View Safety Info SVM129-B OCTOBER, 2006 ® INVERTEC STT TM & STT II TM 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 View Safety Info Safety Depends on You Return to Master TOC Return to Master TOC RETURN TO MAIN MENU Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation . . .
Return to Master TOC i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
Return to Master TOC Return to Master TOC ii ELECTRIC SHOCK can kill. ARC RAYS can burn. 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. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
Return to Master TOC iii WELDING SPARKS can 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 extinguisher readily available. 6.b.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Page Safety .................................................................................................................................................i-iv Installation.............................................................................................................................Section A Operation...............................................................................................................................
Return to Master TOC Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Installation .............................................................................................................................Section A Technical Specifications (Codes 11092 & Below) .......................................................................A-2 Technical Specifications (Codes 11115 & 11116) ........................................................................A-3 Location...................
Return to Master TOC Return to Section TOC A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS –Invertec STT & STT II (For Codes 11092 and BELOW) INPUT- THREE PHASE ONLY STANDARD VOLTAGE INPUT CURRENT AT RATED OUTPUT 208/230/460/3/60 HZ 32/30/16 200/220/380/415/440/3/50/60 HZ 33/30/18/17/16 Return to Master TOC Return to Section TOC RATED OUTPUT DUTY CYCLE AMPS VOLTS AT RATED AMPS 60% Duty Cycle 225 29 100% Duty Cycle 200 28 OUTPUT CURRENT RANGE OPEN CIRCUIT VOLTAGE Peak Current 1 0 - 450
Return to Master TOC Return to Section TOC A-3 A-3 INSTALLATION TECHNICAL SPECIFICATIONS –Invertec STT II (For Codes 11115 AND 11116) INPUT- THREE PHASE ONLY STANDARD VOLTAGE INPUT CURRENT AT RATED OUTPUT 200/208/3/50/60 HZ 36/34 200/208/380/400/415/3/50/60 HZ 36/34/20/19/18 Return to Master TOC Return to Section TOC RATED OUTPUT DUTY CYCLE AMPS VOLTS AT RATED AMPS 60% Duty Cycle 225 29 100% Duty Cycle 200 28 OUTPUT CURRENT RANGE OPEN CIRCUIT VOLTAGE Peak Current 0 - 450 Amps Backgro
Return to Master TOC Return to Section TOC A-4 INSTALLATION MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION Read and understand entire Installation Section before starting installation. WARNING The machine may not be suitable for use in an environment where high frequency is present. For example do not place the machine in close proximity to “TIG” or “PLASMA” operations. To minimize high frequency interference: ELECTRIC SHOCK can kill.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC A-5 INSTALLATION A-5 CASE BACK RATING PLATE INPUT CABLE ENTRY ACCESS & CABLE STRAIN RELIEF FIGURE A.1 CASE BACK Return to Master TOC Return to Section TOC INPUT CABLE INSTALLATION AND CONNECTION A cable strain relief is provided at the supply line entry and is designed to accommodate cable diameters of .310 - 1.070 in. (7.9 - 27.2 mm).
A-6 INSTALLATION Return to Master TOC Return to Section TOC A-6 4A 380-415 OR * 2. Move input voltage switch to Voltage = 380-460V position. 3. Move lead “A” to 380-415 Terminal. * OR 200-208 *(NOT PRESENT ON ALL MODELS) Return to Master TOC Return to Section TOC FIGURE A.
Return to Master TOC Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION Operation...............................................................................................................................Section B Safety Precautions ......................................................................................................................B-2 General Description ....................................................................................................................
Return to Master TOC Return to Section TOC B-2 OPERATION OPERATING INSTRUCTIONS Read and understand entire section before operating machine. GENERAL WARNINGS SAFETY PRECAUTIONS WARNING Return to Master TOC Return to Section TOC ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-3 OPERATION GENERAL DESCRIPTION • High temperature Class H insulation. The Invertec STT II is a 225-ampere inverter based arc welding power source specifically designed for the STT welding process. It 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.
Return to Master TOC Return to Section TOC B-4 B-4 OPERATION OPERATIONAL FEATURES AND CONTROLS All operator controls are located on the case front of the Invertec STT II. Refer to Figure B.1 for locations. 4 5 6 7 2 3 Return to Master TOC Return to Section TOC 8 10 1 9 11 13 14 15 12 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC FIGURE B.1 CASE FRONT CONTROLS 1. POWER SWITCH: Turns output power ON and OFF.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC 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.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC B-6 OPERATION WELDING PARAMETERS AND GUIDELINES The Invertec STT II 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”).
Return to Master TOC Return to Section TOC B-7 B-7 OPERATION WELDING PROCEDURES FOR STT II - (Stainless Steel) Horizontal Fillet (See Table B.3 and B.4) (Steel) Horizontal Fillet (See Table B.1 and B.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC B-8 NOTES INVERTEC STT B-8
Section C-1 TABLE OF CONTENTS - ACCESSORIES Accessories...........................................................................................................................Section C Options/Accessories ...................................................................................................................C-2 LN-742 Wire Feeder Connection Instructions.............................................................................C-3 Connection Diagram ..........................................
