ANALOG ohmmeter to perform the wraparound cover tests shown in Table F 3 3 Perform the Filter Capacitor See the Maintenance section 5 WARNING o 2 2 ELECTRIC SHOCK can kill Before continuing with the test procedure per form the capacitor dis charge procedure to avoid electric shock Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC E F 27 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST continued TABLE F 3 INPUT RECTIFIER TEST TEST POINTS PROBE PROBE ACCEPTABLE METER READING 9 A Greater than 100K ohms 9 B Greater than 100K ohms 9 Greater than 100K ohms A 9 Less than 100 ohms B 9 Less than 100 ohms C 9 Less than 100 ohms 12 A Less than 100 ohms 12 B Less than 100 ohms 12 Less than 100 ohms A 12 Greater than 100K ohms B 12 Greater than 100K ohms C 12 Greater than 100K ohms 6 Replace the input rectifier when any of the tests are NOT OK NOTE When installing a new input rectifier torque
62. AND MATERIALS USED IN THIS ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC UNLESS OTHERWISE SPECIFIE RANGES MANLPACTURNG TOLERANCE PER 2066 DESIGN INFORMATION c REFERENCE EQUIPMENT TYPE INVERTER STT PAGE 1 oF 1 PLACE DECIMALS IS 002 L9657 2 DOCUMENT DOCUMENT ONALLANGLES is DEGREE SUBJECT REMOTE PROTECTION P C BOARD ASSEMBLY REVISION WHITE PUBLISHED STAUDARDS ENGINEER APPROVAL PROJECT L 9657 3 APPROVED Del NA 0207 CRM38136 A A STRP Return to Section TOC Return to Master TOC IB foe NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided INVERTEC STT amp STT ELECTRIC for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine
63. C BOARD ASSEMBLY CHK FV REF 1841 3 m SG 2782 1 Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine INVERTEC STT STT Return to Section TOC Return to Master TOC Return to Section TOC Ojo 5 8 16 gt 2 2 EIE Siz a Return to Section TOC Return to Master TOC Return to Master TOC G 9 ELECTRICAL DIAGRAMS Schematic Control PC Board Codes 11115 11116 24649 Sheet 1 of 2 HBV pev X20 COUNTER 14048 315V POWER SUPPLY FOR DIGITAL TRIGGER amp ANALOG SECTIONS 0306 144007 OVERCURRENT TRIP px CURRENT i 1 1 BOARD LC S CAP m
64. CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC NESS OTHERWISE SPECIFIED YOLENA EQUIPMENT TYPE INVERTER WELDERS pace tort s ems SUBJECT PROTECTION PC BOARD ASSEMBLY REVISION 11 MATERIAL APPROVAL PROJECT DATE 06 19 2006 NUMBER CRM38136 8 L12235 2 A IB e s N NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided INVERTEC STT amp STT ELECTRIC for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper board repairs could result in damage to the machine Return to Master TOC ER ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE HI AGREE WITH PUBLISHED STANDARDS DO ROT SCALE THIS DRAWING Return to Section TOC EN 168 SOLID EDGE G 26 ELECTRICAL DIAGRAMS G 26 Schematic Current Sense PC Board Codes 521410 0712 5 Return to Section TOC Return to Master TOC EXCITATION CURRENT MIN OFF SET SOURCE ADJUSTMENT 100A V CURRENT OUT CURRENT CAL J18 1 VREF 3F C2
65. Codes L9134 G 21 XXX ITEM REQ D PART NO IDENTIFICATION 071 072 2 T 12702 19 1 47424 J9 J10 2 518248 6 HEADER A J11 1 518248 4 HEADER J16 1 5 18248 14 HEADER 01 02 2 112704 75 FET SS R13 i R1 R2 R13 R14 4 T 12300 73 250 20W H4 R5 Re R8 RIO R11 8 519400 1503 150K 1 4W E R7 R12 2 519400 1000 100 1 4W 1 1 S 13000 46 TRANSFORMER E RESISTORS OHMS WATTS CAPACITORS MFD VOLTS INDUCTANCE HENRYS R12 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine INVERTEC STT STT 22 Schematic Protection PC Board Codes 10151 11092 M16097 46091 N ELECTRICAL DIAGRAMS G 22 FROM UPPER CAPACITOR 52 Return to Section TOC Return to Master TOC 5 1 0012 CNY17 3V TO POWER BD 4 Over
66. PLANE 12VFE POS FE POWER PLANE 9 5 V 4 x5 OP AMP COMPARATOR 470 1 2901 v NEG FE PONER NET UNUSED GATES 12 4 work Front End Vac and Varc 000000 Control Energy Trigger Circuit 1 000000 17 000000 1000000 VO and Vac J4 DV DT LEVEL DETECT TO DIGITAL LOGIC SHEET 1 ARC SHORT DETECT TO DIGITAL LOGIC SHEET 1 PINCH KILLER Varc ADJUST SHEET 1 ENERGY CONTROL OPTION ENABLE SHEET 1 RGY CONTROL ON P BOOST SHEET 1 PINCH SIGNAL FOR ENERGY CONTROL OPTION PB START SIGNAL FOR ENERGY CONTROL OPTION WIRE TYPE POSITION ENERGY CONTROL OPTION SHEET 1 NOTES G 7 PRIMARY CURRENT FEEDBACK 125 1 RATIO Y 24 2 2 Y 2 CURRENT TRANS 0203 1N4936 1N4936 5 SHEET 1 THER OPTOCOUPLER 10K lt H R233 1 150A PRIMARY R234 He 1232 gt SHEET 1 EN ON POWER BOARD ENE V OPTOOUPLERS ON PROTECTION
67. R224 R242 R400 R401 R505 R506 19400 1301 1 3K 1 4W C418 513490 126 018 50 R229 R241 19400 2670 267 1 4W c440 513490 25 4 7 35 R234 R522 R562 19400 3323 332K 1 4W 02782 STT CONTROL 465 469 513490 104 39uF 20V R238 R526 518380 1 THERMI STOR 513929 8 RELAY R239 518380 3 THERMI STOR D100 0108 D109 0110 D111 0306 D307 0308 T12199 2 1N4007 R301 T 108 12 39 1 2W TRI R303 R472 19400 5621 5 62K 1 4W 0101 0102 0103 0104 D 115 0116 0117 04 12 0423 0424 T12705 22 18914 R304 8313 T10812 67 100 1 2W TRIMMER R307 R32 1 8442 19400 5622 56 2K 1 4W 0105 D 106 0200 D20 1 D202 0203 0204 0205 0301 0302 0303 040 1 0416 0420 0421 0422 12705 34 1N4936 R309 R485 R5 16 R5 17 R5 18 519400 3322 33 2 1 4W R311 19400 3922 39 2K 1 4W R326 R327 519400 5 110 511 1 4 R328 R425 R441 10812 41 10 1 2W TRIMMER 0107 0112 0113 0114 0206 0207 0208 0209 D2 10 0211 0300 0304 0305 0310 0400 0402 0403 0404 0405 0406 0407 0408 0409 04 10 0411 04 13 04 14 04 15 0417 0418 0419 T12199 1 1N4004 R338 R474 519400 2431 2 43 1 4W R342 R404 R405 R433 R440 R460 R470 R477 R48 1 R489 R49 1 R493 R507 R525
68. R42 4 1619400 4750 M75 1 4W 835 R36 2 1619400 4785 M7 5 1 4W R38 R39 R40 R41 4 519400 3922 39 2 1 4W je NOTE for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine INVERTEC STT STT Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O 515 g 2 cic 5 5 a Return to Section TOC Return to Master TOC G 20 Schematic Driver Board Codes 520799 JT 3 DRIVE lt 12 TO POWER BOARD Power Switch Drive Transformer ELECTRICAL DIAGRAMS TO SWITCH BOARD N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E 2056 ON 2 PLACE DECIMALS IS 02 PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE 1 TO AGREE WITH PUBLISHED STANDARDS Note Ch ge Sht No R3 84
69. SHEET 1 400 SERIES ANALOG LOGIC CIRCUIT SHEET 1 THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A scale paTe 04 04 94 UNLESS OTHERWISE SPECIFIED 1 AW UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED LAST NO USED 165 42 345 564 x36 De 17 201 910 424 w LABELS SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 17 COMMON CONNECTION 177 7 FRAME CONNECTION EARTH GROUND CONNECTION STT CONTROL SUBJECT SCHEMATIC Sheet 2 of 2 SUP S D G io 2781 8 Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine INVERTEC STT STT Il Return to Section TOC Return to Master TOC Return to Section TOC o g Return to Section TOC Return to Master TOC Return to Master TOC 2 D G 8 PC Board Assembly Control
70. STT STT G 28 ELECTRICAL DIAGRAMS G 28 Schematic Remote Protection PC Board Codes M17609 10 PIN REMOTE 6094 LIN AMPHENOL OPTIONAL REMOTE INTERFACE Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC qe 115 T1 aul n Ta 81 L STUD 150V 80J 160J 320V olo O 515 g 2 cic 5 5 a Y 14 WIRE FEEDER AMPHENOL GENERAL INFORMATION LAST NO USED R4 R5 ELECTRICAL SYMBOLS PER E1537 R 8 L7 CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED 0 16 TP 3 332 332 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS D 0 R7 R8 DIODES 1 400V UNLESS OTHERWISE SPECIFIED SU SUPE 332 332 POWER SUPPLY SOURCE POINT NOTES 57 COMMON CONNECTION SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY 7 7 FRAME CONNECTION NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE FILE M17609 EARTH GROUND CONNEC NUMBER
71. TOC Return to Master TOC 7 5 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Machine is dead no output no fan no display POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS The power switch must be in the ON position Check the input voltage Make sure all three phases are applied to the machine With input power removed check that the input voltage set up switch and jumper A the reconnect auxiliary jumper are in the proper position for the input voltage being used With input power removed check the continuity of the 4 amp slow blow fuse located on the reconnect panel TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 The input power switch S1 may be faulty replace 2 Perform the 1 Auxiliar Transformer Test Check or No output or reduced output the first time power is applied to the machine Check input voltages fuses and input voltage reconnect proce dures See the instaliation section If high input voltage higher is applied the capaci tors may need conditioning Let the unloaded machine idle for 30 minutes 1 Contact the Lincoln Electric Service Department 1 888 935 3877 CAUTION If for any reason you do not understand the test procedures or are unable to perform th
72. Voltage 681K FROM BLEEDER RESISTOR Q B14 OCI3 a CNY17 3V TO DRIVER BD Over Voltage Return to Section TOC Return to Master TOC e B53 FROM UPPER CAPACITOR Tin CNY17 3V TO DRIVER BD Over Voltage FROM LOWER CAPACITOR 51 olo O 515 2 2 cic 5 5 a 08 5 FROM CENTER LEG OF INPUT 184007 MM FILE M 16097 2F1 R30 o R31 R29 R25 R24 H5 150K 15 0K 15 0K 15 0K 15 0K 4 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 R CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4 UNLESS OTHERWISE SPECIFIED LABELS D DIODES 1 4007 UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT LAST NO USED TO CONTROL BD 681K Single Phase NOTES SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOA
73. active By adding a switch between pins J and B a LOCAL REMOTE trol switch can be created Switch open for local and closed for remote 3 For robotic control of the PEAK CURRENT a 0 to 10 volt DC signal is applied between pins A and with applied to pin The BACKGROUND CURRENT is controlled with a similar signal applied between pins and C with applied to pin In this application pins J and B must be shorted as described in 2 above NOTE These analog signals should be isolated from the robot circuitry to prevent interference 4 The trigger switch is connected between pins D and These connections are in parallel with the trigger switch from the wire feeder 5 The digital meters for PEAK and BACKGROUND currents will show preset values in both local and remote operation REMOTE PROTECTION BOARD Lo qui EE m iis 22 VOLTAGE SENSE e A CONNECTION 387 9 3 55 291 lt ie 3 4 gt 4 4 O J88 3 2 BG 10K _ 2126 i 6 J38 10 43 x 1 9 5 330 dc 4 12 55 lt De i 32C lt x B 4 TRIGGER 2128 lt lt 5 11 gt GND esset les OPTIONAL dus
74. an ohmmeter measure resistance between either output stud and an unpaint ed surface of the machine case Meter reading should be 500 000 ohms or more If meter reading is less than 500 000 ohms check for electrical components that are not properly insulated from the case Correct insulation if needed Replace machine cover and screws INVERTEC STT LINCOLN 5 D 3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC MAINTENANCE D 4 FIGURE D 2 MAJOR COMPONENT LOCATIONS INVERTEC STT LINCOLN 5 BASE ASSEMBLY REAR NAMEPLATE RESISTORS FAN SHROUD ASSEMBLY PROTECTION PC BOARD DRIVER PC BOARD CONTROL BOX CONTROL PC BOARD BLEEDER RESISTORS RECONNECT PANEL IGBT OR DARLINGTON MODULE WRAPAROUND ASSEMBLY CASE FRONT ASSEMBLY OUTPUT TERMINALS OUTPUT CHOKE ASSEMBLY TRANSFORMER ASSEMBLY OUTPUT RECTIFIER ASSEMBLY AUXILIARY TRANSFORMER FET HEAT SINK ASSEMBLY EN lu 2 q 2 S E K RRS gt M SNS P Return to Master Return to Master TOC o c 5 Return to Master TOC Section E 1 Section E 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION Theory of Operation ettet rts
75. be faulty Check or replace 2 The IGBT driver PC board may be faulty 3 The control PC board may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC E 12 12 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Excessive weld spatter Arc sounds and looks like a standard MIG process Poor welding weld settings drift or output power is low Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS Check the Arc Sense leads for loose or faulty connections Make sure the Arc Sense WORK lead is as close as possible to the welding arc Make sure the machine and wire feed settings are correct for the process and wire being used Make sure the machine settings are correct for the welding process being used Check the welding cables for loose or faulty connections Make sure the reconnect
76. box before installing this equipment Turn the power switch on the Invertec STT OFF before connecting or discon necting input power lines output cables or control cables Do not touch electrically hot parts Always connect the ground terminal to a good electrical earth ground SELECT SUITABLE LOCATION Locate the machine where there is free circulation of clean air Place the machine so that air can freely cir culate into the sides and out of the rear of the machine Dirt and dust that can be drawn into the machine should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shut down of the Invertec STT Il This machine carries an enclosure rating of IP21S It should not be placed in extremely damp or dirty loca tions It should not be exposed to rain or snow STACKING The Invertec STT cannot be stacked TILTING Place the machine on a secure level surface otherwise the unit may topple over MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION The machine may not be suitable for use in an envi ronment where high frequency is present For exam ple do not place the machine in close proximity to TIG or PLASMA operations To minimize high frequency interference Locate the STT II power source more than 15 feet 4 5 m away from high frequency units and more than 25 feet 7 6 m separation between ground connecti
77. feed wire since these feeders have no provision for control of the STT output OPERATING CONTROLS The Invertec STT II has the following controls as stan dard On Off switch Peak Current adjustment Background Current adjustment Hot Start adjustment Tailout and 2 toggle switches one for wire size selec tion and one for wire type selection DESIGN FEATURES AND ADVANTAGES State of the art inverter technology yields high power efficiency excellent welding performance light weight and compact design Twist Mate output terminals Digital meters for procedure settings are standard Automatic Inductance or Pinch Control Solid state circuitry for extra long component life Current feedback ensures that original procedure settings all remain constant Arc Sense lead assembly Electrode and Work connects through a 4 pin case front connector Peak Current and Background Current may be remotely controlled Thermostat and FET over current protector prevent overheating from overloads high ambient tempera tures or loss of air flow OPERATION B 3 High temperature Class H insulation Protection circuits and ample safety margins prevent damage to the solid state components from transient voltages and high currents Preset welding current capability STT II offers improvements over the previous model Approximately 4096 increase in deposition rate capa bility and a significant increase i
78. followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROB LEM will help avoid denial of legitimate PC board warranty claims INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 2 Return to Section TOC Return to Master TOC 3 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical damage is evident POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact your local Lincoln Authorized Field Service Facility TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Contact the Lincoln Electric Service Department 1 888 935 3877 Machine has no open circuit volt age Wire feeds OK Check the control cable between the feeder and the STT unit Make sure the 2 and 4 leads are intact Put a jumper wire between Pins C and D on the 14 pin amphenol lf normal open cir cuit voltage 85VDC is restored the problem is in the feeder control cable or the wire feeder Make sure the reconnect switch S7 is in the correct position for the three phase input voltage being applied CAUTION Do
79. invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The Switch Board Test determines if the switch boards are operating properly This resistance test is preferable to a voltage test with the machine energized because these boards can be damaged easily In addition it is dangerous to work on these boards with machine power ON Return to Master TOC MATERIALS NEEDED Analog Volt ohmmeter Multimeter 5 16 Nut driver Return to Section TOC Note Component locations and disassembly procedures may vary slightly on STT models olo E 2 olg iz 8 515 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC o 5 F 34 TROUBLESHOOTING amp REPAIR SWITCH BOARD TEST continued FIG
80. may be blocked due to inade quate clearance around the machine RECOMMENDED COURSE OF ACTION 1 The IGBT heat sink thermostat or fan thermostat may be defec tive Check or replace CAUTION If for any reason you do understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 2 Return to Section TOC Return to Master TOC o 5 9 9 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS Porosity in the weld Make sure the gas type and 1 Contact the Lincoln Electric flow rate is correct for the pro Service Department 1 888 935 cedure being used Shield the 3877 work from excessive outside air currents Check the gun and nozzle for leaks or obstructions Make certain the machine and wire feed settings are correct for the process CAUTION If for any reason you do not understand the test procedures or are unable to p
81. oS 240 _ 51949025 RENT RET RETO R200 ROT 51945913597 o gt ND C465 C460 7 2 513490104 39ur 20V R222 R223 R224 R400 R401 E 15 998 RELAYDPOTINDG reos rsog 9 2 15100 0108 0109 0110 0111 72199 2 1144007 519400 2670 D306 D907 D306 D309 R232 RIA RED 5 S28 VW E D101 D102 D103 D104 D115 T12705 22 18914 R294 R522 R562 7 7 5 8194009325 332K VAW ________ 515 0116 0117 0412 0423 0424 R238 R526 2 D105 D106 D200 D201 D202 112705547 104956 1 8183803 5 1 0 08 019 OHMS 1 354 D203 D204 D205 301 302 0303 0401 0416 0420 0421 R304 R313 2 1110812657 __ 100 72 TRIMMER 0107 0112 0113 0114 0206 31 12199 1 1N4004 R307 R321 R442 3 _ 519400 5622 UAW LLL D207 D208 D209 D210 D211 F309 R485 R516 R517 Ro18 5 519400 3322 DOS BS 0409 5194003922 39 2 AW aoo 327 77 1 2 89194005110 ST aw ND R328 R425 R441 3 110817241 10K 7 TRIMMER R338 RA52 R474 3 S194002431 2 43K UAW ___________ ND IR342 RA04 RA05 R433 RA40 13 1819400 1000 100 1 4 R470 RATT RAB1 RABO RAO R493 R507 R525 Rora o 78 RW I erst CER iacent T 2 Rais t_ stoa00 2000 3 ER 515001503 Ma I L 18286 HEADER um i 19003321