Return to Master TOC Return to Section TOC C-2 ACCESSORIES OPTIONS / ACCESSORIES K940 SENSE LEADS: These leads are used to accurately sense arc voltage. One set is required for each STT II power source. A 10 ft and 25 ft set are provided 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 adjustment of Peak and Background Current settings.
Return to Master TOC Return to Section TOC C-3 ACCESSORIES LN-742 or STT-10 WIRE FEEDER CONNECTION INSTRUCTIONS The LN-742 or STT-10 is the recommended wire feeder for use with the Invertec STT II. Refer to the LN742 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. WARNING • Only qualified personnel should perform this installation. Return to Master TOC 3.
C-4 ACCESSORIES CONNECTION DIAGRAM - INVERTEC STT II Return to Master TOC Return to Section TOC C-4 WARNING Turn off input power to the Welding Power source using the disconnnect switch at the fuse box before connecting the wire feeder. ELECTRIC SHOCK Only qualified persons should install, use or service this machine. CAN KILL WIRE FEEDER REMOTE WORK LEAD CABLES AND LEADS SHOULD BE TAPED TOGETHER.
Section D-1 TABLE OF CONTENTS -MAINTENANCEMaintenance .........................................................................................................................Section D Input Filter Capacitor Discharge Procedure................................................................................D-2 Preventive Maintenance .............................................................................................................D-3 Major Component Locations ......................................
Return to Master TOC Return to Section TOC D-2 MAINTENANCE WARNING Failure to follow this capacitor discharge procedure can result in electric shock. INPUT FILTER CAPACITOR DISCHARGE PROCEDURE Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC D-3 MAINTENANCE PREVENTIVE MAINTENANCE • Input Filter Capacitors 1. Perform the following preventive maintenance procedures at least once every six months. It is good practice to keep a preventive maintenance record; a record tag attached to the machine works best. • Output Terminals Return to Master TOC Return to Section TOC 2.
FIGURE D.2 – MAJOR COMPONENT LOCATIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Return to Master TOC Section E-1 Section E-1 TABLE OF CONTENTS -THEORY OF OPERATION SECTIONTheory of Operation .............................................................................................................Section E General Description ...............................................................................................................E-2 Input Voltage..........................................................................................................................
E-2 THEORY OF OPERATION Return to Master TOC Return to Section TOC E-2 FIGURE E.
Return to Master TOC Return to Section TOC E-3 E-3 THEORY OF OPERATION FIGURE E.
FIGURE E.
FIGURE E.
FIGURE E.
FIGURE E.
Return to Master TOC Return to Section TOC E-8 THEORY OF OPERATIONS FIGURE E-8 – FIELD EFFECT TRANSISTOR OPERATION GATE TERMINAL (0 VOLTS) SOURCE TERMINAL DRAIN TERMINAL DRAIN (N) SUBSTRATE (P) Return to Master TOC Return to Section TOC SOURCE (N) N CHANNEL A. PASSIVE GATE TERMINAL (+ 6 VOLTS) Return to Master TOC Return to Section TOC SOURCE (N) DRAIN (N) ELECTRONS B. ACTIVE FIELD EFFECT TRANSISTOR (FET) OPERATION Return to Master TOC An FET is a type of transistor.
Return to Master TOC Return to Section TOC E-9 THEORY OF OPERATION E-9 FIGURE E-9 – TYPICAL FET OUTPUTS sec 48 50 sec sec sec Return to Master TOC Return to Section TOC MINIMUM OUTPUT 24 sec 24 sec 2 sec 50 sec MAXIMUM OUTPUT Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the positive and negative portions of the cycle.
Return to Master TOC Return to Section TOC E-10 THEORY OF OPERATION PROTECTIVE CIRCUITS THERMAL PROTECTION Protective circuits are designed into the Invertec machine to sense trouble and shut down the machine before the trouble damages the internal machine components. Both overload and thermal protection circuits are included. Thermostats protect the machine from excessive operating temperatures.
Return to Master TOC Return to Master TOC Section F-1 Section F-1 TABLE OF CONTENTS TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section ................................................................................Section F How to Use Troubleshooting Guide .......................................................................................F-2 PC Board Troubleshooting Procedures .................................................................................F-3 Troubleshooting Guide .
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-2 TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-3 TROUBLESHOOTING & REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the machine OFF before working on equipment. Do 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-4 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) Return to Section TOC Return to Master TOC Return to Master TOC RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is evident. 1. Contact your local Lincoln Authorized Field Service Facility. 1.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-5 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-5 Observe Safety Guidelines detailed in the beginning of this manual.