82. 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the switch boards MATERIALS NEEDED 5 16 Nut driver 7 16 Wrench 3 16 Allen type wrench 3 16 Socket wrench Dow Corning 340 Heat Sink Compound Lincoln E1868 ANALOG Ohmmeter Return to Section TOC Return to Master TOC Note Component locations and disassembly procedures may vary slightly on STT models o 5 o 2 2 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 60 F 60 TROUBLESHOOTING amp REPAIR SWITCH BOARD REPLACEMENT continued FIGURE F 28 SWITCH BOARD REMOVAL Return to Section TOC Return to Master TOC SOCKET HEAD SCREWS o 2 5 2 3 Return to Master TOC PROCEDURE
83. replacing any mechanical part that could affect machine s electrical characteristics OR f you repair or replace any electrical components Return to Section TOC Return to Master TOC MAXIMUM INPUT IDLE AMPS AND IDLE WATTS INPUT CURRENT IDLE 3 5 AMPS INPUT POWER IDLE 800 WATTS MINIMUM ACCEPTABLE OUTPUT AT MAXIMUM BACKGROUND SETTING STATIC GRID LOAD CONTROL MODE AMPS VOLTS BACKGROUND 140 20 OPEN CIRCUIT VOLTAGE RANGE 73 TO 85 VDC Return to Section TOC Return to Master TOC olo E olg gt 212 515 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC F olg gt 8 mlt 515 Return to Section TOC Return to Master TOC Return to Master TOC F 78 F 78 TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACITOR CONDITIONING If the machine will not produce output when turned on and the following two conditions exist The machine is connected to operate at an input voltage of 380 VAC or higher and Power has not been applied to the machine for a long period of time many months Then The Input Filter Capacitor Protection Circuit could have been activated and prevented output This means the Input Filter Capacitors must be conditioned The Input Filter Capacitor Protectio
84. switch S7 is in the correct position for the three phase input voltage being applied CAUTION Do not switch reconnect switch with input power applied to machine RECOMMENDED COURSE OF ACTION 1 The IGBT module may be faulty Check or replace The IGBT driver PC board may be faulty The control PC board may be faulty The current sensor may be faulty Check associated leads for loose or faulty connections The control PC board may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 INVERTEC STT LINCOLN 5 13 13 TROUBLESHOOTING amp REPAIR T1 AUXILIARY TRANSFORMER 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 Return to Section TOC Return to Master TOC 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 trou bleshooti
85. switched to the Hot Start provides approximately 2596 to Background level the conclusion of 2 50 more current during the initial start of preceding Peak Current pulse This knob the weld for improved arc starting and bead tio allows preset adjustment of the amplitude appearance This control adjusts the dura cc of the background current to 125 tion of this Hot Start current The control range is amperes from 0 to 10 where 0 corresponds to the zero or no Start and 10 is maximum for a Start last 2B BACKGROUND CURRENT DISPLAY METER ing for about four 4 seconds This is a digital meter for displaying the preset Background Current This meter 5 TAILOUT Alters the current waveform to increase displays in 1 amp increments This meter deposit rate and travel speed The Minimum setting does not indicate the actual welding cur sets STT Il to the original waveform As tailout rent only the preset current is increased peak and Background current may need to be reduced to maintain optimum perfor 3A PEAK CURRENT OUTPUT CONTROL The mance beginning portion of the welding arc is a pulse of current referred to as Peak lt Current This knob allows preset adjust ment of the amplitude of the peak current up to 450 amperes Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo
86. the ARC SENSE LEAD lead with ring lug step 2 together to the gun block on the LN 742 5 Connect work lead between STT terminal and the Work piece 6 Connect the ARC SENSE LEAD WORK lead with alligator clip to work piece NOTE For best welding performance make this connection as close as possible to the welding arc 7 Connect the wire feeder control cable between the LN 742 or STT 10 and the 14 pin Wire Feeder Receptacle on the STT For the STT 10 Wire Feeder Connect the second wire feeder control cable between the STT 10 and the 10 pin Remote Receptacle on the STT Il AWARNING Turn off input power to the Welding gt Power source using the disconnnect Switch at the fuse box before connecting the wire feeder ELECTRIC SHOCK CAN KILL Only qualified persons should install use or service this machine WIRE FEEDER LN 742 WIRE FEEDER CONTROL CABLE ELECTRODE LEAD ARC SENSE LEAD ELECT CONNECT ELECTRODE LEAD AND ELECT ARC SENSE LEAD TOGETHER TO ELECTRODE TERMINAL OF WIRE FEEDER ARC SENSE LEAD WORK SHOULD BE LOCATED AS CLOSE AS POSSIBLE TO THE WELDING ARC 17657 FIGURE 2 LN 742 to STT II CONNECTION INVERTEC STT LINCOLN 5 ACCESSORIES CONNECTION DIAGRAM INVERTEC STT II Turn off input power to the Welding Power source using the disconnnect Switch at the fuse box before connecting the wire feeder E
87. the mounting nuts in a cross tightening pattern to 6 inch pounds 7 Nm Torque ter minals to 26 inch pounds 3 Nm PROCEED TO STEP 7 TO CHECK RELATED COMPO NENTS 7 Inspect main power switch S1 and replace if faulty Go to step 8 8 Testcapacitors C1 and C2 and replace both capacitors if either is faulty NOTE Faulty capacitors could be the reason for input rectifier failure Visually inspect the capacitors for leakage damage etc and use appropriate test equip ment to determine component integrity 9 Perform the Switch Board Test 10 After all tests are completed install the case wraparound cover INVERTEC STT LINCOLN 5 27 28 NOTES INVERTEC STT LINCOLN F 28 NOL Je1Se A 0 DOL J91Se N 01 DOL 0 DOL J91Se N 01 DOL uonoes DOL uonoes DOL uonoes 0 DOL 29 29 TROUBLESHOOTING amp REPAIR CAPACITOR BALANCE TEST A 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reas
88. to Section TOC Return to Master TOC SWITCH 6 Test for 25 ohms resistance from lead termi 7 Repeat the same procedures to test R5 R6 nal 401 to terminal 12 on the switch board and R7 according to Table F 6 see Figure cde 8 Reconnect leads 401 403 and 402 404 to the a 25 ohms is measured resistor R4 is OK switch board b If 30 ohms or more is measured resistor 9 Install the case wraparound cover R4 is faulty and must be replaced lf 20 ohms or less is measured resistor R4 is faulty and must be replaced TABLE 6 SNUBBER RESISTORS TEST Test Result Conclusion Next Test Step Repair Action Lead 401 to 25 ohms OK Continue Terminal 12 230 ohms R4 open Replace R4 20 ohms R4 faulty olo o E olg gt 8 515 Lead 402 to 25 ohms OK Continue Terminal 9 230 ohms R5 open Replace R5 20 ohms R5 faulty Lead 403 to 25 ohms OK Continue Terminal 12 230 ohms R6 open Replace R6 20 ohms R6 faulty Lead 404 to 25 ohms OK Continue Terminal 9 230 ohms 87 open Replace R7 20 ohms H7 faulty gt GREATER THAN lt LESS THAN Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 40 NOTES INVERTEC STT LINCOLN F 40 NOL Je1Se A 0 DOL J91Se N 01 DOL 0 DOL J91Se N 01 DOL uonoes DOL uonoes DOL uonoes 0
89. to the instantaneous requirements of the arc and optimize performance By sensing changes in welding current and hence the electrode state the power source will supply varying output currents to minimize spatter The Peak and Background currents are two such current outputs that can be adjusted Wire Feed Speed controls the deposition rate Peak Current controls the Arc Length Background Current controls the Bead Contour And Tailout increases Power in the Arc PEAK CURRENT The Peak Current control acts similar to an arc pinch control Peak current serves to establish the arc length and promote good fusion Higher peak current levels will cause the arc to broaden momentarily while increasing the arc length If set too high globular type transfer will occur Setting this level to low will cause instability and wire stubbing In practice this current level should be adjusted for minimum spatter and pud dle agitation Adjust Arc Length with Peak Current Low Optimum High Note In 10096 CO shielding gas applications the peak current level should be set greater than in a corre sponding application using a gas blend with a high per centage of Argon Longer initial arc lengths with 10096 are required to reduce spatter BACKGROUND CURRENT The Background Current provides the control for the overall heat input to the weld Adjusting this level too high will cause a large droplet to form and globular type tr
90. wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc w
91. 0 R308 R329 R332 5 oo l I 15458 2 3846 PWM CONTROLLER 55 R457 R461 R463 515128 10 4 5194002212 5151284 IC LM224 0P AMP CAPACITORS MFD VOLTS G4648 2B0 IADUCIANCE HENRTES CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY SEE E2454 n IDENTIFICATION CODE BEFORE HANDLING ITEM REQ D PART NO DESCRIPTION _ 1 1 SEE BLANK INFO P C BOARD BLANK INK N B MOUNT TO ITEM 4 HEATSINK 2 12 2861 SEALANT N C DO NOT COAT WITH ENCAPSULATION MATERIAL Y ALL COMPONENTS AND MATERIALS USED IN THIS ASSEMBLY 3 2 0 oz 1389 6 SEALANT N D AFTER COMPLETE ASSEMBLY AND TEST SEAL IC PINS ON OPPOSITE 4 520590 1 ARE TO BE RoHS COMPLIANT PER E4253 COMPONENT SIDE OF BOARD WITH ITEM 2 N E SEAL TRIMMERS WITH ITEM 3 AFTER TEST SCHEMATIC REFERENCE G4649 2B0 MAKE PER E1911 ENCAPSULATE WITH E1844 2 COATS TEST PER 4117 OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL IN ag RCE EQUPHENT TIPE INVERTER WELDERS __ tort PLACE DECIMALS 5 4 0 DRAWNBY FE 1 DOCUMENT DOCUMENT NATERA TOLERANCE PE TO AGREE Ee E SUBJECT CONTROL P C BOARD ASSEMBLY NUMBER REVISION 1 MATERIAL APPROVAL PROJECT pseosmow N pare 05 20 2006 wuweca CRM38136 B G4648 CO NOT SCALE THIS DRAWING THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC A
92. 0 HZ 36 34 20 19 18 RATED OUTPUT DUTY CYCLE VOLTS RATED AMPS 60 Duty Cycle 225 29 10096 Duty Cycle 200 28 OUTPUT CURRENT RANGE OPEN CIRCUIT VOLTAGE AUXILIARY POWER Peak Current 0 450 Amps 88 VDC Maximum 115 4 Amps Background 0 125 Amps 42 Q 4 Amps Return to Section TOC Return to Master TOC RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT VOLTAGE FUSE SUPER LAG INPUT AMPERE TYPE 75 C TYPE 75 C AND FREQUENCY OR BREAKER RATING ON COPPER COPPER SIZE NAMEPLATE SUPPLY WIRE GROUND WIRE IN CONDUIT IN CONDUIT AWG IEC SIZES AWG IEC SIZES 200 50 60 208 50 60 380 50 60 10 6 mm 10 6 mm 400 50 60 415 50 60 E WEIGHT o 2 2 100 165 46 kg 1115 not present on European Models Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 O10 Fle a gt mlt 515 ply o Return to Section TOC Return to Master TOC Return to Master TOC 4 4 INSTALLATION Read and understand entire Installation Section before starting installation WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF at the disconnect switch or fuse
93. 1 112702 2 1 4 740 OCI 1 OCI 2 OCI 3 OCI 4 4 S 15000 22 OPTO ISOLATOR R1 R2 2 S 19400 6813 681K 1 4 R3 R13 R16 3 S 19400 1821 1 82K 1 4W RS 11 R12 4 5 19400 1503 150K 1 4W RE RAD R27 5 S 19400 5622 56 2K 1 4W R7 R20 2 T 10812 36 1 2W TRIMMER R14 1 5 19400 1003 100K 1 4W R15 1 5 19400 4750 4 5 1 4W R18 R26 R28 R32 4 5 19400 1002 10K 1 4W R19 1 5 19400 3321 3 32K 1 4W R2 1 R23 R24 R25 R29 R30 8 5 19400 1502 15K 1 4W R3 1 R33 R22 1 S 19400 3323 332K 1 4W R34 R36 2 S 13400 2673 26 K 1 4 R39 R37 2 S 19400 3320 332 1 4W X1 1 2515128 4 LM224 X2 1 515128 5 REG for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine INVERTEC STT STT Il Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O 5 5 gt 2 512 a Return to Section TOC Return to Master TOC G 24 Schematic Protection PC Board Codes 11115 11116 M20352 ELECTRICAL DIAGRAMS 5V 5 19K FROM UPPER CAPACITOR B52 15 0K 18K R32 FROM BLEEDER RESISTOR E x2 814 eS GND 35V 853 FROM UPPER CAPAC
94. 24 3 5 19400 2670 267 1 4W R9 1 5 19400 1503 150K 1 4W 811 19 R41 3 519400 1002 10 1 4W R12 1 5 19400 4753 475K 1740 lo R13 R15 RIG R17 4 19400 3322 33 2K 1 4W o R14 1 S 19400 1502 15K 1 4W eli R18 1 S 19400 2672 26 7K 1 4W 92 R20 1 S 19400 2673 267K 1 4W 8 R21 1 519400 2211 2 21 1 4W o R23 1 S 19400 4751 4 75K 2 R25 1 19400 5111 5 11 174W 5 R42 R43 2 519400 1000 100 174W 9 R44 1 518380 4 THERMI STOR mc R69 1 18380 5 PTC THERMI STOR 1 2 2 13640 15 15 X1 1 518647 REGULATOR ASBLY X4 1 615128 4 LM224 X5 1 518647 1 VOLT REG 8 HEAT SINK ASBLY X67 X68 2 515018 19 0220 FET DRIVER CAPACITORS MFD VOLTS INDUCTANCE HENRYS olo O 515 918 cic 5 5 a foe NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided STT amp STT for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine G 14 ELECTRICAL DIAGRAMS G 14 Schematic Darling
95. 3 If the above tests do not reveal the problem the control PC board or associated wiring may be faulty See Figure F 22 Simplified Trigger Circuit Diagram Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 53 53 TROUBLESHOOTING amp REPAIR IGBT MODULE REMOVAL AND REPLACEMENT 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in the removal and replacement of the IGBT module located in the lower tray assembly MATERIALS NEEDED 5 16 Nut driver Phillips head screw driver 7 16 wrench Needle nose pliers 1 2 Wrench 12mm Wrench 3 16 Allen type wrench Dow Corning 340 Heat Sink Compound Lincoln E1868 Silicone Rubber RTV Coating Lincoln E2861 or Dow 3140 Return to Section TOC Return to Master TOC Note Com
96. 37 TIS Remote 180900000 Ni gelo CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED C uma ns xe Control O OO O QOO O to Control Panel RESISTORS Ohms 14W UNLESS OTHERWISE SPECIFIED LABELS mammu we 227 J2 DIODES 1A 400V UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET HOT START TIME REMOTE BG POT lt Unused Devices PINCH KNEE en 7 Analog Logic 1 0 REFERENCE DESIGNATOR SERIES DEFINITIONS POWER SUPPLY SOURCE POINT J 0000000 Darlington 0000000 Dre Output to Control Panel 100 SERIES ARC SENSE CIRCUIT SHEET 2 57 COMMON CONNECTION 2 START 1 Vac In 200 SERIES TRIGGER CIRCUIT SHEET 2 HH FRAME CONNECTION 300 SERIES DIGITAL LOGIC CIRCUIT SHEET 1j BACKGND TALOUT BACKGND NOTES 400 SERIES ANALOG LOGIC CIRCUIT SHEET 1 2 EARTH GROUND CONNECTION PINCH FAST RAMP J2 x BAL WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY HOLES SIZES PER 2056 8 SANUS NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY CONTROLS HAVING A COMMON CODE QN2 PLACE DEGMALS IS 02 CLEVELAND OHIO U S A SUBJECT SCHEMATIC Sheet 1 of 2 E JMALS IS J N NUM
97. 430 743 aw S 5 5 165657 1 pes OK TRIMER T 400 442 eusi 2 pm 3 5194008251 8 25K 14W C112 0116 0118 0120 C201 26 516668 5 022 50 R143 R144 R235 R416 R424 519400 1003 100K 1 4W C202 C203 C206 C300 C302 IR446 R450 R459 R471 R480 11 00 04 304 312 314 401 403 R496 R552 R559 405 406 415 449 453 R149 R430 2 519400 3320 332 1 4 454 0455 461 463 473 R150 1 110812 56 5K 1 2W TRIMMER RI ______________ 7 _ 519400 6810 681 174W 113 0112 6310 3 111577 52 7 0047 0051400 154 5155 8160 8161 5225 ND C115 1_ 513490 56 R226 R227 R228 242 R503 cii7 ciio 2 51349093 27135 R156 i f8 19400 1824 1 82K 174W 2 3199094 E 3 11081262 500 12W TRIMMER 2988 Rios RASA RBS RAT RSS 5 5194008288 2514 C309 C400 C402 C404 C409 513490 42 1 0 35 IR201 R202 R203 R204 R205 519400 10 412 423 446 447 448 IR230 R434 R466 R483 R484 O C451 C452 C460 C462 IR492 R500 R501 ND e313 ____________1 513490 197 8235 72 FR206 R207 R208 R209 4 S1940026R7 c cor 1 51666510 212 ROSS RAOT RATO 194001502 TER TAW D C A E arp roo R437 R439 R453 R550 R554 21 ce EUN arom ROR 518 ous 1 SEC RAT RATS
98. 518 ITEM REQ D PART NO IDENTIFICATION ITEM PART NO IDENTIFICATION C 100 T11577 58 0047 3000 C101 513490 76 001 400 C 102 C 103 C 105 C30 1 C472 516668 3 100pF 7 100 104 C422 516668 6 4700pF 750 C 106 C205 C303 C305 C306 C470 C471 16668 8 100 C107 C 12 1 C 122 C123 C 124 C125 C 126 127 C 128 C 129 C204 C211 C307 C308 C411 C413 C424 C425 C426 C427 C428 C429 C430 C432 C433 C434 C435 C436 C437 C438 C439 C44 1 C442 C443 C444 C445 C450 C456 C457 C458 C459 C466 C467 C468 516668 11 1 50 R137 R142 R145 R147 R148 R2 13 R2 14 R233 R236 R237 R240 10 12 14 R316 R320 R324 R325 R330 R331 R333 R403 R4 12 R414 R431 R435 R444 R445 R455 R475 R478 R509 R5 10 R527 R528 R529 R536 R539 R540 R551 R56 1 R563 R564 19400 1002 10K 1 4W R138 R406 R452 R495 R508 R54 1 R542 R543 R544 R545 R546 R547 R548 8549 19400 2671 2 67K 1 4W R139 R157 R337 19400 2430 243 1 44 R140 516296 5 TRI R14 1 R146 R530 19400 8251 8 25K 1 4W 108 C4 19 513490 19 1 8 20 C109 C110 C4 16 516668 7 820pF 50 C111 C311 513490 121 1000 35 R143 R144 R232 R235 R4 16 R424 R446 R450 R459 R471 R480 R496 R552 R559
99. ANS Return to Master TOC Return to Section TOC 1 9V 1666 PRIMARY PWM ENABLE TO ANALOG LOGIC SHEET 1 p Le TRIGGER we INTERFACE Fi PHASE 3 b lt LBW NORMAL gt FROM m 23V PINCH START OVERCURRENT FAULT w ERL 292 S n k FROM SHEET 1 CR 4 Mo 14 Ree gt o 0206 22K Return to Section TOC Return to Master TOC ENERGY CONTROL ENERGY CONTROL OPTION ENABLE OPTION ENABLE SHEET 1 C nes lt 150K X28 D COMPARITOR ENERGY CONTROL ENERGY CONTROL xs wena OPTION P BOOST ah on or OPTION P BOOST TIME an IME SHEET 1 2 RIGL 158K PINCH SIGNAL FOR ENERGY CONTROL OPTION SHEET 1 4 4 PB START SIGNAL FOR A ENERGY CONTROL OPTION SHEET 1 WIRE TYPE POSITION A ENERGY CONTROL OPTION SHEET 1 ISOLATED CIRCUIT 5 5 16 gt 2 2 EIE Siz a
100. Analog Volt ohmmeter Multimeter STT Wiring Diagrams 5 16 Nut driver Note Component locations and disassembly procedures may vary slightly on STT models INVERTEC STT LINCOLN 5 38 38 TROUBLESHOOTING amp REPAIR SNUBBER RESISTORS TEST continued FIGURE F 12 REMOVING LEADS Return to Section TOC Return to Master TOC 2 5 2 3 Return to Master TOC TEST PROCEDURE 4 Locate and gain access to the switch board ojo 1 Turn off Invertec STT and disconnect main 5 Remove leads from terminals 401 403 E AC input power to the machine 402 404 on the switch board See Figure 515 2 Using the 5 16 nut driver remove the case F 12 918 wraparound cover gt olg 3 Perform the Filter Capacitor cle Discharge Procedure See the a a Maintenance section 9 WARNING ELECTRIC SHOCK can kill Before continuing with the test procedure perform the capacitor discharge js procedure to avoid electric e shock 9 S PEN 5 2 EIE 3 z Dlo cc INVERTEC STT LINCOLN 5 39 39 TROUBLESHOOTING amp REPAIR ge SNUBBER RESISTORS TEST continued S 83 FIGURE F 13 SWITCH BOARD TEST POINTS 401 403 9 12 402 404 Return