Return to Master TOC Return to Section TOC F-6 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS Machine is dead - no output - no fan - no display. 1. The power switch must be in the "ON" position. Return to Master TOC Return to Master TOC 2. Perform the T1 Transformer Test. Auxiliary 4.
Return to Master TOC Return to Section TOC F-7 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS No output. Main fuses are open, indicating excessive current draw. Return to Section TOC F-7 Machine loses output when gun trigger is pulled or arc is struck.
Return to Master TOC Return to Section TOC F-8 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Machine loses output while welding. The thermal indicator light is lit. Normal welding output returns after about 10 minutes.
Return to Master TOC Return to Section TOC F-9 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) F-9 POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Porosity in the weld. 1. Make sure the gas type and flow rate is correct for the procedure being used. Shield the work from excessive outside air currents. 1. Contact the Lincoln Electric Service Department. 1-888-9353877.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-10 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-10 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Weld bead appears "cold." 1. One or more of the machine settings may be wrong. Check the Background, Peak Current, Tailout (STT II Only), and Wire Speed controls for proper settings.
Return to Master TOC Return to Section TOC F-11 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT(S) WELDING PROBLEMS Molten weld puddle appears excessively "violent." 1. The Wire Type switch may be in the wrong position for the electrode wire being used.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-12 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-12 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Excessive weld spatter. Arc sounds and looks like a standard MIG process. 1. Check the Arc Sense leads for loose or faulty connections. 1. The IGBT module may be faulty. Check or replace.
Return to Master TOC TROUBLESHOOTING & 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 Master TOC Return to Section TOC F-14 TROUBLESHOOTING & REPAIR T1 AUXILIARY TRANSFORMER TEST (continued) FIGURE F.1 – T1 AUXILIARY TRANSFORMER AND J30/J31 LOCATION Return to Master TOC Return to Section TOC PLUG J30 PLUG J31 T1 AUXILIARY TRANSFORMER Return to Master TOC Return to Section TOC TEST 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.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-15 TROUBLESHOOTING & REPAIR T1 AUXILIARY TRANSFORMER TEST (continued) FIGURE F.2 – PRIMARY LEAD PLUG J21 LOCATION PLUG J21 LOCATION BEHIND RECONNECT PANEL RECONNECT PANEL 5. Locate the primary lead molex plug (J21) just behind the reconnect panel assembly on the right side of the machine. Check for broken or loose wires.
Return to Master TOC Return to Section TOC F-16 TROUBLESHOOTING & 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 the Input Filter Discharge Procedure. Capacitor 12. Reconnect Plugs J30 & J31. 13.
Return to Master TOC Return to Section TOC F-17 TROUBLESHOOTING & REPAIR T1 AUXILIARY TRANSFORMER TEST (continued) 15. Apply the correct input power and carefully test for the correct primary voltages at plug J21. See Table F.1. WARNING ELECTRIC 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. 16.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-18 NOTES INVERTEC STT F-18
Return to Master TOC Return to Section TOC F-19 TROUBLESHOOTING & 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-20 TROUBLESHOOTING & REPAIR T4 AUXILIARY TRANSFORMER TEST (continued) FIGURE F.3 – OUTPUT CHOKE/IGBT MODULE SPLICED CONNECTION OUTPUT CHOKE/ DARLINGTON MODULE SPLICED CONNECTION Return to Master TOC Return to Section TOC LOWER TRAY AREA TEST PROCEDURE WARNING 1. Turn off the Invertec STT and disconnect main AC input power to the machine. ELECTRIC SHOCK can kill.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-21 TROUBLESHOOTING & REPAIR T4 AUXILIARY TRANSFORMER TEST (continued) FIGURE F.4 – PLUG J1 LOCATION J1 CURRENT SENSING PLUG OUTPUT CHOKE/ DARLINGTON MODULE SPLICED CONNECTION LOWER TRAY AREA Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC F-22 TROUBLESHOOTING & REPAIR T4 AUXILIARY TRANSFORMER TEST (continued) FIGURE F.6 – STT ON ITS RIGHT SIDE Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC MOUNTING BOLTS (5) 7. Carefully lift and tilt the Invertec STT machine onto its right side. See Figure F.6. 9. Carefully slide out and support the lower tray assembly for testing purposes. 8.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-23 T4 AUXILIARY TRANSFORMER TEST (continued) FIGURE F.8 – T4 TRANSFORMER LEAD CONNECTIONS LEADS 32A, 32B, 33A, 33B Return to Master TOC Return to Section TOC T4 AUXILIARY TRANSFORMER LEADS 32A, 32B, 33A, 33B T4 AUXILIARY TRANSFORMER Return to Master TOC Return to Section TOC STT STT II 11. Locate and remove leads #32A, #32B and #33A, #33B from the T4 transformer tabs. See Figure F.8. 12.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-24 TROUBLESHOOTING & REPAIR T4 AUXILIARY TRANSFORMER TEST (continued) TABLE F.