101. BER V COMMAND SIGNAL ON ALL ANGLES IS 5 OF A DEGREE ScAE NONE SHT MATERIAL TOLERANCE 77 TO AGREE SD 2781 pieni cn DR DATE 04 12 94 SUP S D G G J Jy AoH NA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE UNLESS OTHERWISE SPECIFIED TOLERANCE La THE LINCOLN ELECTRIC CO En STT CONTROL T Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided INVERTEC STT amp STT ELECTRIC for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator Technician Improper PC board repairs could result in damage to the machine Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O Fg 515 1 g 2 cic 5 5 a Return to Section TOC Return to Master TOC G 7 ELECTRICAL DIAGRAMS Schematic Control PC Board Codes 10151 11092 02781 Sheet 2 of 2 Varc FILTERED TO ENERGY CONTROL OPTION
102. C 15 ISOLATOR NAND Pronn NAND ON R333 P 1 X15 DARL DANE COUNTER TT TOAD hae vss D NAND NAND M 2 p X6 MC14040 DP V SYNC 4 PWM_SYNC xn 0 2 M gum NAND D Ku suar 110 0302 o pu moane R325 nano R320 X15 TE ay D301 1N4007 pa R305 GROUND PLANE 178 JPBLOCAL _ S 5 cN AC El wo ATSK C305 0303 DETECT M 1936 1 FROM FE SHEET 2 100v 10 0 3 BOOST ONLY AFTER RESET 1 8 msec PLASMA OVERCURRENT TRIP MUR 4 18 BOOST TIME LIMIT xn Ke ARG START a PINCH R323 Hp iv CURRENT 0301 5 ST 51 4 s P BOOST NAND A 5 50V LOCAL 1 1 100 97 romocenoncur 10 E nano CLOCK t ic vc 3 BPS RESET CLOCK2 5 A Eg C CRI ii 1948 RESET 2 415V 8557 8 SET 1 02 E 8 J28 E C310 00471 dos 7 1400V T D308
103. CTRIC SHOCK can kill With input power ON there are high voltages inside the machine Do not reach into the machine or touch any internal part 3 Carefully apply the correct input power to the machine NOTE This test should only be conducted when the machine reconnect switch and jumper are set for high voltage above 380VAC and the proper line voltage is applied 4 Test for VDC across terminals 9 and 12 of one switch board and repeat the test for the other switch board See Table F 4 in this procedure for expected voltage readings See Figure F 10 A If less than 25VDC difference is mea sured between each switch board the capacitive balance is OK This indi cates that capacitors C1 C2 and resis tors R1 and R9 are functioning proper ly Proceed to Step 5 B If more than 25VDC difference is mea sured between each switch board test each of the following components Capacitors C1 C2 and resistors H1 and R9 See the Invertec STT Wiring Diagram INVERTEC STT LINCOLN 5 31 31 TROUBLESHOOTING amp REPAIR O O CAPACITOR BALANCE TEST continued 9158 ols lt TABLE 4 EXPECTED VOLTAGE READINGS o 2 If VAC Input is VDC at terminals 9 and 12 should be approximately 460 VAC 325VDC 440 VAC 311VDC 415 VAC 293VDC 380 VAC 269VDC 5 Adjust the Peak and Background controls to 8 After all tests are completed remove the t
104. Codes 18441 G 19 2 Schematic Driver Board All Codes 820799 G 20 2 PC Board Assembly Driver All Codes 19134 G 21 gt Schematic Protection PC Board Codes 10151 11092 M16097 G 22 PC Board Assembly Protection Codes 10151 11092 17915 G 23 2 Schematic Protection PC Board Codes 11115 11116 M20352 G 24 PC Board Assembly Protection Codes 11115 11116 112235 G 25 Schematic Current Sense PC Board All Codes 521410 G 26 PC Board Assembly Current Sense All Codes 17591 G 27 Schematic Remote Protection PC Board Codes 17609 G 28 PC Board Assembly Remote Protection All Codes 19657 G 29 9 5 INVERTEC STT LINCOLN G2 ELECTRICAL DIAGRAMS G 2 Wiring Diagram Entire Machine Codes 10151 10153 G2773 TOROIDAL NEN CORE 207400 402 404 288B 4 i VOLTAGE SWITCH i SENSE BOARD i pk 90 1 9 coNNECTI 5 LEFT i 2 29183 401 403 j Rw R wi 8 1 _ 4 5 Return to Section TOC Return to Master TOC 1 1 1 403 3 3 4021 5 412 1234041 P
105. EDER RESISTORS ARE A MATCHED SET N G C1 C2 CAPACITORS ARE A MATCHED SET N H PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR 380 460V OPERATION P22 J22 N I DENOTES A TWISTED WIRE PAIR OR GROUP 1 2 3 4 5 6 7 8 dUe 5143121 N J NOT PRESENT ON EUROPEAN VERSION o 1911121314 3318 1913141312 1110 9 N K NOT PRESENT ON EUROPEAN VERSIONS CODE 10309 AND HIGHER E N L PRESENT ON EUROPEAN VERSIONS CODE 10309 AND HIGHER N M PRESENT ON EUROPEAN VERSIONS CODE 10383 AND HIGHER J30 P29 P31 J29 J31 P21 21 112113 112113 43 4156 6 4 4115 116 n INLINE CONNECTOR CAVITY NUMBERING SEQUENCE VIEWED FROM WIRE SIDE OF CONNECTOR Return to Section TOC Return to Master TOC G3136 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine STT STT G 4 Wiring Diagram Entire Machine Codes 11090 11092 G4500 ELECTRICAL DIAGRAMS REMOTE PROTECTION BOARD TOROIDAL CORE T 2898 2888 m 289 288 VOLTAGE SENSE 1 290 4 lt 1 9
106. EIE 8 4648 23 20 ohm 5 watt D 59 R10 R11 R12 R13 R14 6 4649 7 2 10W 15 R16 R17 R18 4 19400 1001 K 1 4W X2 5 12 8 PI SS CAPACITORS MFD VOLTS RESISTORS OHMS olo e 5 8 Oo 2 ala NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided STT amp STT ELECTRIC for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design may result in danger to the Machine Operator Technician Improper PC board repairs could result in damage to the machine G 16 ELECTRICAL DIAGRAMS G 16 Schematic IGBT Drive Board Codes 11090 11116 L12144 NEGATIVE BIAS FOR TGBT olo Fie 5 D DP 5 9 AUXILLARY 4 tar 021 c POWER 18V AN 10VAC R6 T a 6VAC O Fg 918 HOLD OFF stats ae a 5 gt o gle 5 zm a Bee eli te an 6 1 cc STT II CONTROL BOARD 15V d 15
107. ESHOOTING amp REPAIR CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 35 REMOVING THROUGH BOLTS Return to Section TOC Return to Master TOC PLASTIC RETAINING INSULATORS Return to Section TOC Return to Master TOC 15 Place the machine on its side as shown in 16 Remove the switch board and capacitor Figure F 35 Slide the plastic retaining insu assembly from the machine lators that go through the base of the machine to one side Pull the through bolts out of the machine being careful to save all the insulation and standoff material Set aside for reassembly olo E 2 olg iz 8 mlt 515 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 71 71 TROUBLESHOOTING amp REPAIR CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 36 REMOVING CAPACITOR NUTS Return to Section TOC Return to Master TOC O10 EP 55 o o gt 2 5 B 17 Remove the two 7 16 hex bolts that hold the 18 Loosen the set screw of the capacitor clamp 2 capacitor to the switch board Figure ring and remove the capacitor from the clamp F 36 ring See Figure F 37 FIGURE 7 LOOSENING THE CLAMP RING SET SCREW O10 O10 E 5 5 5 9 17 Remove the two 7 16 hex bolts that hold the 18 Loosen the set screw of the capacitor clamp 2 E capacito
108. ESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED DIODES 14 409V UNLESS OTHERWISE SPECIFIED LABELS SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION Note Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine INVERTEC STT STT G 25 ELECTRICAL DIAGRAMS G 25 PC Board Assembly Protection Codes 11115 11116 L12235 ojo 2 6 2211 ENGINEERING CONTROLLED CHANGE DETAIL NEW D EM PARINO SQ QDENIPCATION PIE MANUFACTURER No B5 B14 B51 B52 B53 Goasse 6 fess o2e0 O 2 2 2788 d 51 ponsen 6 1121991 olg pet 0270227 ol9 NC CDS 1506 P C BOARD BLANK INFORMATION 5 Re 2 519006813 OOO E MAKE FROM 519399 MAKES 8 BOARDS PER PANEL RGRERERIQRI7 5 5194005622 SEE ELECTRONIC F
109. GEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT STAINLESS PINOUT OF FRONT PANEL CONNECTORS REAR VIEW COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER L PLACE LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE 6 CONNECTION SHOWN ISF OR 380 415V OPERATION 502 THERMAL P29 P31 J29 J31 P21 D1 THRU 05 OUTPUT DIODES ARE A MATCHED SET OVERLOAD Te d TI D7 THRUD 11 OUTPUT DIODES ARE A MATCHED SET INDICATOR 2 514 NF 1 9 BLEEDER RESISTORS MATCHED SET C1 C2 CAPACITORS A MATCHED SET N H PLACE SWITCH IN APPROPRIATE POSITION OR INPUT VOLTAGE CONNECTION SHOWN IS OR 380 415V OPERATION 2 6 8 8 7 6 312 N I DENOTES A TWISTED WIRE OR GROUP 10 11 14 16 16 15 14 11 10 N J NOT PRESENT ON EUROPEAN VERSIONS NOT PRESENT ON EUROPEAN VERSIONS INLINE CONNECTOR CAVITY NUMBERING SEQUENCE N L PRESENT ON EUROPEAN VERSIONS VIEWED FROMWIRE SIDE Or CONNECTOR Return to Master TOC Return to Section TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to
110. GES TEST POINTS NORMAL VOLTAGE PLUG J30 PINS 1 TO2 115VAC LEADS 32 TO 33 PLUG J31 PINS 1 TO 4 18VAC LEADS 501 TO 504 PLUG J31 PINS 2 TO 24VAC LEADS 212 TO 503 PLUG J31 PINS2 TO 5 42VAC LEADS 212 TO 43 PLUG J21 PINS 1 TO 4 200 208VAC LEADS H1 TO H2 PLUG J21 PINS 1 TO2 220 230VAC LEADS H1 TO H3 PLUG J21 PINS 1 TO LEADS H1 TO H4 380 415 VAC PLUG J21 PINS 1 TO6 440 460VAC LEADS H1 TO H5 H6 NOTE If the main AC input supply voltage varies the auxiliary transformer voltages will vary by the same percentages INVERTEC STT LINCOLN 5 16 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC Q E 17 TROUBLESHOOTING amp REPAIR T1 AUXILIARY TRANSFORMER TEST continued WARNING ELECTRIC SHOCK can kill 16 e e With input power ON there are high voltages inside the machine Do not reach into the machine or touch any internal part 18 15 Apply the correct input power and carefully test for the correct primary voltages at plug J21 See Table If the correct AC input voltages are applied to the primary windings and any or all of the secondary voltages are missing or not cor rect the T1 auxiliary transformer may be faulty 17 After a
111. GURE F 14 REMOVING THE FRONT PANEL ASSEMBLY Return to Section TOC Return to Master TOC POWER PC BOARD 2 Located on Back of r Case Front Return to Section TOC Return to Master TOC QUICK CHECK PROCEDURE OK Ifthe relays are NOT being activated the power board could be faulty Continue 1 Turn off the Invertec STT and disconnect with the voltage tests main AC input power to the machine 2 Using the 5 16 nut driver remove the case wraparound cover VOLTAGE TEST PROCEDURE 3 Locate relays CR1 and justto the frontof 1 Remove input power to the Invertec STT the tan matoi 2 Perform the Input Filter Capacitor Discharge See the section WARNING ELECTRIC SHOCK can kill WARNING e e With input power ON ELECTRIC SHOCK can kill 5 o 2 2 i Nd Before continuing with the not reach into the machine 1851 procedure ponon the capacitor discharge anyintarnal pan procedure to avoid electric shock olo 4 Apply the correct input power and turn ON the Invertec STT machine 3 Using the 5 16 nut driver loosen the front 515 5 After about 5 second delay the relays control panel by removing the four sheet 8 8 should activate This can be determined by metal screws from the top and bottom of the 0 2
112. IAGRAM MAY 135 FRAME CONNECTION NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE a EARTH GROUND CONNECTION NUMBER FILE M17581_1AB UNLESS OTHERWISE SPECIFIED TOLERANCE EQUIP 5 19 05 THE LINCOLN ELECTRIC CO TYPE INVERTER WELDERS 3 29 96 CLEVELAND OHIO U S A suBsect _ SCHEMATIC DARLINGTON DRIVE MATERIAL TOLERANCE 17 TO AGREE NONE SHT WITEIEUBCSHED STANDARDS pr __MLD DATE 03 23 94 CHK BS SUP S D G no M17581 Return to Section TOC Return to Master TOC IB e fo NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided STT amp STT ELECTRIC for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator Technician Improper PC board repairs could result in damage to the machine G 15 ELECTRICAL DIAGRAMS G 15 PC Board Assembly Darlington Drive Codes 10151 10383 G2778 2 2 Return to Master TOC
113. ILE FOR ADDITIONAL INFORMATION Ra 7 LL 19400 1008 us 1 919494750 475 AW 3 pron BLANK PART NUMBER L12235 B us 5 R21 R23 F24 R25 R29 R30 Ed udo 15K 1 4W R31 R33 gt 3 199405355 532 AW 2 10400 2678 09264 X22 NB bosses e T i CAPACITORS MFD VOLTS 2 E 0 INDUCTANCE HENRIES EI 4700 yum RESISTANCE OHMS 5 5 1 E ITEM REQ D PART NO DESCRIPTION n 2 1 SEE BLANK INFO P C BOARD BLANK ____ olg 2 1 2 oz E2861 SEALANT MANUFACTURED AS 2400 M NA IDENTIFICATION CODE MAKE PER E1911 ENCAPSULATE WITH E1844 2 COATS TEST PER E4117 PR SCHEMATIC REFERENCE 20352 2 0 olo O 5 5 gt 2 512 a NOTES N A MOUNTING HOLES TO BE FREE OF ENCAPSULATION MATERIAL 5 PLACES COVER THIS AREA TOP amp BOTTOM WITH ITEM 2 FILL SLOT COMPLETELY ITEM 2 IS TO FILL AREA BETWEEN UNDERSIDE OF COMPONENT amp PC BOARD WITH NO VOIDS N C DO NOT COAT WITH ENCAPSULATION ALL COMPONENTS AND MATERIALS USED THIS p ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 FOR PARTS ORDERS PERFORM PARTS ORDERS TEST PER E4117 PR A PAGE 2 f THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp
114. INCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE o g SNUBBER Al an RESISTOR 1 NEGATIVE INPUT Return to Master TOC Return to Section TOC 30Nvu3 vnvulsnv Eje fo NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided STT amp STT for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o g Return to Section TOC Return to Master TOC 2 D 3 G 19 ELECTRICAL DIAGRAMS PC Board Assembly Switch Codes L8441 EES ON LN LN ss srel wg el orel ea m oa 4 EH E EH L J EH
115. ITOR V 5 R28 R22 19K D6 1 82K 5 a FROM LOWER CAPACITOR 5K a a 851 150K 150K B 15 0K J8 i5 08 FROM CENTER LEG OF INPUT 5 Ho BK 15 0K 1500 15 0K 15 0K TO CONTROL BD c5 Single Phase 2 gt 5V NOTES SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INT RCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER 1 THE LINCOLN ELECTRIC TYPE INVERTER PADE or d BY LINCOLN ELECTRIC GLOBAL INC CLEVELAND OHIO U S A suBJECr _ SCHEMATIC PROTECTION DOCUMENT NOT BE DUPLICATED COMMUNICAREO TO OTHER 7 PARTIES OR USED FOR ANY PURPOSE WITHOUT f NOT ENGR MLO T scate MATERIAL APPROVAL g 19 2996 PROJECTCRM38136 0 REVISION THE EXPRESS WRITTEN PERMISSION OF SCALE THIS MAB DISPOSITION 67 12 2006 kumaen 91558 MPg352 2B0 LINCOLN ELECTRIC GLOBAL INC DRAWING G 24 0 Qver Voltage a 5 10 1 CNYi7 3v J 4 681K R37 i e oci3 s 1 12 2 TO ORIVER 80 Over Voltage 4 gt V R35 2 332 BRIVER 20 Voltage s V GENERAL INFORMATION ELECTRICAL SYMBOLS PER 1537 CAPACITORS MFO 822 56V UNLESS OTHERWISE SPECIFIED R
116. LECTRIC Only qualified persons should install SHOCK use or service this machine CAN KILL Return to Section TOC Return to Master TOC WIRE FEEDER REMOTE WORK LEAD CES CABLES AND LEADS SHOULD BE TAPED TOGETHER WIRE FEEDER STT 10 ELECTRODE LEAD ELECTRODE LEAD ELECTRODE SENSE LEAD IS BOLTED TOGETHER WITH ELECTRODE LEAD ON THE WIRE FEEDER CONTACT BLOCK REMOTE Return to Section TOC Return to Master TOC ARC SENSE LEAD WORK SHOULD BE LOCATED AS CLOSE AS POSSIBLE TO THE WELDING ARC vas WORK 17657 8 FIGURE STT 10 to STT II CONNECTION O10 o E mlt 515 ply 9 ajo Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 Section D 1 Section D 1 TABLE OF CONTENTS Maintenance 2 1 1 1200 04002 2001000800000000000000000000000000000000000000403 Section D gt Input Filter Capacitor Discharge D 2 8 Preventive qe D 3 2 Major Component LoCations vanes ova D 4 Return to Master TOC Q E Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Retur
117. LEMS The 42VAC circuit breaker CB1 may be tripped Reset if neces sary Check the 4 amp slow blow fuse located on the reconnect panel Replace if faulty Put a jumper between pins A and C on the 5 pin amphenol located on the LN 742 wire feeder If wire feeds check the gun trigger Repair or replace if necessary Check for the presence of 42VAC at pins K and I on the 14 pin amphenol If the 42VAC is present and the feeder does not work the problem is in the feeder control cable or the wire feeder RECOMMENDED COURSE OF ACTION 1 If 42VAC is NOT present at pins and I on the 14 pin amphe nol perform 1 Auxiliary Transformer Test Check leads 43 and 212 for loose or faulty connections between the T1 auxiliary trans former and the remote protec tion board See the Wiring Diagram Also check the conti nuity through the remote protec tion board to the 14 pin amphe nol See the Remote Protection Board Schematic CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q HE 2 2 Return to Section
118. LESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued FIGURE F 19 PLUG J31 LOCATION Return to Section TOC Return to Master TOC 2 5 2 3 Return to Master TOC TEST PROCEDURE 1 Turn off the Invertec STT and disconnect main WARNING AC input power to the machine ELECTRIC SHOCK can kill o 9 2 Using the 5 16 nut driver remove the case e Before continuing with the ja wraparound cover test procedure perform 912 the capacitor discharge 8 3 the Input Filter Capacitor procedure to avoid electric gt Discharge the Maintenance shock 5 EIE 513 E 4 Locate plug J31 at the left side of the machine See Figure F 19 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 51 51 TROUBLESHOOTING amp REPAIR TRIGGER CIRCUIT TEST continued FIGURE F 20 14 PIN AMPHENOL AND PLUG J31 PIN ASSIGNMENTS Return to Section TOC Return to Master TOC 212 PLUG J31 5 Using the ohmmeter check for approximately 3 5 ohms resistance from pin D of the 14 pin amphenol to plug J31 pin 2 lead 7212 See Figure F 20 and Figure F 22 Simplified Trigger Circuit Diagram FIGURE 21 CONTROL PC BOARD MOLEX PLUG o 2 5
119. LIED WITH INPUT CABLE FOR SINGLE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE 138 CONNECT BLACK amp WHITE LEADS TO SUPPLY CIRCUIT AUN WRAP RED LEAD WITH TAPE TO PROVIDE 600V INSULATION CONTROL kesse er e C FOR THREE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE BOARD f Q ON CONNECT BLACK RED amp WHITE LEADS TO SUPPLY CIRCUIT FOR MACHINES NOT SUPPLIED WITH INPUT CABLE OY HOT START 10K 365 4 S R13 CONTROL FOR SINGLE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES WIRE SIZE T CONNECT TERMINALS U amp W SUPPLY CIRCUIT 045 035 9 D 2 FOR THREE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES 368 gt x f 18 CONNECT TERMINALS U W TO SUPPLY CIRCUIT 367A DL SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING WIRE TYRE gt THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT STAINLES PINOUT OF FRONT PANEL CONNECTORS REAR VIEW COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER 369 PLACE A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR 440 460V OPERATION 502 P29 P31 J29 J31 P21 J21 N E 01 THRU D5 OUTPUT DIODES ARE A MATCHED SET Jer eem 2 HAR D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET de R1