Return to Master TOC Return to Section TOC F-25 TROUBLESHOOTING & 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 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.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-26 INPUT RECTIFIER TEST (continued) FIGURE F.9 - INPUT RECTIFIER LOCATION Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A 9 INPUT RECTIFIER C B 12 TEST PROCEDURE 4. Locate the input rectifier. See Figure F.9. 1. Turn off the Invertec STT and disconnect main AC input power to the machine. 5. Locate the leads needed to perform the tests. See Figure F.9. 2.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-27 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (continued) TABLE F.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-28 NOTES INVERTEC STT F-28
Return to Master TOC Return to Section TOC F-29 TROUBLESHOOTING & REPAIR CAPACITOR BALANCE 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 Return to Section TOC Return to Master TOC F-30 TROUBLESHOOTING & REPAIR CAPACITOR BALANCE TEST (continued) FIGURE F.10 – SWITCH BOARD TEST POINTS 9 12 Return to Master TOC Return to Section TOC L8441 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 Return to Master TOC Return to Section TOC ELECTRIC SHOCK can kill.
Return to Master TOC Return to Section TOC F-31 TROUBLESHOOTING & REPAIR CAPACITOR BALANCE TEST (continued) TABLE F.4 – EXPECTED VOLTAGE READINGS Return to Master TOC 460 440 415 380 Return to Section TOC VDC at terminals #9 (+) and #12 (-) should be approximately: If VAC Input is: VAC VAC VAC VAC 325VDC 311VDC 293VDC 269VDC 5. Adjust the Peak and Background controls to the minimum settings (controls on case front). 8.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-32 NOTES INVERTEC STT F-32
Return to Master TOC Return to Section TOC F-33 TROUBLESHOOTING & 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 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 Return to Section TOC Return to Master TOC F-34 TROUBLESHOOTING & REPAIR SWITCH BOARD TEST (continued) FIGURE F.11 - SWITCH BOARD RESISTANCE TEST TEST PROCEDURE WARNING Return to Master TOC Return to Section TOC 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).
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-35 SWITCH BOARD TEST (continued) TABLE F.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-36 TROUBLESHOOTING & REPAIR SWITCH BOARD TEST (continued) TABLE F.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-37 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-38 TROUBLESHOOTING & REPAIR SNUBBER RESISTORS TEST (continued) FIGURE F.12 - REMOVING LEADS TEST PROCEDURE 4. Locate and gain access to the switch board. 1. Turn off Invertec STT and disconnect main AC input power to the machine. 5. Remove leads from terminals 401/403, 402/404 on the switch board. See Figure F.12. 2.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-39 TROUBLESHOOTING & REPAIR SNUBBER RESISTORS TEST (continued) FIGURE F.13 - SWITCH BOARD TEST POINTS 9 401/403 401 L8441 12 Return to Master TOC Return to Master TOC Return to Section TOC 402/404 12 SWITCH 6. Test for 25 ohms resistance from lead terminal 401 to terminal 12 on the switch board. See Figure F.13. Return to Section TOC F-39 a. If 25 ohms is measured, resistor R4 is OK. b.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-40 NOTES INVERTEC STT F-40
Return to Master TOC Return to Section TOC F-41 TROUBLESHOOTING & 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Section TOC F-42 TROUBLESHOOTING & REPAIR POWER BOARD TEST (continued) FIGURE F.14 – REMOVING THE FRONT PANEL ASSEMBLY POWER PC BOARD Return to Master TOC Return to Section TOC (Located on Back of Case Front) QUICK CHECK PROCEDURE Return to Master TOC Return to Section TOC 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.
POWER BOARD TEST (continued) FIGURE F.15 – POWER PC BOARD TEST POINTS 309 212A 310 Return to Master TOC Return to Section TOC J7 POWER BOARD 313 Return to Master TOC Return to Master TOC J14 501 311 J6 211A 275 305 504 4. Secure and insulate the front panel assembly for POWER ON testing. Return to Section TOC 301 302 L8033 Return to Section TOC F-43 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-43 5. Apply the correct input power and turn ON the machine. 6.
Return to Master TOC Return to Section TOC F-44 F-44 TROUBLESHOOTING & REPAIR POWER BOARD TEST (continued) FIGURE F.16 – SIMPLIFIED TRIGGER CIRCUIT POWER BOARD CONTROL BOARD 7J6 FROM PROTECTION BOARD OVERVOLTAGE 2J6 #301 11J4 #305 3J4 PWM OUTPUTS TO POWER BOARD P W M REMOTE PROTECTION BOARD Return to Master TOC Return to Section TOC STT II Only T1 AUXILIARY TRANSFORMER 3J31 14 AMPHENOL #379 6J22 #503A 2 4 V A C #224 TO POWER BOARD 3.