120. MINIPCB A4 PIN 1 5182485 CONNECTOR MOLEX MINI PCB 6 PIN S15000 28 OPTOCOUPLER LOGIC OUT HCPL2201 8S TRANSISTOR PMF 10200 6A 100V SS _2 Yt d N EN 074 DZS och 171270480 TRANSISTOR NM TO220 4A T00V IRF510 SS RESISTOR WW 5W 0 5 1 19400 1501 19400 3921 19400 2670 zzz gt gt zz 21 gi OOO Salas 549138 1 2 2 5 oiv SES ES Slag RESISTOR MF 1 4W 196 RESISTOR MF 1 4W 3 92K 196 RESISTOR MF 1 4W 267 1 19400 1080 RESISTOR MF 1 4W 10 0 196 23 RESISTOR WW 5W 20 5 SQ RESISTOR WW 10W 2 7 5 SQ RESISTOR WW 10W 100 5 SQ RESISTOR MF 1 4W 1 00K 1 IC CMOS DRIVER MOSFET 4429 R6 7 zzz 519400 1001 515018 12 gt MFD VOLTS RESISTORS OHMS MAKE PER E1911 ENCAPSULATE WITH E1844 2 COATS TEST PER E4104 SCHEMATIC REFERENCE L12144 2CO 8 75 9 00 04 NOTES MANUFACTURED AS N A CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY SEE E2454 BEFORE HANDLING L12145 2CO N B DO NOT COAT WITH ENCAPSULATION MATERIAL N C BEFORE ENCAPSULATION SECURE COMPONENTS TO IDENTIFICATION CODE P C BOARD WITH ITEM 9 AS SHOWN 20 PLACES ALL COMPONENTS AND MATERIALS USED IN THIS ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMI
121. N ALL MODELS 2 Move input voltage switch to Voltage 380 460V position 3 Move lead A to 380 415 Terminal 380 400 or 415 VAC Codes 11115 and Open reconnect panel access door on wrap around 11116 2 Move input voltage switch to Voltage 380 460V position 3 Move lead A to 380 415 Terminal 220 or 230 VAC Codes 11092 and s Open reconnect panel access door on wrap around below 2 Move input voltage switch to Voltage 200 230V position 3 Move lead A to 220 230 Terminal 200 208 Codes 11092 and Open reconnect panel access door on wrap around below 2 Move input voltage switch to Voltage 200 230V position 3 Move lead A to 200 208 Terminal 200 or 208 VAC 1 Open reconnect panel Codes 11115 and access door on wrap around 11116 2 Move input voltage switch to Voltage 200 230V position 3 Move lead A to 200 208 Terminal OUTPUT CONNECTIONS WIRE FEEDER OUTPUT CONNECTIONS Refer to Accessories section of this manual for instructions on connecting a wire feeder to the Invertec STT Il The LN 742 or STT 10 wire feeder is the recommend ed feeder for use with the Invertec STT INVERTEC STT Il LINCOLN 5 Section B 1 Section B 1 TABLE OF CONTENTS P OPERATION SECTION e Section B Safety
122. ND MAY NOT BE DUPLICATEI d SOLID EDGE 5 8 16 2 2 2 EIE Size EN 170 INVERTEC STT STT IB NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine G 12 ELECTRICAL DIAGRAMS G 12 Schematic Power PC Board All Codes M16018 Vin Vc OUT P7 5 J7 X67 GND TO PULSE 18Vac TAN TRANSFORMER FROM AUXILIARY NI IN J7 P7 TRANSFORMER 8 e cT E 07 Return to Section TOC Return to Master TOC Vin Vc 025 OUT e 12V 4 X68 GND INVIN J7 6 J6 J6 J6 J7 3 6 3 1 Yer P6 P6 P6 Yos TO TO PWM PWM 0 PILOT CONTROL SIGNAL SIGNAL CONTROL PILOT LIGHT BOARD BOARD LIGHT 15V COM 8
123. NG ELECTRIC SHOCK can kill e With input power ON there high voltages inside the machine Do not reach into the machine or touch any internal part 5 Apply the correct input power and turn the machine ON 6 Test for approximately 1VDC from plug J8 pin 1 lead 311 to plug J8 pin 3 lead 313 See Figure F 17 A If approximately 1VDC is present the protection PC board is functioning prop erly B If more than 5 VDC is measured per form the Capacitor Balance Test INVERTEC STT LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC 5 TROUBLESHOOTING amp REPAIR PROTECTION BOARD TEST continued FIGURE F 18 LEADS 309 309 AT CR1 CR2 RELAYS CR2 CR1 309 7 If the Capacitor Balance Test is OK and more than 5VDC is present at leads 311 to 313 Step 6 the protection PC board may be faulty NOTE The above voltage checks pertain only to the over voltage signal from the protection PC board to the power PC board The capaci tor precharge circuits are also incorporated within the protection PC board If the problem has not been identified carefully proceed with the following steps 8 Remove input power to th
124. O FRONT END SHEET 2 ojo 515 0 4 9 2 cic S2 a OR RAMP CTRL Em E 1 KEEP ALIV CURRENT LEVEL ATK _1 cate PB_SCALED 820p gt lt 50 BACKGROUND METER 18K R448 Le 8446 LOCAL BG POT 7 0216 21042 12 35V T V R498 ARG_START Hor_start 20 0K R497 PREMOTE pos 150 11 BACKGROUND INCREASE R548 DURING HOT START 2 67 HOT START x o R440 e PLASMA BOOST METER E 494 e Input Current Feedback START uy HENGTE GENERAL INFORMATION Im Yo HOT START C 105 242 345 584 PINCH RAL ELECTRICAL SYMBOLS PER E15
125. OARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A ORC xg IB EET CIRCUIT 2 i g xig Your lg 5 ale ag Jocs i cU T uk REN yo METER 2 32 5 dan Fi ia 4 1 2231 PWM OUTPUT 6 4 Ay LES E xl MUT memes gt TO FRONT END Fi 3 11 vc SHEET 2 s 8 aje 1 2231 5 P 8009652 xia 7 mea 8 RST HSV fi E PB_SCALED i lt 5 5 COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE Input Current Feedback 00990 5 nanote 199990990 8 Analog Logio 1 0 40000014 Control 3000000005 to Control Panel J27 12 0000000 Darlington gt Analog Logic 1 0 Drive o Control Panel In 128 23 PROPRIETARY amp CONFIDENTIAL THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN ELECTRIC GLOBAL INC AND MAY REFERENCE THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A D CALE NONE mph DS NOT BE DUPLICATED COMMUNICARED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN ELECTRIC GLOBAL INC MATERIAL DISPOSITION GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS RESISTORS Ohms DIODES 14 408V UNLESS REFERENC 100 SERIES ARC SENSE CIRCUIT 260 SERIES TRIGGER CIRCUIT SIGNATOR SERIES DEFINITION
126. OHIO U S A SCHEMATIC ON 3 PLACE DECIMALS IS 002 9 27 96F ON ALL ANGLES IS 5 OF A DEGREE __ _ 5 SHT MATERIAL TOLERANCE t TO AGREE 2 pr MLD pate 03 21 04 SUP S D G _____ 9 21410 SUBJECT Return to Master TOC Return to Section TOC IB NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided STT amp STT ELECTRIC for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator Technician Improper PC board repairs could result in damage to the machine Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O 5 5 2 2 cic 5 5 a Return to Section TOC Return to Master TOC G 27 PC Board Assembly Current Sense Codes M17591 ELECTRICAL DIAGRAMS G 27 CURRENT SENSE Note grid Go R14
127. OX 6222 LAO OK ES power lt 54 A BOARD 3281 lt 1234 REMOTE PROTECTION 14 AMPHENOL 3 5 ohms 223 gt 8033 1303692 3 5 ohms 5J36 gt 405 7 Using the ohmmeter check for continuity zero ohms from plug J31 pin 503 to plug pin 6 lead 210 See Figure F 22 Simplified Trigger Circuit Diagram 8 If any of the resistance checks are abnormal ly high in steps 5 6 or 7 check for broken or loose wires connections or open ther mostats Also check the small inductors on the Remote Protection Board See Figure F 22 Simplified Trigger Circuit Diagram WARNING ELECTRIC SHOCK can kill e With input power ON there are high voltages inside the machine Do not reach into the machine or touch any internal part 9 Apply the correct input power to the machine and turn ON 10 Locate plug J6 on the power PC board See Figure 15 the Power Board Test 11 Carefully check for approximately 1VDC from plug J6 pin 2 lead 305 to plug J6 pin 7 lead 301 If the approximately 1VDC is present the power PC board and protection PC board are functioning properly for the trig ger circuit to operate If the correct DC volt age is NOT present perform the Board Test and the Power Board Test 12 Test to make sure the T1 auxiliary trans former is producing 24VAC See Figure F 22 Simplified Trigger Circuit Diagram 1
128. PONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW REFERENCES PART NUMBER DESCRIPTION 2 S21421 1 P C BOARD BUSHING C1 C2 C3 C4 C5 C6 COMPONENT SIDE CT CB 2557 BOARD Return to Section TOC Return to Master TOC P C BOARD BLANK INFORMATION S 87 1 518248 6 ____ 6 ______________ MAKE FROM 519299 MAKES 6 BOARDS PER PANEL SEE 1 ELECTRONIC FILE FOR ADDITIONAL INFORMATION 1 18182484 OCONNECTORMOLEXMINIPCBAPIN ___________ 4 N R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 SECTION THRU BUSHING CAPACITORS MFD VOLTS POEDER DE LAI INDUCTANCE HENRYS RESISTOR 1 4W 1 00K 1 Return to Section TOC Return to Master TOC NOTES N A KEEP THESE AREAS FREE OF ENCAPSULATION MATERIAL N B KEEP MOLEX FREE OR ENCAPSULATION MATERIAL 5 PLACES N C PRESS BUSHING INTO OPPOSITE COMPONENT SIDE OF BOARD CONTINUOUS FILLET OF SOLDER REQUIRED ON OPPOSITE COMPONENT SIDE NO PROJECTION OF SOLDER PERMITTED IN HOLE OR ON OR ABOVE SURFACE OF BUSHING FACES AND HOLE OF BUSHING MAY BE MACHINED TO BARE BRASS MANUFACTURED AS L9657 3D0 IDENTIFICATION CODE olo O 5 5 gt 2 512 a STT REMOTE MAKE PER E1911 ENCAPSULATE WITH E1844 2 COATS TEST PER E3472 RM SCHEMATIC REFERENCE 17609 300 ALL COMPONENTS
129. PPLY CIRCUIT WRAP RED LEAD WITH TAPE TO PROVIDE 600V INSULATION FOR THREE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE mem CONNECT BLACK RED amp WHITE LEADS TO SUPPLY CIRCUIT BOARD 2 FOR MACHINES NOT SUPPLIED WITH INPUT CABLE FOR SINGLE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES CONNECT TERMINALS U amp W TO SUPPLY CIRCUIT FOR THREE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES f CONNECT TERMINALS U V amp W TO SUPPLY CIRCUIT __ 0 SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING MA THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT srANLESS 59 502 2 o v z 2 tc 1 7 1 8 0000000 00000000 9000000 2 8 MW 9 A 16 P C BOARD CONNECTOR CAVITY NUMBERING SEQUENCE VIEWED FROM COMPONENT SIDE OF BOARD o g NOTES cw 1 TAILOUT CONTROL 500K R14 t 378 t ve HOT START 2w 295 CONTROL 366 367 367A WIRE SIZE COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER PLACE A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR 440 460V OPERATION D1THRU 05 OUTPUT DIODES ARE A MATCHED SET D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET vw Rt R9 BLEEDER RESISTO
130. R CIRCUITRY OF CONTROLS HAVING COMMON CODE BY LINCOLN ELECTRIC GLOBAL INC AND MAY CLEVELAND OHIO U S A SUBJECT SCHEMATIC CONTROL PCB DOCUMENT in NUMBER NOT BE DUPLICATED COMMUNICARED TO OTHER REVISION PARTIES oR USED FOR ANY PURPOSE WITHOUT ENGR MLI NONE APPROVAL gg PROJECT _p DOC 57 THE EXPRESS WRITTEN PERMISSION OF DRBY MAB eo YS DISPOSITION N A DATE NUMBER CRM38136 8 ios 54649 2 A Return to Master TOC Return to Section TOC LINCOLN ELECTRIC GLOBAL INC IB e s N fo NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided INVERTEC STT amp STT for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine G 11 PC Board Assembly Control Codes 11115 11116 G4648 ELECTRICAL DIAGRAMS
131. R9 BLEEDER RESISTORS ARE A MATCHED SET 4 3 514 5 RII n ISIA C2 CAPACITORS ARE A MATCHED SET N H PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR 380 460V OPERATION AEE BAE N I DENOTES A TWISTED WIRE PAIR OR GROUP 5 N J NOT PRESENT ON EUROPEAN VERSIONS N K NOT PRESENT ON EUROPEAN VERSIONS CODE 10309 AND HIGHER INLINE CONNECTOR CAVITY NUMBERING SEQUENCE PRESENT ON EUROPEAN VERSIONS CODE 10309 AND HIGHER VIEWED FROM WIRE SIDE OF CONNECTOR Return to Section TOC Return to Master TOC 062773 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine INVERTEC STT amp STT G 3 ELECTRICAL DIAGRAMS G 3 Wiring Diagram Entire Machine Codes 10381 10383 G3136 20 400 i i 25 i i 3 4 _ J VOLTAGE 25W SWITCH i SENSE 25 2200 BOARD m 25W450V LEFT CURRENT R8 401 403 SENSE 1 59 RW R wi 83 1 BOARD Return to Section TOC Return to Master TOC
132. RD MAY CHANGE 5 COMMON CONNECTION WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY 7 7 FRAME CONNECTION NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER EARTH GROUND CONNEC UNLESS OTHERWISE SPECIFIED TOLERANCE ON 2 ON 3 ON ALL A HOLES SIZES PER E 2056 PLACE DECIMALS IS 02 PLACE DECIMALS IS 002 NGLES IS 5 OF A DEGREE MATERIAL TOLERANCE t TO AGREE 1 25 91 _ 9 11 92 12 10 93A THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A SCALE NONE Ch ge Sht No EQUIP TYPE INVERTEC V300 SUBJECT PROTECTION SHT CHK TJP SUP S D G NO WITH PUBLISHED STANDARDS Return to Section TOC Return to Master TOC or BS DB DATE 9 7 89 M 16097 Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine 908 Note INVERTEC STT STT Return to Section TOC Return to Master TOC Ret
133. RETURN TO MAIN MENU SVM129 B OCTOBER 2006 INVERTEL STT amp For use with machine code numbers 10151 10152 10153 10309 10381 10382 10383 11090 11091 11092 11115 11116 Return to Master TOC View Safety Info Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info 8 9 5 gt gjo gt o SERVICE MANUAL E MM LINCOLN Copyright 2006 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 1 888 935 3877 FAX 216 486 1751 WEB SITE www lincolnelectric com Return to Master TOC View Safety Info SAFETY A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects o
134. ROUND U BLUE CONTROL e 4 8 14 Eum 16 P C BOARD CONNECTOR CAVITY NUMBERING SEQUENCE NOTES VIEWED FROM COMPONENT SIDE Or BOARD BACKGROUND METER 5 8 16 gt 2 2 EIE Siz a FOR MACHINES SUPPLIED WITH INPUT CABLE FOR SINGLE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE HOT START 93 CONNECT BLACK amp WHITE LEADS TO SUPPLY CIRCUIT 0609 CONTROL B WRAP RED LEAD WITH TAPE TO PROVIDE 600V INSULATION CONTROL CONNECT BLACK RED amp WHITE LEADS TO SUPPLY CIRCUIT MACHINES NOT SUPPLIED WITH INPUT CABLE 367A TOR SINGLE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES I 367 Q FOR THREE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE BOARD 366 op 7 0 938 ea Poss 0 WIRE SIZE CONNECT TERMINALS amp W TO SUPPLY CIRCUIT 045 r FOR THREE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES 9388 10 _ 0 CONNECT TERMINALS U V amp W TO SUPPLY CIRCUIT 387A Q SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING m UNS THE INTERCHAN
135. RS ARE A MATCHED SET Gi 9213 G C1 C2 CAPACITORS ARE A MATCHED SET 41516 5 Bag PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE e E CONNECTION SHOWN IS FOR 380 460V OPERATION p22 J22 e A TWISTED WIRE PAIR OR GROUP PECHE NOT PRESENT EUROPEAN VERSION NOT PRESENT ON EUROPEAN VERSIONS CODE 10309 AND HIGHER N L PRESENT ON EUROPEAN VERSIONS CODE 10309 AND HIGHER INLINE CONNECTOR CAVITY NUMBERING SEQUENCE N M PRESENT ON EUROPEAN VERSIONS CODE 10383 AND HIGHER VIEWED FROM WIRE SIDE OF CONNECTOR WIRE TYPE PINOUT OF FRONT PANEL CONNECTORS REAR VIEW THERMAL OVERLOAD INDICATOR P29 P31 J29 131 P21 Return to Master TOC Return to Section TOC G4500 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine INVERTEC STT amp STT Il G 5 ELECTRICAL DIAGRAMS G 5 Wiring Diagram Entire Machine Codes 11115 11116 64557 REMOTE PROTECTION BOARD TOROID AL CORE ARC J19 VOLTAGE M 290 1 SENSE MAIN CONNECTION TRANSFORMER D7 de 2 ie
136. SSION OF LINCOLN GLOBAL INC EQUIPMENT TYPE STT ll WELDERS L12145 1 E PROPRIETARY amp CONFIDENTIAL 145 DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED UNIES OTHERWISE SP D N 3 PLACE DECIMALS IS 002 DRAWN BY DOCUMENT DOCUMENT ONALL ANGLES IS DEGREE SUBJECT IGBT DRIVE PC BD ASSEMBLY NUMBER REVISION MATERIAL TOLERANCE AGREE ENGINEER SCALE WITH PUBLISHED STANDARDS L12145 2 A MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING none NA SOLID EDGE G 17 INVERTEC STT STT G 18 ELECTRICAL DIAGRAMS G 18 Schematic Switch Board Codes L8440 LAST NO USED A SUPPLY VOLTAGE NET eO POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION L EARTH GROUND CONNECTION 77 7 FRAME CONNECTION Return to Section TOC Return to Master TOC INVERTEC V300 SWITCH BOARD SCHEMATIC Q2 1 100V IRFD110 SUBJECT POSITIVE o9 INPUT 1N4936 Q6 600mA 3 02 03 D4 05 SNUBBER IRFD110 a 460 RESISTOR 5 V BYT12P600 402 UNLESS OTHERWISE SPECIFIED 11 25 91 NONE 1 4W UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED 022 50V 055 52 63 84 55
137. STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo E olg iz 212 515 Return to Section Return to Master TOC Return to Master TOC A 6 INSTALLATION A 6 VOLTAGE ACCESS DOOR SWITCH LOCATION 380 415 380 460 FIGURE A 2 RECONNECT PANEL INPUT VOLTAGE RECONNECT PROCEDURE As shipped from the factory multiple voltage machines are internally configured for the highest input voltage 440 460 VAC for Codes 11092 and below and 380 415 for Codes 11115 and 11116 1 For Connections to 440 or 460 VAC verify the inter nal configurations to the procedures shown below and refer to Figure A 2 2 For Connections to 200 208 220 230 380 400 or 415 VAC follow the procedure shown below and refer to fig ure A 2 NOTE Turn main power to the machine OFF WARNING before performing reconnect procedure Failure to do so will result in damage to the machine DO NOT switch the reconnect bar with machine power ON To Operate at Procedure 460 or 440 VAC 1 Open reconnect panel Codes 11092 and access door on wrap around below 2 Move input voltage switch to Voltage 380 460V pos ition 3 Move lead A to 440 460 Terminal 380 or 415 VAC 1 Open reconnect panel Codes 11092 and access door on wrap around below 4A SLOW BLOW FUSE 440 460 NOT PRESENT O
138. T CURRENT AT RATED OUTPUT 208 230 460 3 60 HZ 32 30 16 Return to Section TOC Return to Master TOC 200 220 380 415 440 3 50 60 HZ 33 30 18 17 16 RATED OUTPUT DUTY CYCLE AMPS VOLTS AT RATED AMPS 60 Duty Cycle 225 29 10096 Duty Cycle 200 28 OUTPUT CURRENT RANGE OPEN CIRCUIT VOLTAGE AUXILIARY POWER Peak Current 0 450 Amps 85 VDC Maximum 115 4 Amps Background 0 125 Amps 42 VAC Q 4 Amps Return to Section TOC Return to Master TOC RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT VOLTAGE FUSE SUPER LAG INPUT AMPERE TYPE 75 C TYPE 75 C AND FREQUENCY OR BREAKER RATING ON COPPER COPPER SIZE NAMEPLATE SUPPLY WIRE GROUND WIRE IN CONDUIT IN CONDUIT AWG IEC SIZES AWG IEC SIZES 208 60 230 60 460 60 200 50 60 220 50 60 380 50 60 415 50 60 440 50 60 O10 E a gt 2 2 5 5 WEIGHT 100 Ibs 46 kg At low input voltages below 208 VAC and input voltages of 380 VAC through 415 VAC there be 15 reduction in Peak Current 2 115 VAC not present on European Models Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 INSTALLATION TECHNICAL SPECIFICATIONS Invertec STT For Codes 11115 AND 11116 INPUT THREE PHASE ONLY STANDARD VOLTAGE INPUT CURRENT AT RATED OUTPUT 200 208 3 50 60 HZ 36 34 Return to Section Return to Master TOC 200 208 380 400 415 3 50 6
139. TED CIRCUIT X24 X35 15128 16 LINEAR INTEGRATED CIRCUIT x25 M15458 2 PWM CONTROLLER X26 X33 515128 10 VOLTAGE REF X29 X34 w w w gt w 15128 4 LM224 R123 R 127 8513 R5 14 19400 68 12 68 IK 1 4W R124 R448 R449 R469 R476 8511 R520 8533 R534 19400 1004 IM 1 4W R126 19400 5112 51 IK 1 44 R129 R45 1 R538 519400 2672 26 7K_1 4W R130 131 R152 R153 163 R164 R300 R308 R329 R332 R457 R46 1 8463 5 19400 3921 3 92K 1 4W R132 R2 10 R499 R555 19400 2212 22 IK 1 4W R134 R200 R345 R427 R428 R432 R436 R532 19400 1001 1 4W R135 R423 R490 19400 2673 267K 1 4W THIS SHEET CONTAINS PROPRIETARY INFORMATIGN UNLESS OTHERWISE SPECIFIED snt OWNED BY THE LINCOLN ELECTRIC CO AND s ON HOLE SIZES PER E2056 TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO ON 2 PLACE DECIMALS IS 302 ON PLACE DECIMALS IS 3002 ON ALL ANGLES IS 45 OF A DEGREE MATERIAL TOLERANCE TO AGREE WITH PUBLISHED STANDARDS v THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A SCALE FULL DATE 5 3 CAPACITORS MFD VOLTS RESISTORS OHMS STT INVERTER WELDER _ CONTROL P