Return to Master TOC Return to Section TOC F-45 TROUBLESHOOTING & 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-46 F-46 TROUBLESHOOTING & REPAIR PROTECTION BOARD TEST (continued) FIGURE F.17 – PROTECTION PC BOARD TEST POINTS L7915-[ ] PROTECTION 315 313 J8 314 317 J15 316 Return to Master TOC Return to Section TOC 311 TEST PROCEDURE WARNING 1. Turn off the Invertec STT and disconnect main AC input power to the machine. ELECTRIC SHOCK can kill. • With input power ON, there are high voltages inside the machine.
PROTECTION BOARD TEST (continued) FIGURE F.18 - LEADS #309, #309A AT CR1, CR2 RELAYS CR2 CR1 309 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 309A 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-48 NOTES INVERTEC STT F-48
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-49 TRIGGER CIRCUIT TEST WARNING Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC F-50 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.19 – PLUG J31 LOCATION Return to Master TOC Return to Section TOC PLUG J31 TEST PROCEDURE Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 1. Turn off the Invertec STT and disconnect main AC input power to the machine. WARNING ELECTRIC SHOCK can kill.
Return to Master TOC Return to Section TOC F-51 F-51 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.20 – 14 PIN AMPHENOL AND PLUG J31 PIN ASSIGNMENTS C B D L M AJ K E N H Return to Master TOC PLUG J31 G Return to Section TOC F I 212 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 #212). See Figure F.20, and Figure F.22, Simplified Trigger Circuit Diagram.
Return to Master TOC Return to Section TOC F-52 F-52 TROUBLESHOOTING & REPAIR TRIGGER CIRCUIT TEST (continued) FIGURE F.22 – SIMPLIFIED TRIGGER CIRCUIT DIAGRAM POWER BOARD CONTROL BOARD 7J6 #301 11J4 FROM PROTECTION BOARD OVERVOLTAGE 2J6 #305 3J4 PWM OUTPUTS TO POWER BOARD P W M REMOTE PROTECTION BOARD Return to Master TOC Return to Section TOC STT II Only T1 AUXILIARY TRANSFORMER 14 AMPHENOL #379 3J31 6J22 #224 3.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-53 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-54 TROUBLESHOOTING & REPAIR IGBT MODULE REMOVAL AND REPLACEMENT (continued) FIGURE F.23 – OUTPUT CHOKE LEAD DISCONNECTION OUTPUT CHOKE/ IGBT MODULE SPLICED CONNECTION LOWER TRAY AREA PROCEDURE Return to Master TOC Return to Section TOC 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-55 TROUBLESHOOTING & REPAIR IGBT MODULE REMOVAL AND REPLACEMENT (continued) FIGURE F.24 – PLUG J1 DISCONNECTION J1 CURRENT SENSING PLUG OUTPUT CHOKE/ IGBT MODULE SPLICED CONNECTION LOWER TRAY AREA J1 and associated leads from the control PC board compartment. See Figure F.24. FIGURE F.25 – PLUG J22 DISCONNECTION Return to Master TOC Return to Section TOC 5.
Return to Master TOC TROUBLESHOOTING & REPAIR IGBT MODULE REMOVAL AND REPLACEMENT (continued) FIGURE F.26 – STT PLACED ON ITS RIGHT SIDE Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC MOUNTING BOLTS (5) Return to Section TOC Return to Section TOC Return to Section TOC F-56 7. Carefully lift and tilt the Invertec STT machine onto its right side. See Figure F.26. 11. Using the 1/2" wrench, remove the IGBT cable from the negative output terminal. 8.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-57 TROUBLESHOOTING & REPAIR IGBT MODULE REMOVAL AND REPLACEMENT (continued) FIGURE F.27 – IGBT MODULE CONNECTIONS IGBT MODULE E C E G STT II Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC For steps 14-18, see Figure F.27. 14. Using the phillips head screw driver, remove the small leads from the small "E" and "B" terminals. Note lead placement for reassembly. 15.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-58 NOTES INVERTEC STT F-58
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-59 SWITCH BOARD 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC TROUBLESHOOTING & REPAIR SWITCH BOARD REPLACEMENT (continued) FIGURE F.28 – SWITCH BOARD REMOVAL SOCKET HEAD SCREWS Return to Master TOC Return to Section TOC Return to Section TOC F-60 Return to Master TOC Return to Section TOC PROCEDURE NOTE: If a test indicates that a switch board is defective, both switch boards must be replaced at the same time.
Return to Master TOC Return to Section TOC F-61 TROUBLESHOOTING & 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 the screws. 7. Carefully remove the switch board. Return to Master TOC Return to Section TOC 8. Clean the heat sink surfaces thoroughly to remove all the heat sink compound.
Return to Master TOC Return to Section TOC F-62 TROUBLESHOOTING & REPAIR SWITCH BOARD REPLACEMENT (continued) TEST AFTER REPAIR OF SWITCH BOARDS AND/OR CAPACITORS The following test must be performed after the switch boards and/or the capacitors have been replaced. 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 style (new part number). 3.