140. URE F 11 SWITCH BOARD RESISTANCE TEST TEST PROCEDURE NOTE There are two switch boards One is located on each side of the machine NOTE The switch boards are designed to receive gate turn on signals from the driver board pulse transformer secondaries The internal board circuitry processes the signals and outputs them to the FETs The switch board cir cuitry contains snubber circuitry to protect the FETs This protection is supplemented by off board resistors The switch board design accom modates the connection point s for the capaci tor s main transformer primary windings input rectifier and reconnect switches 1 Turn off Invertec STT and disconnect main AC input power to the machine 2 Using the 5 16 nut driver remove the case wraparound cover 3 Perform the Filter Capacitor Discharge Procedure See the WARNING ELECTRIC SHOCK can kill e Before continuing with the test procedure perform the capacitor discharge procedure to avoid electric shock 4 Disconnect all wiring harness leads 401 403 1 8 9 12 4 5 402 404 from the Switch board 5 Fold the leads up so they do not interfere with the exposed terminals See Figure F 11 6 Using an analog ohmmeter perform the resis tance tests detailed in Table F 5 and shown in Figure F 11 If any test fails replace both switch boards See Switch Board Removal and Hepl
141. V Bi vss 14042 ARC SHORT DETECT FROM FE SHEET 2 PB_START PB START SIGNAL TO FE SHEET 2 FOR ENERGY CONTROL OPTION PINCH PINCH COMMAND R453 330p 4 76 56 2 1N DEADTIME 10 425 427 1N4936 100 COMMAND 0382 4936 RAMP ARC amp RAMP CTRL COMMAND PB LOCAL 9 9 4J5K 0393 144936 AS cago 330p vss SET 2 140138 10 0K 9 4 92 5 CLOCK 1 2 RESET 1 CLOCK 2 l 8 RESET 2 2 SET 1 PWM SYNC 7 8 KEEP IN P B00S UNTIL ARC STARTS T C389 18 av Ead ei 1 3 mseo PLASMA BOOST TIME LIMIT
142. acement procedure 7 If the switch boards appear to be burned overheated or if the machine was supplied by a 380 VAC or higher voltage supply when the failure occurred replace the capacitors and the switch boards INVERTEC STT LINCOLN 5 F 35 F 35 TROUBLESHOOTING amp REPAIR SWITCH BOARD TEST continued TABLE F 5 SWITCH BOARD RESISTANCE TEST Return to Section TOC Return to Master TOC Apply Positive Apply Negative Test Probe to Test Probe to Terminal Terminal Test Result Conclusion Repair Action Next Procedure Notes 1 8 12 Greater than OK None Continue 1K ohm Less than Shorted Replace both Snubber Test 100 ohms switch boards Less than OK None Continue 100 ohms Greater than Replace both Snubber Test 1K ohm switch boards Greater than OK None Continue 1K ohm Less than Shorted Replace both Snubber Test 100 ohms switch boards Return to Section TOC Return to Master TOC Less than OK None Continue 100 ohms Greater than Replace both Snubber Test 1K ohm switch boards Less than None Continue 100 ohms Greater than Replace both Snubber Test 1K ohm switch boards Greater than OK None Continue 1K ohm Less than Shorted Replace both Snubber Test 100 ohms switch boards o 5 Less than OK None Continue 100 ohms Greater than Replace both Snubber Test 1K ohm Switch boards Q 2 2
143. acitor discharge procedure FIGURE D 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS CAPACITOR TERMINALS POWER RESISTOR INSULATED PLIERS INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o Fle 515 0 gt 2 2 2 a Return to Section TOC Return to Master TOC MAINTENANCE PREVENTIVE MAINTENANCE 1 Perform the following preventive mainte nance procedures at least once every six months It is good practice to keep a pre ventive maintenance record a record tag attached to the machine works best 2 Remove the machine wraparound cover and perform the input filter capacitor dis charge procedure detailed at the begin ning of this chapter 3 Clean the inside of the machine with a low pressure airstream Be sure to clean the following components thoroughly Power Switch Driver Protection and Control printed circuit boards Power Switch Main Transformer Input Rectifier Heat Sink Fins Input Filter Capacitors Output Terminals Lower base compartment Examine capacitors for leakage or oozing Replace if needed Examine wraparound cover for dents or breakage Repair as needed Cover must be kept in good condition to assure high voltage parts are protected and correct spacings are maintained Check electrical ground continuity Using
144. agram Section G STT cd cmd P294 INVERTEC STT LINCOLN 5 V Section 1 Section 1 TABLE OF CONTENTS INSTALLATION SECTION 5 necp E eased heacee eit Section A 8 Technical Specifications Codes 11092 amp A 2 9 Technical Specifications Codes 11115 4 11116 A 3 M 4 c crece RM 4 Ee EP 4 Machine Grounding and High Frequency Interference 4 Input ee A A 4 Supply Connections ee a 4 Input Cable Installation and A 5 Ground COMMS table 5 5 Input Voltage Reconnect 6 8 eroe A 6 9 Wire Feeder Output COMeetlO 19 ccn eui A 6 c E Return to Master TOC INVERTEC STT LINCOLN 5 INSTALLATION TECHNICAL SPECIFICATIONS Invertec STT amp For Codes 11092 and BELOW INPUT THREE PHASE ONLY STANDARD VOLTAGE INPU
145. ain transformer choke output diodes IGBT module and out put terminals If the correct open circuit volt age is NOT present perform Switch Board Test The output diodes may be faulty Check or replace if nec essary The driver PC board and or control PC board may be faulty The IGBT module may be faulty Check or replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed INVERTEC STT LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E E olg gt 8 515 o Return to Section TOC Return to Master TOC F 11 F 11 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Molten weld puddle appears exces sively violent POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS The Wire Type switch may be in the wrong position for the elec trode wire being used The Peak Current or Back ground Setting may be too high Adjust for optimum welding per formance The Tailout may not be set cor rectly for the process STT Only TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 The IGBT module may
146. amework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN CYLINDER may explode if damaged 7 a 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 All hoses fittings etc should be suitable for the application and maintained in good condition B Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available f
147. an audible click which can be heard when the front panel Carefully move the front panel 8 8 relays are activated If the relays are being assembly to the right to gain access to the 2 activated the power PC board is most likely power PC board See Figure F 14 t o INVERTEC STT LINCOLN 5 43 43 TROUBLESHOOTING amp REPAIR POWER BOARD TEST continued FIGURE F 15 POWER PC BOARD TEST POINTS Return to Section TOC Return to Master TOC POWER BOARD Return to Section TOC Return to Master TOC 4 Secure and insulate the front panel assembly 5 Apply the correct input power and turn ON the for POWER ON testing machine 6 Carefully test for 18VAC input from the T1 Auxiliary Transformer between plug J7 pin 5 WARNING lead 501 and plug J7 pin 6 lead 504 at the power PC board See Figure F 15 ELECTRIC SHOCK can kill NOTE If the 18VAC is NOT present perform e With input power ON the T1 Auxiliary Transformer Test Also check there are high voltages associated wiring See the Wiring Diagram inside the machine Do not reach into the machine or touch any internal part olo o E olg gt 212 515 o Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section Return to Master TOC Return to S
148. ansfer to occur resulting in increased spatter Adjusting this level to low will cause wire stubbing and also poor wetting of the weld metal This is similar to a low voltage setting on a standard CV machine Adjust Bead Shape using Background Current Optimum Note Background Current levels for applications using 100 is less than similar procedures involving gas blends with high percentages of Argon This is a result of the greater heat generated in the 100 CO arc 100 CO is 35 volts cm and 10096 Argon is 20 volts cm 75 Argon 25 CO is about 24 volts cm Contact Tip to Work Distance Short Long Optimum HOT START The Hot Start control can be set to enhance establish ing the arc and provide the capability of increasing the heat at the start of the weld to compensate for a cold work piece Hot start adjusts the time that additional current is applied during the starting of the arc Refer to Operational Features and Controls in this section for a description of this control TAILOUT The tail out provides additional heat without the molten droplet becoming too large Increase as necessary to add Heat to the arc without increasing arc length This will allow for faster travel speeds and produce improved wetting As tailout is increased the peal and or background current is usually reduced WELDING ARC PERFORMANCE For optimum spatter reduction the arc should be con centrate
149. ansformer The opposite directions of cur rent flow through the main transformer primary and the offset timing of the switch boards induce an AC square wave output signal at the secondary of the main trans former The DC current flow through each primary winding which is monitored by the current transformer T3 is redirected or clamped back to each respective input capacitor when the FETs are turned off This is need ed due to the inductance of the transformer primary windings The cross coupling of the primaries along with the clamping action of the diode maintain capaci tor balance when they are connected in the series high voltage input configuration 42 The firing of both switch board pairs occurs during halves of 50 microsecond intervals creating a constant 20 KHZ output The AC output from the main transformer secondary is rectified to a DC output and is applied through a stabi lizer output choke current sensor IGBT module and remote protection board to the output terminals NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INVERTEC STT LINCOLN 5 6 6 THEORY OF OPERATION FIGURE E 6 CONTROL BOARD IGBT DRIVE AND MODULE Return to Section TOC Return to Master TOC MAIN TRANSFORMER T2 CURRENT SENSOR CHOKE VOLTAGE SENSING RECEPTACLE LINE INPUT SWITCH RECTIFIER CURRENT CONTROL
150. autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Si on utilise la machine souder comme une source de 11 Pour obtenir de plus amples renseignements sur la s ret voir courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PRECAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie du LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel donc TRANSFORMATEUR ET REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou Ae quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflam
151. cr TRIGGE 1155 411 GND E CH PROTECTION 52 1204 12 16 57 1288 RECONNECT DRIVER 1 b 914 4 1 i 371 6 1 9D amp 8 T i 1 i i 4 315 4 2 374 4 1 1 2 6 2 55 21 N J13 0 4 5 J39 FEEDER SS Ne SPARE 14 414 B GND 66406 H 21 CURRE i N 9874 9 DARLINGTO 82 3873 DRIVEBOARD Pam 81 9 402 404 SWITCH i 455 7500 i i i i 5 p x De 4 7 25W 25W M AD 13 2413 C2 H 25 2200 165 316 42 1 128 12825 514 H4 1 12B 128 12 L 401 403 POWER LIN FILTER mode Jes ASSEMBLY 1 371510 371 1374 13 874 2085 I i i i gs ee H 2 3 438 42 3 gt 6 gt 42 6AMPVAC 1 amp 3244 22 THERMOSTA H 8 i 2 gt r 326 1 32 111 503 1 L 374A 1 1 5 Ma od i 243 46 7 1 1 hb 33D o 2 115 RS 224 224A 2445 14 47 4557 81A o GAMPVAC 303 4 3 8 b aL uo 33G 8 3387 FAN 1 302 4 11 rorem THERMOSTAT 1 i 304 4 10 2 162 2754 6 11b ze 125 oe P 9 350 SES 6 g
152. d on the puddle INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 G 3 Return to Section TOC Return to Master TOC 3 7 OPERATION WELDING PROCEDURES FOR STT II Steel Horizontal Fillet See Table B 1 and B 2 1 DIRECTION i TRAVEL g 75 TOP VIEW 1 1 DIRECTION TRAVEL E N 1 N END VIEW FRONT VIEW Table B 1 100 CO Gas Shield Set for Steel Mode Plate Thickness mm Electrode size mm WFS min m min Peak Current Background Current Tailout setting Average Amperage Travel Speed min m min Gas Flow cfh L min Electrical Stickout mm Table B 2 7596 CO 25 Ar Gas Shield Set for Steel Mode Plate Thickness mm Electrode size mm WFS min m min Peak Current Background Current Tailout setting Average Amperage Travel Speed min m min Gas Flow cfh L min Electrical Stickout mm Stainless Steel Horizontal Fillet See Table B 3 and B 4 DIRECTION OF TRAVEL 75 TOP VIEW DIRECTION 1 AN q OF o 45 TRAVEL ij T E o 1 N 11
153. d to describe how much time is devoted to conduction in the positive and negative portions of the cycle Changing the pulse width is known as MODULATION Pulse Width Modulation PWM is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine MINIMUM OUTPUT By controlling the duration of the gate signal the FET is turned on and off for different durations during a cycle The top drawing above shows the minimum out put signal possible over a 50 microsecond time period A FET group consists of the sets of FET modules grouped onto one switch board The positive portion of the signal represents one FET group conducting for 1 microsecond The negative portion is the other FET group The dwell time off time is 48 microseconds both FET groups off Since only 2 microseconds of the 50 microsecond time peri od is devoted to conducting the output power is mini mized MAXIMUM OUTPUT By holding the gate signals on for 24 microseconds each and allowing only 2 microseconds of dwell time off time during the 50 microsecond cycle the output is maximized The darkened area under the top curve can be compared to the area under the bottom curve The more dark area under the curve the more power is present INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o Fle PEN 5 5 2
154. de is provided to help you locate and repair possible machine malfunc tions Simply follow the three step procedure list ed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into two main categories Output Problems and Welding Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub ject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure Al
155. e 1 e 25 e 18 p 4 CURRENT FEEDBACK BV J3 al WIRE SIZE SELECT E 035 WIRE 33 lt lt gt 045 DIA WIRE MILD lt 3 STAINLESS mM ME 10 VDC REMOTE POTS 8 glx 758 POWER i 9504 s 218 461 cag LOCAL_POTS SM 2 g g E E EN 15 0K 2 10K 8 40k 8407 9 2 C406 287K 26 267K 287 R546 6545 R544 8406 2 E 8 5 g E 8 E o E ARC START NOTE LINCOLN ELECTRIC 562 OVERCURRENT OUTPUT DISABLE ANALOG LOGIC POWER PLANE POWER PLANE 14 n t 14 u t 444 0425 435 C436 xi C430 4 8 C426 59 427 81 Bt Bij TM QUE ET E sus 1 conpanaror 4 5 4093 4go33 52 SHR 4i ov 90 7 7 7 7 a 4 DVZUT KILLER Ea E 002 85 METER i DV OT LEVEL DETECT FROM FE SHEET 2 we v 6 METER 2 Wem 21068 5 VOLT 32 518 x07 Fm 64 a3 COUNTER 35
156. e Invertec STT machine 9 Perform the Input Filter Capacitor Discharge See Maintenance Bection WARNING ELECTRIC SHOCK can kill Before continuing with the test procedure per form the capacitor dis charge procedure to avoid electric shock 10 Locate and remove leads 309 and 309 from CR1 and CR2 relays See Figure F 18 WARNING ELECTRIC SHOCK can kill With input power there are high voltages inside the machine Do not reach into the machine 11 Apply correct input power and turn ON the machine or touch any internal part 12 Check for approximately 12VDC from plug 415 1 lead 314 to plug J15 pin 4 lead 315 See Figure 17 13 Check for approximately 12VDC from plug J15 pin 3 lead 316 to plug J15 pin 6 lead 317 See Figure 17 14 If a low voltage is present in either steps 12 or 13 approximately 1VDC perform the Capacitor Balance Test 15 If the Capacitor Balance Test is OK the protection PC board may be faulty 16 Be certain to replace leads 309 and 309 onto the CR1 and CR2 relays 17 After all tests are completed install the case wraparound cover INVERTEC STT LINCOLN 5 F 47 48 NOTES INVERTEC STT LINCOLN F 48 NOL Je1Se A 0 DOL J91Se N 01 DOL 0 DOL J91Se N 01 DOL uonoes DOL uonoes
157. e machine Reduce welding current demands or remove the fault in welding cables Make sure that the gun tip is not shorted to the work surface and that the proper welding pro cedures are being used The current sensor may be faulty The control PC board may be faulty CAUTION If for any reason you do understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 INVERTEC STT LINCOLN 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 2 zi Return to Section TOC Return to Master TOC o 5 PROBLEMS SYMPTOMS Machine loses output while weld ing The thermal indicator light is Normal welding output returns after about 10 minutes POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check to make sure the fan is running and operating correctly Welding exceed cycle application may recommended duty Dirt and dust may have clogged the cooling channels Blow out the unit with clean dry com pressed air Air intake and exhaust louvers
158. e test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 INVERTEC STT LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 zi Return to Section TOC Return to Master TOC E TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS No output Main fuses are open indicating excessive current draw Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS With the input power removed inspect input leads for possible shorts or grounds or miscon nections Install new fuses and reapply power If fuses open again contact your local Lincoln Authorized Field Service Facility RECOMMENDED COURSE OF ACTION Check the input power switch S1 and the reconnect switch for shorted or grounded wires or connections Perform the Rectifier 3 Perform the Switch Board Machine loses output when gun trigger is pulled or arc is struck Machine output returns after a few seconds and trigger is pulled again The thermal indicator light is lit The overcurrent sensor is acti vated indicating that too much output current is being drawn from th
159. ecting a work cable and clamp to the workpiece 15 ELECTRODE TERMINAL This twist mate connection is the positive output terminal for connecting an electrode cable to the wire feeder conductor block Refer to the Accessories Section for wire feeder connection instructions WELDING OPERATION Familiarize yourself with the controls on the Invertec STT II before beginning to weld Familiarize yourself with the operating manual for the wire feeder and the wire feeder controls before begin ning to weld in this section for the function of these Set the Wire Size and Wire Type selection switches per the appropriate wire Refer to l Operational Features and Controls switches INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 E 2 512 2 5 Return to Section TOC Return to Master TOC Return to Master TOC B 6 B 6 OPERATION WELDING PARAMETERS AND GUIDE LINES The Invertec STT is neither a constant current CC nor a constant voltage CV power source In general wire diameter will be increased one size compared to conventional CV power sources The larger the wire diameter the higher the deposition rate Up to 1 16 Wire sizes below 035 are unnecessary for most appli cations The Invertec STT is a current controlled machine which is capable of changing the electrode current quickly in order to respond
160. ection TOC Return to Master TOC o 2 2 3 Return to Section TOC Return to Master TOC o 3 i TROUBLESHOOTING amp REPAIR a POWER BOARD TEST continued FIGURE F 16 SIMPLIFIED TRIGGER CIRCUIT POWER BOARD CONTROL BOARD 1174 FROM PROTECTION K BOARD OVERVOLTAGE 2 6 gt OUTPUTS REMOTE TOPOWER PROTECTION STT II Onl ache THAUXLIARY a i d 44 AMPHENOL TRANSFORMER A ig 3 5 ohms gt 3319 7 OX y 1228 gt 412 v POWERS lt 54 BOARD 3 5 ohms 281 lt 124 5036 gt A 212 7 Carefully test for 15VDC output from the power PC board at plug J6 pin1 lead 275 and plug J6 pin 6 lead 302 See NOTE If the 18VAC is present but the 15VDC is NOT the power PC board may be faulty 8 Carefully test for 24VAC input from the T1 Auxiliary Transformer between plug J6 pin 4 lead 211A and plug J6 pin 9 lead 212A See Figure F 15 NOTE If the 24VAC is NOT present perform the T1 Auxiliary Transformer Test Also check the associated wiring See the Wiring Diagram The control PC board or thermostats may be faulty See Figure F 16 the Simplified Trigger Circuit diagram 9 Carefully test for 24VDC at the power board at J7 pin 2 lead 309 to plug J14 pin2 lead 313 See Figure F 15 NOTE If t
161. ee aaam R451 R663 2 1519400 2432 No pasa ease 2 6 9 oon e 22 5794004780 alg eeo 15 ME o ND 9 PLACES Qi 02 05 04 06 08 09 010 8 11270458 _ _ ______________ R515 ____________ 1 5194001560 2 6 REY 115194002215 021 wrwawswa 4 5183171 0 01 OHM INSULATED JUMPER 9 g 2 109 8110 8112 8114 8133 13 5194004752 47 14W 21 1 1552545 INTEGRATED CIRCUIT R211 R215 R231 R409 R415 i o __________ _ __ 515126 12 7915 REGULATOR _____ E RASRA2ORB9 81 1 1 451565 I CMOS SAMPLEIHOLD QUAD 5 RITLRTIS 6 6194002751 4 78K 1 1 181512822 IC OP AMP QUAD LO NOISE 5 25558 __________ _ 51512811 12 PIN QUAD COMPARATOR 30 STT CONTROL NA DSXHXIZXISXT4 XI5 X16 10 S15018 1 14 PINI C SS 17 18 36 0 4 519400 6812 68 1K 1 4 81 1 51839523 H S ASBLY R124 R48 R49 R469 RATE 19400 1004 1M 14W NADpexo 2 15150189 CMOS MC145388 55 RS11 R520 R533 R534 14 PIN I C SS Res NA peos gt senes re PINTS 55 92 2588 27 519400 2672 26 7K 174W X22 X80 X8T 74 5150186 DIGITAL INTEGRATED CIRCUIT SS MANUFACTURED AS 7 50 7 80 RiSO RISLRI62 R153 Ri60 15 519400 3921 3 92K 1 4W ______ 5 OSES 800 R164 R30
162. electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous E 40 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have held combustibles 4 RAYS can burn 2 Wear eye ear and body protection Observe additional Safety Guidelines detailed in the beginning of this manual INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo E iz 8 JE ply o 9 Return to Section Return to Master TOC Return to Master TOC B 3 GENERAL DESCRIPTION The Invertec is a 225 ampere inverter based arc welding power source specifically designed for the STT welding process lt is neither a constant current CC nor a constant voltage CV machine It is a power source that delivers current of a desired wave form and characteristics that are superior to conventional short circuiting GMAW The process is optimized for short circuiting GMAW welding G RECOMMENDED EQUIPMENT The LN 742 or STT 10 wire feeder is recommended for use with the STT Il The LN 7 GMA LN 9 GMA 5 and NA 5R can all be used with the STT However these units can only be used to
163. er TOC INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC 5 2 2 ACCESSORIES OPTIONS ACCESSORIES K940 SENSE LEADS These leads are used to accu rately sense arc voltage One set is required for each STT Il power source 10 ft and 25 ft set are provid ed as standard with the machine Additional sets are available in 10 ft K940 10 25 ft K940 25 and 50 ft K940 50 lengths K942 1 REMOTE CONTROL Allows remote adjust ment of Peak and Background Current settings REMOTE RECEPTACLE For optional remote interface Connection to the STT 10 Wire Feeder or Robotic Control 1 The 10 pin MS connector labeled Remote Control located on the front panel of the STT is used for remote control of the power source Control for the PEAK PB pot and BACKGROUND BG pot cur rent along with the trigger switch is provide through this connector 2 Refer to figure C 1 below for details about the remote receptacle J38 Note that pins J and are shorted together This short circuit tells the STT control board to accept PEAK and BACK GROUND inputs on this connector rather than from the front panel controls If this short is removed the front panel controls will be
164. erform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the protection PC board is functioning properly MATERIALS NEEDED 5 16 Nut driver Volt ohmmeter Multimeter Wiring Diagrams Note Component locations and disassembly procedures may vary slightly on STT models INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 2 3 Return to Section TOC Return to Master TOC o 3 TROUBLESHOOTING amp REPAIR PROTECTION BOARD TEST continued FIGURE F 17 PROTECTION PC BOARD TEST POINTS PROTECTION 311 TEST PROCEDURE 1 Turn off the Invertec STT and disconnect main AC input power to the machine 2 Using the 5 16 nut driver remove the case wraparound cover 3 Perform the Input Filter Capacitor Discharge See the Maintenance fection A WARNING ELECTRIC SHOCK can kill Before continuing with the test procedure per form the capacitor dis charge procedure to avoid electric shock 0 gt 4 Locate the protection PC board just in front of the input rectifier and relay mountings 314 316 WARNI
165. erform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 2 Return to Section TOC Return to Master TOC 5 10 TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Weld bead appears cold Call 1 888 935 3877 F 10 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS One or more of the machine settings may be wrong Check the Background Peak Current Tailout STT 11 Only and Wire Speed controls for proper set tings Adjust for optimum weld ing performance Make sure the Wire Type and Wire Size switches are in the correct position for the elec trode wire being used RECOMMENDED COURSE OF ACTION Check for the correct open cir cuit voltage approximately 85VDC If the correct open cir cuit voltage IS present the Background control R12 or the Peak Current R11 and associated wiring may be faulty See the Wiring Diagram The control PC board may be faulty Also check for loose or faulty connections on the heavy cur rent carrying conductors i e m
166. eturn to Master TOC O o Fle 515 0 gt 2 2 2 Return to Section TOC Return to Master TOC F 75 F 75 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT continued FIGURE F 40 MAIN TRANSFORMER DIODE CONNECTIONS MAIN TRANSFORMER SECONDARY LEADS 9 Remove the two sleevings from the diode connections at the main transformer See Figure F 40 10 Using the 7 16 wrench remove the diode leads from the main transformer sec ondary leads Note washer and lead placement for reassembly INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 2 Return to Section TOC Return to Master TOC 5 76 F 76 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT continued FIGURE F 41 SWITCH BOARD CAPACITOR ASSEMBLY THROUGH BOLTS 11 12 13 14 15 16 Using the 3 8 nut driver remove the rear nuts and washers from the switch board capacitor assembly through bolts See Figure F 41 Using the 3 8 nut driver loosen the front nuts from the switch board capacitor assembly through bolts Carefu
167. 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 elec trical 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the output diode heat sink assembly Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 3 8 Nut driver 7 16 Wrench Slot head screw driver Dow Corning 340 Heat Sink Compound Lincoln E1868 Note Component locations and disassembly procedures may vary slightly on STT models 5 o 2 2 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 2 Return to Section TOC Return to Master TOC 5 74 74 TROUBLESHOOTING a
168. ges inside the machine Do not reach into the machine or touch any internal part INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC 5 16 TROUBLESHOOTING amp REPAIR T1 AUXILIARY TRANSFORMER TEST continued 8 If the correct secondary voltages are present according to Table F 1 the T1 transformer is functioning properly 9 If the secondary voltages are missing or incorrect the primary voltages must be checked 10 Remove input power to the STT machine 11 Perform 12 Reconnect Plugs J30 amp J31 ELECTRIC SHOCK can kill WARNING Before continuing with the test procedure per form the capacitor dis charge procedure to avoid electric shock 7 the nput Filter apacitor 13 Gain access to the primary lead plug J21 by removing the reconnect panel assembly from the upper support panel using the 3 8 wrench and slot head screwdriver This will allow the reconnect panel assembly to be moved out of the way Be careful NOT to stress the leads connected to the reconnect panel See 14 Before applying input power make certain the reconnect panel assembly is insulated and supported for safe operation TABLE 1 T1 AUXILIARY TRANSFORMER VOLTA
169. h new style new part number INPUT FILTER CAPACITOR CONDITIONING If the machine will not produce output when turned on and the following two conditions exist The machine is connected to operate at an input voltage of 380 VAC or higher and Power has not been applied to the machine for long period of time many months Then The Input Filter Capacitor Protection Circuit could have been activated and prevented output This means the Input Filter Capacitors must be condi tioned The Input Filter Capacitor Protection Circuit mon itors the voltage across input filter capacitors C1 and C2 When it senses an overvoltage condi tion the protection circuit will prevent the machine from operating To condition the Input Filter Capacitors 1 Turn main power OFF 2 Remove any load and do not load machine until conditioning procedure is complete Turn main power ON 3 4 Let the unloaded machine sit for 30 minutes 5 Turn main power OFF 6 Turn main power ON NOTE The machine should be ready to operate and the protection circuit should have automati cally reset once the capacitors have been condi tioned and capacitor voltage has reached the acceptable operating level INVERTEC STT LINCOLN 5 F 73 F 73 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric
170. he 24VAC is present but the 24VDC is NOT the power PC board may be faulty 10 Carefully test for approximately 24VDC at plug J7 pin 2 309 to plug J7 pin 4 lead 310 If the 24VDC is NOT present test for approximately 1VDC at plug J14 pin1 lead 311 to plug J14 pin 2 313 See Figure 15 NOTE more than 1VDC is measured perform the Protection Board Test NOTE f approximately 1VDC IS present and the 24VDC is NOT present at leads 309 to 310 the power PC board may be faulty 11 After all tests are completed install the front panel assembly 12 Install the case wraparound cover INVERTEC STT LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC 5 45 45 TROUBLESHOOTING amp REPAIR PROTECTION 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 elec trical 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 p
171. he PWM signal received iror he contol board discussion This drive signal is applied to the primary winding of the pulse transformer which is located on the driver board The pulse transformer secondary windings generate the proper gate pulse for the switch board FETs See Field Effect Transistor FET The power board supplies a 15VDC supply voltage for the control board and also powers the input relays CR1 and CR2 42VAC REMOTE PROTECTION BOARD The remote protection board provides noise suppres sion and by pass filtering to protect the internal circuit ry of the STT machine NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INVERTEC STT LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC O10 E E a gt 818 mlt 515 ply o 9 ojo Return to Section TOC Return to Master TOC Return to Master TOC E 8 E 8 THEORY OF OPERATIONS FIGURE E 8 FIELD EFFECT TRANSISTOR OPERATION GATE TERMINAL 0 VOLTS SOURCE TERMINAL SOURCE N SUBSTRATE P DRAIN TERMINAL DRAIN N N CHANNEL A PASSIVE GATE TERMINAL 6 VOLTS SOURCE N G amp g g 2 6 g e g 2 2 2 2 g DRAIN ELECTRONS B ACTIVE FIELD EFFECT TRANSISTOR FET OPERATION An FET is a type of transistor FETs are semiconduc tors well suited for high frequency switchi
172. he minimum settings controls on case jumper between pins C and D on the 14 pin front amphenol 6 Jumper together pins C and D on the 14 9 Install the case wraparound cover pin amphenol This will energize the output terminals 7 Test for VDC across terminals 9 and 12 of one switch board and repeat the test for the other switch board See Table F 4 in this procedure for expected voltage readings See Figure F 10 A less than 15VDC difference is mea sured between each switch board the test is OK B If more than 15VDC difference is mea sured between each switch board the Switch board s and or power PC board may be faulty Perom Switch Perform the Power Board Return to Section TOC Return to Master TOC O10 O10 Fle mlt 515 ply Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 32 NOTES O tr 5 gt E NOL Je1Se A 0 DOL J91Se N 01 DOL 0 DOL J91Se N 01 F 32 DOL uonoes DOL uonoes DOL uonoes 0 DOL F 33 F 33 TROUBLESHOOTING amp REPAIR SWITCH 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
173. hen welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 2 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Wo
174. her readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Hecommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building fr
175. ion TOC Return to Master TOC Return to Section TOC olo gt 2 5 ply o 9 Return to Section TOC Return to Master TOC Return to Master TOC F 55 F 55 TROUBLESHOOTING amp REPAIR IGBT MODULE REMOVAL AND REPLACEMENT continued FIGURE F 24 PLUG J1 DISCONNECTION J1 CURRENT SENSING PLUG OUTPUT CHOKE IGBT MODULE SPLICED CONNECTION 5 Disconnect the current sensing plug J1 from J1 and associated leads from the control PC the control PC board remove plug board compartment See Figure F 24 FIGURE F 25 PLUG J22 DISCONNECTION PLUG J22 6 Locate and disconnect plug J22 from the wiring harness See Figure F 25 INVERTEC STT LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC E 56 56 TROUBLESHOOTING amp REPAIR IGBT MODULE REMOVAL AND REPLACEMENT continued FIGURE 26 PLACED ON ITS RIGHT SIDE MOUNTING BOLTS 5 gt UU 7 Carefully lift and tilt the Invertec STT 11 machine onto its right side See Figure F 26 8 Using the 7 16 wrench remove the five 12 bolts holding the lower tray assembly to the case bott
176. iring Diagrams Isolated 115VAC supply 5 16 Nut driver 7 16 Wrench Note Component locations and disassembly procedures may vary slightly STT II models 5 o 2 2 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 20 20 TROUBLESHOOTING amp REPAIR T4 AUXILIARY TRANSFORMER TEST continued FIGURE F 3 OUTPUT CHOKE IGBT MODULE SPLICED CONNECTION Return to Section TOC Return to Master TOC 2 5 2 3 Return to Master TOC OUTPUT CHOKE DARLINGTON MODULE SPLICED CONNECTION olo at 5 o amp gt TEST PROCEDURE WARNING 2 p 1 Turn off the Invertec STT and disconnect 5 5 main input power to the machine ELECTRIC SHOCK can kill Dlo or amp 2 Using the 5 16 nut driver remove case e Before continuing with wraparound cover s the test procedure per form the capacitor dis 3 Perform the Filter Capacitor charge procedure to Discharge Procedure See the avoid electric shock Maintenance fection 4 Locate the lead connection splice from the output choke to the IGBT module Remove the insulating sleeve Cut any necessary cable ties Using the 7 16 wrench discon nect the lead splice Thread the lower lead do
177. l of the referred to test points components terminal strips etc can be found on the referenced elec trical wiring diagrams and schematics Refer to the Contents to locate the appropriate diagram F 2 OSCILLOSCOPE WARNING Do not use oscilloscopes and other test equipment which are powered by 115 VAC This equipment should not be used with inverter type machines such as Invertec STT There are high voltages pre sent which are floating off case ground floating ground Connecting the ground lead of a test probe which may be connected to the case of the test equipment to a high voltage potential presents a shock hazard as well as the possibility of damage to the equipment in question CAUTION 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 Call1 888 935 3877 ojo O10 E 2 gt e 515 0 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC olo E olg gt 8 mlt 515 o Return to Section Return to Master TOC Return to Master TOC F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK kill