Return to Master TOC Return to Section TOC F-63 TROUBLESHOOTING & REPAIR SWITCH BOARD REPLACEMENT (continued) 9. With the output free of a load, check open circuit voltages of the output. Voltage should be 85 VDC maximum. WARNING ELECTRIC SHOCK can kill. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC • With input power ON, there are high voltages in the machine.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-64 NOTES INVERTEC STT F-64
Return to Master TOC Return to Section TOC F-65 TROUBLESHOOTING & 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-66 TROUBLESHOOTING & REPAIR CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.30 – OUTPUT CHOKE LEAD DISCONNECTION OUTPUT CHOKE/ IGBT MODULE SPLICED CONNECTION LOWER TRAY AREA PROCEDURE Return to Section TOC Return to Master TOC Return to Master TOC 1. Turn off Invertec STT and disconnect main AC input power to the machine. Return to Section TOC F-66 WARNING ELECTRIC SHOCK can kill.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-67 TROUBLESHOOTING & REPAIR CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.31 – PLUG J1 DISCONNECTION J1 CURRENT SENSING PLUG OUTPUT CHOKE/ IGBT MODULE SPLICED CONNECTION LOWER TRAY AREA Return to Master TOC Return to Section 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.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-68 TROUBLESHOOTING & REPAIR F-68 CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.33 – STT 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. 11. Using the 1/2" wrench, remove the IGBT cable from the negative output terminal.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-69 TROUBLESHOOTING & REPAIR CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.34 – REMOVING HEX HEAD NUTS OF THROUGH-BOLTS HEX NUT CAPACITOR REPLACEMENT Return to Section TOC Return to Master TOC Return to Master TOC NOTE: Capacitors must always be replaced in matched sets (C1 and C2 as a set).
Return to Master TOC Return to Section TOC F-70 TROUBLESHOOTING & REPAIR F-70 CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.35 – REMOVING THROUGH-BOLTS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC PLASTIC RETAINING INSULATORS 15. Place the machine on its side as shown in Figure F.35. Slide the plastic retaining insulators that go through the base of the machine to one side.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-71 TROUBLESHOOTING & REPAIR F-71 CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.36 – REMOVING CAPACITOR NUTS 17. Remove the two 7/16” hex bolts that hold the capacitor to the switch board. See Figure F.36. 18. Loosen the set screw of the capacitor clamp ring and remove the capacitor from the clamp ring. See Figure F.37.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-72 TROUBLESHOOTING & 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.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-73 OUTPUT RECTIFIER REMOVAL AND REPLACEMENT WARNING Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC F-74 TROUBLESHOOTING & REPAIR F-74 OUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) FIGURE F.39 – CHOKE LEAD/HEAT SINK CONNECTION HEAT SINK TAB Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 Capacitor Discharge Procedure.
Return to Master TOC Return to Section TOC F-75 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) FIGURE F.40 – MAIN TRANSFORMER DIODE CONNECTIONS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC MAIN TRANSFORMER SECONDARY LEADS 9. Remove the two sleevings from the diode connections at the main transformer. See Figure F.40. 10.
Return to Master TOC Return to Section TOC F-76 TROUBLESHOOTING & REPAIR F-76 OUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) FIGURE F.41 – SWITCH BOARD/CAPACITOR ASSEMBLY THROUGH-BOLTS Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC THROUGH-BOLTS 11. Using the 3/8" nut driver, remove the rear nuts and washers from the switch board/capacitor assembly through-bolts. See Figure F.41. 17.
Return to Master TOC Return to Section TOC F-77 F-77 TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR Retest the INVERTEC STT: • If it fails any test and the test requires removing or replacing any mechanical part that could affect the machine's electrical characteristics. OR • If you repair or replace any electrical components. MAXIMUM INPUT IDLE AMPS AND IDLE WATTS INPUT CURRENT @ IDLE 3.
Return to Master TOC Return to Section TOC F-78 TROUBLESHOOTING & REPAIR INPUT FILTER CAPACITOR CONDITIONING ENVIRONMENTAL PROTECTION 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. . .
Return to Master TOC Section G-1 TABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Section G-1 Electrical Diagrams ...............................................................................................Section G Wiring Diagram - Entire Machine - Codes 10151-10153 - (G2773) . . . . . . . . . . . . . .G-2 Wiring Diagram - Entire Machine - Codes 10381-10383 - (G3136) . . . . . . . . . . . . . .G-3 Wiring Diagram - Entire Machine - Codes 11090-11092 - (G4500) . . . . . . . . . . . . . .
Wiring Diagram - Entire Machine - Codes 10151 - 10153 - (G2773) 9A 9A INPUT RECTIFIER 9D9D D13 9C C D+ C H1 TP1 H1 B B TP3 TP2 A A A F - Return to Master TOC A 12C 12D12D 9D S7 RECONNECT 9B 9B 9C 12A 12C 12A 9B N.F. LOAD CR2 309A 310A 12B 12B 12B 12B 52 52 6 3 2 51 4 1 2 3 4 8 J11 J10 12 J16 7 DRIVER 3 BOARD 1 J9 2 14 3 6254 1 13 9D 12D 12B 52 314 315 316 317 9B N.G.