178. ld be installed to pro ELECTRIC SHOCK can kill tect against excessive current flow caused by a short circuit during the procedure Return to Section TOC Return to Master TOC Before continuing with the a test procedure perform the capacitor discharge procedure to avoid electric shock FIGURE F 29 SHORTING TERMINALS 14 AND 53 OF PROTECTION BOARD L7915 PROTECTION olo o E olg gt 8 mlt 515 JUMPER TERMINALS Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 63 63 TROUBLESHOOTING amp REPAIR SWITCH BOARD REPLACEMENT continued 9 With the output free of a load check open cir WARNING cuit voltages of the output Voltage should be 85 VDC maximum Return to Section TOC Return to Master TOC Erevan SHOCK 10 Remove input power Then remove the With input power ON there 5 amp fuses from the input supply fuse hold are high voltages in the ers machine De Het 11 Install 20 amp fuses and test under load into the machine or touch any internal part NOTE A resistive type grid load bank is recom mended 8 With the machine connected for 440 460 volt Panormi MarS Kepa operation and the proper input voltage applied turn on input power to the machine Return to Section TOC Return to Master TOC
179. ll tests are complete reconnect plugs J30 and J31 Install the case wraparound cover INVERTEC STT LINCOLN 5 17 18 NOTES INVERTEC STT LINCOLN F 18 NOL Je1Se A 0 DOL J91Se N 01 DOL 0 DOL J91Se N 01 DOL uonoes DOL uonoes DOL uonoes 0 DOL 19 19 TROUBLESHOOTING amp REPAIR T4 AUXILIARY TRANSFORMER 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 elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct voltages are being a applied to the primary of the T4 auxiliary transformer b induced on the secondary windings of the T4 auxiliary transformer Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter Multimeter Invertec STT W
180. lly lift the horizontal baffle away from the upper tabs of the output rectifier heat sink assembly Slide the heat sink assembly to the right facing the back of the machine to disen gage the bottom tabs from the lower hori zontal baffle Carefully remove the output rectifier heat sink assembly and leads from the STT machine Remove the nut that secures each diode that is to be replaced NOTE The output diodes must be replaced in matched sets INVERTEC STT LINCOLN 5 17 18 19 20 gt 5 Before mounting the new diode sets clean and brighten the mounting surfaces of both the diode sets and the heat sink with fine steel wool Apply an even coating of DOW Corning 340 Heat Sink Compound to the mounting surfaces of the diodes that contact the heat sink This compound layer should be less than 001 inch thick DO NOT apply the compound to the diode studs or mounting nut threads Insert the diode sets into the mounting hole and tighten the diode mounting nuts to a torque of 25 inch pounds 3 Nm Replace the rectifier heat sink assembly leads and connections that were previous ly removed Install the fan and motor assembly note insulation placement Install the case back and the case wrap around cover 77 77 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest the INVERTEC STT f it fails any test and the test requires removing or
181. lt 7 i REMOTE PT INTERFACE ae 8 de ae WIRE FEEDER J39 N ELECTRODE SENSE LEAD PORTION OF G3136 WIRING DIAGRAM REFER TO ACTUAL DIAGRAM PASTED INSIDE YOUR MACHINE INVERTEC STT LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 o E E E a 5 5 Return to Section TOC Return to Master TOC C 3 C 3 ACCESSORIES LN 742 or STT 10 WIRE FEEDER CONNECTION INSTRUCTIONS The LN 742 or STT 10 is the recommended wire feed er for use with the Invertec STT Refer to the LN 742 or STT 10 Operator Manual for Wire Feed Operation Refer to Figure C 2 or C 3 and follow the instructions below to connect the LN 742 or STT 10 A WARNING e ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF at the discon nect switch or fuse box before connecting the wire feeder 1 Turn the Invertec STT power off 2 Connect the ARC SENSE LEAD MS connector to the mating connector on STT II front panel e REMOTE WORK LEAD CONTROL ELECTRODE ARC SENSE ELECT AND ARC SENSE WORK CABLES SHOULD BE TAPED TOGETHER 3 Connect the electrode lead Twist Mate to out put terminal on STT Il 4 Connect the other end of electrode lead Step 3 and
182. mables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN 5 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 V MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Page haved ieee eels i iv eet me sii a se nel eL EE Section A Section B Section C entente ntes Section D Theory of Operation NENNEN TENUES Section E Troubleshooting and SO0tlon F Electrical Di
183. mm wrench remove the large reassemble the small leads to the small E lead and the 7287 lead from the large C and terminals Torque to 13 inch terminal Note lead placement for reassem pounds i 24 Apply the Silicone Rubber RTV Coating 17 Using the 3 16 Allen type wrench remove Lincoln E2861 or Dow 3140 to the termi the four socket head cap screws that mount nals and lead connections as was previously the module to the heat sink removed 18 Carefully remove the IGBT module 25 Replace the lower tray assembly 19 Upon reassembly use Dow Corning 340 26 Connect plug J22 to the wiring harness Heat Sink Compound Lincoln E1868 plug J1 to the control PC board Deween ere ife esce tnis 27 Connect the lead splice between the output 20 Mount the new module using the socket choke and the IGBT module x Seres and Torque 28 Install the case wraparound cover Note The torque should be rechecked after three hours INVERTEC STT LINCOLN 5 58 NOTES INVERTEC STT LINCOLN F 58 NOL Je1Se A 0 DOL J91Se N 01 DOL 0 DOL J91Se N 01 DOL uonoes DOL uonoes DOL uonoes 0 DOL 59 59 TROUBLESHOOTING amp REPAIR SWITCH BOARD REPLACEMENT A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized
184. mp REPAIR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT continued FIGURE F 39 CHOKE LEAD HEAT SINK CONNECTION HEAT SINK TAB CHOKE LEAD PROCEDURE 1 Turn off Invertec STT and disconnect main AC input power to the machine 2 Using the 5 16 nut driver remove the case wraparound cover 3 Perform the Input Filter gt Discharge Procedure See nd Main ionene section WARNING ELECTRIC SHOCK can kill Before continuing with the test procedure per form the capacitor dis charge procedure to avoid electric shock INVERTEC STT LINCOLN 5 Using the slot head screw driver loosen the input cable strain relief Using the 5 16 nut driver remove the four Screws securing the case back to the inter nal horizontal baffles Carefully pull the case back away from the output rectifier assembly NOTE The case back will NOT detach from the case bottom T Using the 7 16 wrench remove the four bolts and washers mounting the fan motor bracket to the top horizontal baffle Carefully set the fan and motor assembly aside insulation placement for reassembly NOTE The fan motor leads do NOT have to be cut 8 Using the 7 16 wrench remove the choke lead from the heat sink See Figure F 39 Return to Section TOC Return to Master TOC Return to Section TOC R
185. n Circuit monitors the voltage across input filter capacitors C1 and C2 When it senses an overvoltage condition the protec tion circuit will prevent the machine from operating To condition the Input Filter Capacitors 1 Turn main power OFF 2 Remove any load and do not load machine until conditioning procedure is complete 3 Turn main power ON 4 Let the unloaded machine sit for 30 minutes 5 Turn main power OFF 6 Turn main power ON NOTE The machine should be ready to operate and the protection circuit should have automatically reset once the capacitors have been conditioned and capac itor voltage has reached the acceptable operating level ENVIRONMENTAL PROTECTION High voltage connections are covered with an RTV sealant to prevent malfunction in severe environments Sealant must be applied to connections which have been opened or otherwise lost their protection A non corrosive electronic grade sealant such as Dow Corning 3140 3145 or 738 Columbus Adhesives 0172 or GE RTV 162 is recommended Sealant may also be purchased from Lincoln Electric order E2519 Silicone Rubber RTV Coating Apply sealant after machine is repaired and tested All five terminals of the input rectifier require this type of sealant INVERTEC STT LINCOLN 5 Section G 1 TABLE OF CONTENTS Section G 1 ELECTRICAL DIAGRAMS SECTION o 2 9 gt Electrical DIagEalms ii noni
186. n to Master TOC o 2 2 Return to Section TOC Return to Master TOC E A WARNING Failure to follow this capacitor discharge proce dure can result in electric shock INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 1 Turn off input power or disconnect input power lines 2 Remove hex head screws from side and top of machine and remove wrap around machine cover 3 Be careful not to make contact with the capacitor terminals that are located in the center of the Switch Boards 4 Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resistor is not sup plied with machine NEVER USE A SHORTING STRAP FOR THIS PROCE DURE 5 Locate the two capacitor terminals large hex head cap screws shown in Figure D 1 Use safety glasses electrically insulated gloves and insulated pliers Hold body of the resistor and connect resistor leads across the two capacitor terminals Hold resistor in place for 10 seconds DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS Repeat discharge procedure for capaci tor on other side of machine Check voltage across terminals of all capacitors with a DC voltmeter Polarity of capacitor terminals is marked on PC board above terminals Voltage should be zero If any voltage remains repeat this cap
187. n travel speed WELDING CAPABILITY The Invertec STT Il is rated at 225 amps 29 volts at 60 duty cycle on a ten minute basis It is capable of higher duty cycles at lower output currents If the duty cycle s are exceeded a thermal protector will shut off the output until the machine cools to a reasonable operating temperature LIMITATIONS May not be suitable for use in an environment with High Frequency present Machine Grounding and High Frequency Protection the Installation section of this manual Suitable for indoor use only IEC 215 INVERTEC STT LINCOLN 5 B 4 B 4 OPERATION OPERATIONAL FEATURES AND CONTROLS All operator controls are located on the case front of the Invertec STT Refer to Figure B 1 for locations Return to Section TOC Return to Master TOC 2 5 2 3 Return to Master TOC FIGURE B 1 CASE FRONT CONTROLS 1 POWER SWITCH Turns output 3B PEAK CURRENT DISPLAY METER This power ON and OFF This switch 3 ON is a digital meter for displaying the preset 3 also controls auxiliary power Peak Current This meter displays in 1 available through the 14 pin Wire amp increments This meter does not indi amp Feeder Receptacle Q cate actual welding current only the preset ea pies current 912 8 2A BACKGROUND CURRENT OUTPUT CONTROL 4 HOT START CONTROL POTENTIOMETER 02 The output current is
188. ng Drawing A above shows an FET in a passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain terminal of the FET may be connected to a voltage supply but since there is no conduction the circuit will not supply current to downstream components connected to the source The circuit is turned off like a light switch in the OFF position Drawing B above shows the FET in an active mode When the gate signal a positive DC voltage relative to the source is applied to the gate terminal of the FET it is capable of conducting current A voltage supply con nected to the drain terminal will allow the FET to con duct and henceforth supply current to downstream components Current will flow through the conducting FET to downstream components as long as the gate signal is present This is similar to turning on a light Switch INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o HE 2 2 Return to Section TOC Return to Master TOC 7 5 THEORY OF OPERATION FIGURE E 9 TYPICAL FET OUTPUTS lusec 48 1 1 usec 50 sec MINIMUM OUTPUT 24u sec 2 24sec 50 sec MAXIMUM OUTPUT PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION is use
189. ng assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct voltages are being a applied to the primary of the T1 auxiliary transformer b induced upon the secondary windings of the T1 auxiliary transformer Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter Multimeter Invertec STT wiring diagrams 5 16 Nut driver 3 8 Wrench Slot head screw driver Note Component locations and disassembly procedures may vary slightly on STT models o 5 o 2 2 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 14 14 TROUBLESHOOTING amp REPAIR T1 AUXILIARY TRANSFORMER TEST continued FIGURE F 1 T1 AUXILIARY TRANSFORMER AND J30 J31 LOCATION Return to Section TOC Return to Master TOC PLUG J30 PLUG olo J31 JE SIAN y Ex if 8 3 92 T1 AUXILIARY j TRANSFORMER 2 gt EIE TEST PROCEDURE olo E olg gt 212 515 o Return to Section TOC Return to Master TOC 1 Turn off Invertec STT and disconnect main 4 AC input power to the machine 2 Using the 5 16 nut driver remove the case wraparound cover 3 Perform the Filter Capacitor Di
190. not switch reconnect switch with input power applied to machine 1 Perform the 7 Auxiliary Transformer Test 2 Perform the 74 Auxiliary Transformer Test 3 Perform the Power Board Test Trigger Circuit 5 Perform Capacitor Balance Test 6 Perform the Protection Board 7 Perform the Switch Board 4 Perform the Check for loose or broken con nections on the heavy current carrying conductors i e main transformer choke output diodes IGBT module and out put terminals The control PC board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 2 Return to Section TOC Return to Master TOC E F 5 F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Machine has no welding output no open circuit voltage and the wire feeder does not feed wire when the gun trigger is pulled Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROB
191. oards and o NOTE Always make sure that the switch boards are changed in matched pairs Never mix an old style switch board different part number with new style new part number INVERTEC STT LINCOLN 5 F 61 62 62 TROUBLESHOOTING amp REPAIR SWITCH BOARD REPLACEMENT continued TEST AFTER REPAIR OF SWITCH 3 Connect a shorting conductor across termi BOARDS AND OR CAPACITORS nals 14 and 53 of the protection PC board See Figure F 29 4 Set an ANALOG ohmmeter to X1000 range and place the probes on terminals 9 and The following test must be performed after the Switch boards and or the capacitors have been Return to Section TOC Return to Master TOC 946 12 of one switch board The meter will NOTE Always make sure that switch boards are show the capacitors charging up and may changed in matched pairs Never mix an old style take a minute or so to stabilize The final different part number switch board with a new meter reading should not exceed 8600 ohms style new part number 8 6 on the scale 5 Test the other switch board the same way TEST PROCEDURE NOTE Repeat the Filter Capacitor Discharge Procedure 1 Turn main power OFF 9 6 Remove the shorting conductor set up in ste 2 Perform Input Filter Capacitor Discharge 3 9 See the Maintenance section 7 Replace 20 fuses with 5 amp fuses in the input supply fuse holders WARNING NOTE These fuses shou
192. olding the lower tray assembly to the case bottom 9 Carefully slide out and support the lower tray 10 assembly Using the needle nose pliers remove the strain relief holding the J22 lead harness to the case bottom 11 12 13 INVERTEC STT LINCOLN 5 Using the 1 2 wrench remove the IGBT cable from the negative output terminal Carefully remove the lower tray assembly clear from the machine and set aside Carefully disconnect the leads at the top of the switch board Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo E 2 olg iz 8 mlt 515 Return to Section TOC Return to Master TOC F 69 TROUBLESHOOTING amp REPAIR CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 34 REMOVING HEX HEAD NUTS OF THROUGH BOLTS IHEX NUT CAPACITOR REPLACEMENT NOTE Capacitors must always be replaced in matched sets C1 and C2 as a set When replacing Capacitors remove the entire FET heat sink assembly including the capacitors and switch board as a unit Disassemble and reassemble only one unit at a time Use the other unit as a model during reassembly so that all parts are reinstalled prop erly 14 Remove the two 3 8 hex head nuts from the top of the through bolts The hex nuts are located on top of the fan shroud See Figure F 34 INVERTEC STT LINCOLN 5 70 70 TROUBL
193. om 13 9 Carefully slide out and support the lower tray assembly 10 Using the needle nose pliers remove the strain relief holding the J22 lead harness to the case bottom Using the 1 2 wrench remove the IGBT cable from the negative output terminal Carefully remove the lower tray assembly clear from the machine Remove the rubber RTV coating from the IGBT module INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC 5 F 57 F 57 TROUBLESHOOTING amp REPAIR IGBT MODULE REMOVAL AND REPLACEMENT continued FIGURE F 27 MODULE CONNECTIONS IGBT MODULE For steps 14 18 see Figure 27 14 Using the phillips head screw driver remove 21 Using the 12mm wrench assemble the large the small leads from the small E and B lead and the smaller 289 lead to the large terminals Note lead placement for reassem E terminal Torque to 86 inch pounds by 22 Using the 12mm wrench assemble the large 15 Using the 12mm wrench remove the large lead and the smaller 7287 lead to the large lead and the 289 lead from the large E ter C terminal Torque to 86 inch pounds minal Note lead placement for reassembly 23 Using the phillips head screw driver 16 Using the 12
194. on you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the capacitors bleeder resistors and switch boards are func tioning properly MATERIALS NEEDED 5 16 Nut driver Analog Volt ohmmeter Multimeter Return to Section TOC Return to Master TOC Note Component locations and disassembly procedures may vary slightly on STT models o 5 o 2 2 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 2 Return to Section TOC Return to Master TOC o 5 TROUBLESHOOTING amp REPAIR CAPACITOR BALANCE TEST continued FIGURE F 10 SWITCH BOARD TEST POINTS 9 Kk f f 12 3 VA L8441 SWITCH TEST PROCEDURE 1 Turn off the Invertec STT and disconnect main AC input power to the machine 2 Using the 5 16 nut driver remove the case wraparound cover WARNING ELE
195. ons or welding arcs of high frequency units Provide proper electrical ground to the machine per local and national electrical codes INPUT CONNECTIONS FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE IMMEDIATE FAILURE OF COMPO NENTS WITHIN THE WELDER Turn the input power off at the disconnect switch before attempting to connect the input power lines Connect the green lead of the power cord to ground per local and national electrical codes SUPPLY CONNECTIONS Be sure the voltage phase and frequency of the input supply is as specified on the rating plate Input Power supply line entry in provided on the case back of the machine Sed figure A 1 for location of the rating plate The Invertec STT should be connected only by a qualified electrician Installation should be made in accordance with local and national codes Refer to the Technical Specifications the beginning of this section for proper fuse sizes ground wire and input supply power cable sizes Some models come from the factory with an input power cord If your model does not include the input power cord install the proper size input cable and ground cable according to INPUT CABLE INSTAL INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC o
196. oting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided ELECTRIC for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine 5 92 ITEM USED WITH PART NUMBER DESCRIPTION Ho EEEN PCBONRDBUNK zer 1 cros eS2X 8 8ROUNDHEADMACHNESCREW sey 1 Eo AS REG 805 PLASTIC EXPANSION NUT 038 ay 1 ser HEATSINKALUMNUMEXIRUDEDFOR 11020 ________ 1502 JE28i SEALANT REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW E SIT CAPACITOR CEMO OT SV AE Nc 0 012 C16 3 9194052 OAPACIORALELSSO 60V 30 70 1 813490 84 CAPACITOR PEMP0 38 200V 10 816566 5 CAPACITORCEMO 02280V 204 1 Hi57758K CAPACITORCD ITSDQV U Di 52 58 54 4 1270546 521 023 ZENER DIODE 1W 18V 57 INA746 1 ZENER DIODE 1W 12V 596 1N4742 2 1270229 2 DIODE 1W 15V 596 1N4744A 1 618244 CONNECTOR MOLEX
197. ponent locations and disassembly procedures may vary slightly on STT models 5 o 2 2 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 54 54 TROUBLESHOOTING amp REPAIR IGBT MODULE REMOVAL AND REPLACEMENT continued FIGURE F 23 OUTPUT CHOKE LEAD DISCONNECTION o HE 9 2 Return to Master TOC 5 8 PEN gt 918 EIE 33 OUTPUT CHOKE 212 IGBT MODULE SPLICED CONNECTION AREA PROCEDURE 1 Turn off the Invertec STT and disconnect main 4 Locate the lead connection splice from the AC input power to the machine output choke to the IGBT module Remove olo the insulating sleeve Using the 7 16 wrench e o 2 Using the 5 16 nut driver remove the case disconnect the lead splice Thread the lower S5 wraparound cover lead down into the lower tray assembly area 5 3 Perform the Input Filter Capacitor See Figure 23 gt Discharge Procedure See the Maintenance 8 8 section EIE 55 e cc WARNING ELECTRIC SHOCK can kill 0 Before continuing with the test procedure perform the capacitor discharge procedure to avoid electric shock Qjo S gt 2 EIE 55 t o INVERTEC STT LINCOLN 5 Return to Sect
198. r The T4 transformer supplies power to the IGBT drive board and the control board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INVERTEC STT LINCOLN 8 E 3 E 3 THEORY OF OPERATION FIGURE E 3 RECONNECT PROTECTION BOARD RECTIFICATION AND PRECHARGE Return to Section TOC Return to Master TOC MAIN TRANSFORMER T2 v 1 5 B 1 0 CURRENT ni gt i SENSOR 1 gt 1 1 FET E ie 0 D LI 188 1 i CHOKE R VOLTAGE PRE 1 E SENSING LINE INPUT CHARGE 1 A RECEPTACLE SWITCH RECTIFIER R A 1 1 F E D p 1 CR1 B 1 o 1 A TRANS 1 1 CONTROL Olio N v RECEPTACLE e Pn 5 R 0 E 1 1 2 m l 0 1 51 CHARGE 2 WIRE 9 9 inp MOS To 1 FEEDER E RECEPTACL gt Ti t 1 5 515 UNS LESS THAN 1VDC CURRENT FEEDBACK PULSE TRANSFORMER SIGNAL PWM SIGNAL ao oc 15VDC GUN TRIGGER CONTROL BOARD IGBT DRIVER BOARD VOLTAGE FEEDBACK EOC Orbe TAILOUT BACK WIRE THE CURRENT GROUND E SIZE TYPE ETER
199. r other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Return to Master TOC Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE 1 h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 5 Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors Return to Master TOC ELECTRIC AND MAGNETIC FIELDS _ 58 may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding curren
200. r the wire feeder connection 115 and 42 VAC along with the trigger switch connections are provid ed Only 42 VAC is available on European mod els There are no provisions for voltage control of the power source by the wire feeder Refer to the Accessories section of this manual for wire feeder connection instructions 11 ARC SENSE RECEPTACLE This is a four pin MS type connector for WORK and ELECTRODE sense leads The STT requires a WORK sense and ELEC TRODE sense lead for proper operation The ELECTRODE sense lead is bolted together with power source electrode lead at the wire feeder gun block The WORK sense lead is furnished with an alligator type clip for connection to the work piece Refer to the LN 742 or STT 10 wire feeder connec tion instructions in the Accessories section of this manual for proper connection of these leads 12 42V AUXILIARY POWER CIRCUIT BREAKER The 42 VAC supply is protected from excessive current draws with a 6 amp circuit breaker When the breaker trips its button will extend Depressing this button will reset the breaker 13 115V AUXILIARY POWER CIRCUIT BREAKER Not on European Models The 115 VAC supply is protected from excessive current lt gt draws with a 6 amp circuit breaker When the breaker trips its button will extend Depressing this button will reset the breaker 14 WORK TERMINAL This twist mate con nection is the negative output terminal for conn
201. r to the switch board See Figure ring and remove the capacitor from the clamp F 36 ring See Figure F 37 g 2 3a o c INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section TOC Return to Master TOC 5 F 72 TROUBLESHOOTING amp REPAIR CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 38 COMPLETE SWITCH BOARD ASSEMBLY READY FOR INSTALLATION 19 Install the new capacitor and tighten the two 7 16 hex bolts to a torque of 55 inch pounds 6 Nm Tighten these bolts in increments of 10 inch pounds alternating between the two bolts Capacitor installation is complete See Figure F 38 Proper capacitor polarity must be noted when attaching the capacitor to the switch board assembly 20 Install the switch board and capacitor assembly into the machine Take special care that ALL insulators and sleevings are in their proper positions See Figure F 38 21 Install the lower tray assembly and all previ ously disconnected loads and plugs 22 Perform the Test After Repair of Switch Boards and or Capacitors NOTE Always make sure that the switch boards are changed in matched pairs Never mix an old style switch board different part number wit
202. rker expo sure level should be checked upon installation and periodi cally thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits 5 c Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 5 d Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 5 e Read and understand the manufacturer s instructions for this 5 f AUG 06 LINCOLN 5 equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Return to Master Return to Master TOC E Return to Master TOC SAFETY WELDING SPARKS gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguis
203. rom the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 Return to Master Return to Master TOC D 5 Return to Master TOC PR CAUTIONS DE S RET i SAFETY zones l on pique le laitier Pour votre propre protection lire et observer toutes les instructions 6 Eloigner les mat riaux inflammables ou les recouvrir afin de et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met
204. scharge gt Procedure See the Maintenance section WARNING ELECTRIC SHOCK can kill Before continuing with the test procedure per form the capacitor dis charge procedure to avoid electric shock 0 gt Locate the T1 auxiliary transformer and sec ondary lead molex plugs J30 and J31 on the left side just in front of the main trans former assembly Check for broken or loose wires See Figure F 1 INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 O10 E mlt 515 ply 9 ajo Return to Section TOC Return to Master TOC F 15 F 15 TROUBLESHOOTING amp REPAIR T1 AUXILIARY TRANSFORMER TEST continued FIGURE F 2 PRIMARY LEAD PLUG J21 LOCATION PLUG J21 LOCATION BEHIND RECONNECT PANEL PANEL 5 Locate the primary lead molex plug J21 7 Apply the correct input power to the machine just behind the reconnect panel assembly on and test for the correct secondary voltages the right side of the machine Check for bro at plugs J30 and J31 Make sure the recon ken or loose wires See Figure F 2 nect panel is configured properly for the input voltage being applied Table 6 Disconnect plugs J30 and J31 from the wiring harness A WARNING ELECTRIC SHOCK can kill e e With input power ON there are high volta
205. t 35 1 126 35 212A 210 x d 8 35 H 2 35 16 35 13 35 1i 4 55 35 15 35 AUXILIARY TRANSFORMER aab 1625 30 Dun E Bi 735 361 i c d 14 362 BACKGROUND 305 3 p 363 METER 245 4 1 5 5 J1 J8 J3 J9 223 4 9 gt p J11 J12 J14 J10 J13 ELECTRICAL SYMBOLS PER E1537 211A 5 J18 J37 J15 J35 J6 J27 J33 2126 4 12 NE COLOR CODE 210 lt 6 E 00000 BLACK D 4 GREEN 502 de 1 374 4 6 gt 10 N BROWN O ORANGE J4 J17 J16 J28 J2 J36 6 R RED 2 1 i 1 6 1 8 WHITE i METER PINOUT VIEWED FROM BACK OF METER Y YELLOW H U BLUE 1 2 2 gt T 3 i 5 p 363 e 1 1 1 Return to Section TOC Return to Master TOC 354 358 313 CW MAX 10K 359 4 low R11 360 36 GW BACKGROUND 10K 362 44 29 12 CONTROL olo O 515 g 2 cic 5 5 a 6 gt P C BOARD CONNECTOR CAVITY NUMBERING SEQUENCE NOTES J3 1 b VIEWED FROM COMPONENT SIDE OF BOARD 4 5 364 0 CW FOR MACHINES SUPP
206. t creates EMF fields around welding cables and welding machines 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools gt E Return to Master TOC away from V belts gears fans and all other moving parts when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan Do not attempt to override the governor idler by pushing on the throttle control rods while the engine is running M To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect
207. tat will prevent output voltage or current The meter will remain on during this time In addition the yellow thermo LED will light Thermostats are self resetting once the machine cools sufficiently If the thermostat shutdown 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 a 15 minute period If the fan is not turning or the air intake louvers were obstructed then the power must be switched off for 15 minutes in order to reset The fan problem or air obstruction must also be corrected INVERTEC STT LINCOLN 5 Return to Master Return to Master TOC o E Return to Master TOC Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION Troubleshooting amp Repair Section F How to Use Troubleshooting F 2 PC Board Troubleshooting F 3 Troubleshooting QUIC tita icri ea F4 F 12 Uude M F 13 T1 Auxiliary Transformer 0 13 4 Auxiliary Transformer F 19
208. technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 troubleshoot ing assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the input rectifier and associated components are functioning properly Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver Analog Voltmeter ohmmeter Multimeter Inverter STT Wiring Diagrams Note Component locations and disassembly procedures may vary slightly on STT models olo E 2 olg iz 8 515 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 26 26 TROUBLESHOOTING amp REPAIR EB INPUT RECTIFIER TEST continued 5 5 8 8 FIGURE 9 INPUT RECTIFIER LOCATION oje ele 5 5 INPUT RECTIFIER Return to Section TOC Return to Master TOC TEST PROCEDURE 4 Locate the input rectifier See Figure F 9 1 Turn off the Invertec STT and disconnect 5 Locate the leads needed to perform the main AC input power to the machine tests See Figure F9
209. the screws 7 Carefully remove the switch board 8 Clean the heat sink surfaces thoroughly to remove all the heat sink compound During machine operation this compound helps conduct heat from the switch board to the heat sinks 9 Apply a thin layer 002 of Dow Corning 340 Heat Sink Compound Lincoln E1868 to the mounting surfaces of the new switch board and to the capacitor terminals DO NOT allow the compound to enter the mounting screw holes It can distort the torque values 10 Prepare to mount the new switch board on the heat sink by first lining up the mounting holes Then press the switch board into place 11 Insert each of the four socket head screws into the mounting holes Thread them finger tight The threads are soft be careful no to cross thread them 12 Insert each of the two hex head screws into the capacitor terminal holes Thread them finger tight Be careful not to cross thread the screws 13 Torque both sets of screws in 10 inch pound increments Use diagonal tightening sequence Torque the four socket head screws to 44 inch pounds 5 Nm Torque the two hex head screws to 55 inch pounds 6 Nm A CAUTION Failure to connect the switch board leads correct ly can result in damage to the Invertec STT machine when power is applied 14 Reconnect all the leads to the switch board Be sure each lead is connected to the correct terminal 15 Perform the Test after Repair of Switch B
210. the spark plug wires distributor cap or magneto wire as appropriate LINCOLN 5 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source Return to Master Return to Master TOC o 5 Return to Master TOC SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while
211. ton Drive Board Codes 10151 10383 M17581 1892 N XILLARY TRANSFORMER WINDING POWER SUPPLY Return to Master TOC Return to Section TOC NEGATIVE BIAS for DARLINGTON DARLINGTON MODULE 2 HOLD OFF BLUE e TWISTED PAIR y Wo 1N5402 1 5402 Return to Section TOC Return to Master TOC STT CONTROL BOARD 151 Symmetric Gate Drive Layout ON Darlington OFF Darlington OFF olo O 515 g 2 cic 5 5 a GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 R 18 07 3 CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS D 13 DIODES 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET NOTES O POWER SUPPLY SOURCE POINT SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE COMMON CONNECTION WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS D
212. turn to Master TOC Note Component locations and disassembly procedures may vary slightly on STT models 7 5 o 2 2 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 66 66 TROUBLESHOOTING amp REPAIR CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 30 OUTPUT CHOKE LEAD DISCONNECTION o HE 9 2 Return to Master TOC O10 919 5 8 olg a gt olg OUTPUT CHOKE iz gt IGBT MODULE PLICED NNECTION d AREA SPLICED CONNECTIO PROCEDURE WARNING 1 Turn off Invertec STT and disconnect main AC input power to the machine ELECTRIC SHOCK can kill 2 Using the 5 16 nut driver remove the case Before continuing with the wraparound cover test procedure perform the capacitor discharge proce 3 Perform the Filter Capacitor d re to avoid electric Discharge Procedure See the Maintenance shock section 4 Locate the lead connection splice from the output choke to the IGBT module Remove the insulating sleeve Using the 7 16 wrench disconnect the lead splice Thread the lower lead down into the lower tray assembly area See Figure F 30 Return to Section TOC Return to Master TOC Return to Section TOC
213. urn to Section TOC Return to Master TOC olo O 515 g 2 cic 5 5 a Return to Section TOC Return to Master TOC G 23 PC Board Assembly Protection Codes 10151 11092 L7915 e E E nd RIZ Cn D3 ae 32551 08 R23 R24 R25 Lm R29 21 T R31 als gt R30 co R20 ext co ray IT R8 19 g X1 C 827 E RSS D 52 D6 R22 R35 R32 R28 m R37 R19 18 B53 C2 mE Dzi T R16 2 27 7 e 6 J15 ae mE US R36 04 81671 O NOILO31O0Hd NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided ELECTRICAL DIAGRAMS 0 23 I TEM REQ D PART NO IDENTIFICATION C 1 C3 C4 C5 5 5 16668 5 022 50 C2 1 5 13490 93 27 38 D1 D3 D4 05 05 07 6 118193 1 1 4004 08 1 112199 2 1 400 071
214. wn into the lower tray assembly area See Figure F 3 Return to Section TOC Return to Master TOC INVERTEC STT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC E gt 2 5 ply o 9 Return to Section TOC Return to Master TOC Return to Master TOC F 21 F 21 TROUBLESHOOTING amp REPAIR T4 AUXILIARY TRANSFORMER TEST continued FIGURE F 4 PLUG J1 LOCATION J1 CURRENT SENSING PLUG OUTPUT CHOKE DARLINGTON MODULE SPLICED CONNECTION 5 Disconnect the current sensing Plug J1 from the control PC board Carefully remove Plug J1 and associated leads from control board compartment See Figure F 4 FIGURE F 5 PLUG J22 LOCATION PLUG J22 6 Locate and disconnect plug J22 from the wiring harness See Figure F 5 INVERTEC STT LINCOLN 5 22 F 22 TROUBLESHOOTING amp REPAIR O10 O O 5 T4 AUXILIARY TRANSFORMER TEST continued 518 o lt FIGURE STT ON ITS RIGHT SIDE o 5 2 Pc MOUNTING BOLTS 5 O10 5 8 a gt 2 2 Pc 7 Carefully lift and tilt the Invertec 9 Carefully slide out and support the lower tray machine onto its right side See Figure F 6 assembly for testing purposes 8 Using the 7 16 wrench remove the five
215. y P D B D 9 CR1 R R 1 C 9 current TRANS 1 1 v CONTROL N E At v al REGEPTACLE 1 N T R E p 5 H 5 O D R amp E N k N L m T 7 PRE E ICHARGE B WIRE B 1 RECEPTACLE TRANS rr i 1 N m E 1 FET p REN MEANS LESS THAN iVDG CURRENT FEEDBACK PULSE TRANSFORMER SIGNAL CONTROL BOARD DRIVER BOARD dd Ch VOLTAGE FEEDBACK Ho WIRE TAILOUT BACK CURRENT GROUND Air METER METER GONTHOL GONSROL switch Whien AND 6 42 FIGURE E 1 INVERTEC STT INVERTEC STT LINCOLN 5 Return to Section TOC Return to Section TOC olo o E g olg gt 8 515 o Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC E 2 E 2 THEORY OF OPERATION FIGURE E 2 INPUT VOLTAGE rod zo 2 gt 00 POSITIVE MAIN TRANSFORMER T2 CURRENT SENSOR CHOKE VOLTAGE SENSING J Pre LINE INPUT a CHARGE SWITCH R Ep E 5 D B R o CURRENT u TRANS N GA N b R N 5 ib PRE ICHARGE
216. your code is pasted inside one of the enclosure panels of your machine INVERTEC STT STT G 6 ELECTRICAL DIAGRAMS G 6 Schematic Control PC Board Codes 10151 11092 02781 Sheet 1 of 2 415V 18 9 POWER PLANE 15 power pLaNe Gowen PLANE t hs t t t t t t t C439 0013 di X19 X20 X32 9 x10 x36 1 n X22 X30 x23 a 5440 COUNTERS TIMER TIMER SWITCH SWITCH COMPARATOR MC140138 MC14040 MC14040 MC14538B MC14538B 171014 40988 40668 20668 1 2901 HP2231 Pror Ei Bus e e e 2 87K Qn x feit DV DT KILLER 2 L AEPETITIOUS CUTE d R340 PINCH LIMITER DIGITAL LOGIC 0 5 7 15V POWER SUPPLY FOR O 8 ELE DIGITAL TRIGGER 8 ANALOG SECTIONS PONER PLANE oc ER DETECT a gt PINCH SIGNAL 09 PINCH KILLER Varo 5 3 TO FE SHEET 2 DONMN R ADJUST FE SHEET 2 FOR ENERGY a 0 HP2231 n K 5 VOLT MC14040 518395 23 METER Return to Master TOC Return to Section TO

Lincoln Electric INVERTEC SVM129-B User's Manual

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