Wiring Diagram - Entire Machine - Codes 10381 - 10383 - (G3136) 9A 9A INPUT RECTIFIER 9D9D D13 9C C D+ H1 TP1 H1 B TP3 TP2 A F A - B A Return to Master TOC A 12C 12D12D LOAD 309 309A 310 CR1 310A 1 53 3 J8 2 4 14 9D N.H. S7 RECONNECT 9B 9B 9C 12A 12C 12A 9B 310A 12B 12B 12B 12B POWER LINE FILTER ASSEMBLY H1 H3 A A V R C C W 4 AMP SLOW BLOW H3 RIGHT FAN MOTOR S1 POWER ON OFF W U B B H1 J4, J17 52 52 9D 12D 12B 52 314 315 316 317 9B N.G.
Return to Master TOC ELECTRICAL DIAGRAMS G-4 Wiring Diagram - Entire Machine - Codes 11090 - 11092 - (G4500) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-4 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.
N.L. N.G. 14 14 A 12C 309A 12B 12B 12B 9B 9B 12B R5 25 25W + 25 2200 F 12B 25W 450V 51 R4 12B 12B - A W 1 } B J4, J17 H3 H4 3 12 6 8 12 N.E. 62 54 371 374 N N O O 1 T3 CURRENT TRANSFORMER W R W R 4,5 N.E.
+15V +15V POWER PLANE 7 CW A X18 A 3 C405 REMOTE 13 DURING HOT START J2 1W 12 X29 D LM224 14 13 10.0K D408 +15V 10K 10.0 J27 6 CW J27 100K GENERATOR 5 R481 100 R485 C469 39 20V 33.2K R536 12 10.0K 9 8 562 R479 4 3 J27 J27 4 5 Q /Q 9 R331 4.75K 13 NAND 11 D 511 D422 H= OPTION PB TIME L=DISABLE OPTION PB TIME 1N4936 L= LOCAL PB TIME 1W X30 C454 3 B X18 12 10K D X22 100K PHB OUTPUT 3 +15V 11 TO FE (SHEET 2) R463 R461 3.92K 3.92K 0.
R107 13.7K R105 R106 13.7K 13.7K R103 10 2.67K 100V TRUNCATES DT_DELAYED 11 R151 R242 1.30K R205 R236 10K R237 R233 10K 100K 10K 100K 267 R241 R232 R203 R202 R201 R204 10.0 10.0 10.0 R213 10K R215 47.5K 2.21K 60V .13 8 Varc ADJUST 6 ( SHEET 1 ) CONTACT ) R225 13 1.50K 11 DZ4 43V 1W T1 AUX XFMR J4 DZ5 43V 12 1W J4 C J4 D 9 R154 1 A ENERGY CONTROL TO POWER BOARD 5 R217 R218 R226 1.30K 1.30K 1.50K R219 R220 R227 1.30K 1.30K 1.
ITEM X20 C442 C456 G2782-[ ] X32 R537 R559 X28 R234 D423 R563 DZ6 R562 D207 R240 R229 D210 DZ4 R219 R217 R223 R221 R225 R228 R227 R226 D204 D202 D203 D201 R206 C200 R207 DZ5 R222 R220 R224 R238 R216 D206 CR1 D412 R513 R467 R519 R466 C423 R526 C412 R405 R489 R476 R477 R342 R483 R404 R491 R484 R443 R433 R435 R434 D304 R501 R327 R326 R402 C401 C310 R502 C400 J28 R543 R470 J2 R549 R478 J3 X33 R401 R218 D416 D100 R120 R118 R116 D108
Return to Master TOC ELECTRICAL DIAGRAMS G-9 Schematic - Control PC Board - Codes 11115 - 11116 - (G4649 Sheet 1 of 2) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-9 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty.
Return to Master TOC ELECTRICAL DIAGRAMS G-10 Schematic - Control PC Board - Codes 11115 - 11116 - (G4649 Sheet 2 of 2) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-10 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty.
Return to Master TOC ELECTRICAL DIAGRAMS G-11 PC Board Assembly - Control - Codes 11115 - 11116 - (G4648) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-11 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty.
Schematic - Power PC Board - All Codes - (M16018) +15V 1.0 5W .25 R44 D5 R69 18Vac FROM AUXILIARY TRANSFORMER TP1 3300 15J R6 100K Vin + Vc X67 R7 2.67K 50V 150 OUT DZ4 12V J7 3 J6 8 P7 TO 12V X68 1W GND J6 3 P6 P6 TO J6 P6 PWM SIGNAL SIGNAL D6 50V 30V 30V 1.0A 1.0A 1 P6 P7 TO TO PILOT CONTROL CONTROL PILOT LIGHT BOARD BOARD LIGHT (+15V) (COM) (+) D7 J7 1 PWM C9 0.1 INV IN (-) 4 7 G R15 6 C5 15V 1W 20V R20 Q5 26.
PC Board Assembly - Power - All Codes - (L8033) Return to Master TOC Return to Master TOC R69 R1 R25 R24 X4 R3 R4 R2 R10 X1 D R11 R20 C3 R44 C6 R19 R42 R15 R12 C X67 R16 D13 R14 DZ1 B R18 DZ5 Q40 Q5 C5 D8 R17 D9 R9 R43 D6 C8 C1 X68 OCI1 TP2 D10 D11 R21 DZ4 R22 C10 C11 D7 D12 DZ6 E X5 C7 D16 C9 R8 R13 TP1 F R7 D4 D15 C2 Return to Master TOC Return to Section TOC Return to Section TOC D3 D2 R6 D1 J6 R41 PART NO.
+V .5 +V 5W R1 D1 8A 400V 2 C15 3300 J13 POWER 10.0 SUPPLY R6 100V 2 10W 2.7 5 2 AMP BASE DRIVE 2.7 10W J13 R12 2.7 400V GND 6VAC Q1 6A 50V J13 6 3 1 8A 400V Return to Master TOC 1000V 500p D2 8A R C16 3300 50V 3 R 1W 10W C12 D3 C17 18V R11 400V J13 DZ1 2.7 8A 10W D4 WINDING R9 AUXILLARY TRANSFORMER R10 NEGATIVE BIAS for DARLINGTON DARLINGTON HOLD - OFF 10W R13 2.7 D6 1N5402 PAIR 2 +V 1 J13 R2 R4 1.
Return to Master TOC Return to Section TOC G-15 G-15 ELECTRICAL DIAGRAMS PC Board Assembly - Darlington Drive - Codes 10151 - 10383 - (G2778) STT DARLINGTON DRIVE XXX IDENTIFICATION R11 XXX R9 XXX R12 XXX R10 XXX R13 XXX XXX R14 XXX R16 XXX R15 XXX DZ1 C17 Q1 R18 R17 XXX XXX XX X X X R7 DZ3 X R6 C6 R5 R4 C5 X2 Q2 C16 DZ2 R1 XX X X X R8 C9 X X R3 R2 D3 D4 X C12 X D9 C10 XXXX X X X X X D8 C14 X XXX OCI1 X X X D7 D13 D5 C15 Return to M
Return to Master TOC ELECTRICAL DIAGRAMS G-16 Schematic - IGBT Drive Board - Codes 11090 - 11116 - (L12144) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-16 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty.
Return to Master TOC ELECTRICAL DIAGRAMS G-17 PC Board Assembly - IGBT Drive - Codes 11090 - 11116 - (L12145) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-17 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty.
402 --404 R9 10.0 R33 R36 1W R20 Q9 Q10 DZ8 3.3V 40V 2N4403 1W IRFD110 1W Q8 600mA D8 DZ12 10V 1W 1/2W R31 15V C8 G1 10.0 G2 D1 D2 D3 D4 L 8440 SHT. NO. SUP'S'D'G. BS NONE 11-25-91 CHK. .047 1200V D5 A1 401 --403 IRFP460 G3 G4 10.0 G5 R25 S1 S2 S3 S4 S5 10.0 475 475 A1 R27 SNUBBER RESISTOR A1 10.0 2700p 50V 100 R19 R26 1W 15.
Return to Master TOC PC Board Assembly - Switch - All Codes - (L8441) 21B 11B 9B 01B 3B 7B C3 5B 6B 2B ITEM 1B C4 D6 R1 Q11 R21 R31 Q1 Q12 R20 DZ8 R30 Q2 R23 D1 C5 C1 D4 D5 R14 DZ5 R7 D2 R3 R16 R12 Q7 Q4 R13 Q3 B4 Q10 .022/50 C2, C8 2 S16668-4 2700pF/50 C3, C4 2 S13490-112 .047/1200 10 T12705-34 1N4936 DZ1, DZ2, DZ3, DZ12 4 T12702-27 1N4740 DZ4, DZ7 2 T12702-29 1N4744A DZ6, DZ9 2 T12702-40 1N4735 DZ5, DZ8 2 T12702-53 3.
20799 8 10 4 J11 3 J11 Return to Master TOC 1 T1 J9 GATE 1 9 DRIVE 5 12 GATE 8 TO POWER 6 BOARD J9 GATE 7 J9 J10 J10 J10 J10 G1 1 S1 3 G2 250 6 S2 1 S3 4 G3 6 S4 3 G4 R4 150K 150K 150K R5 4 J16 R3 20W R2 TO 250 20W SWITCH BOARD R6 J9 3 R1 Return to Master TOC Schematic - Driver Board - All Codes - (S20799) GATE Return to Section TOC G-20 ELECTRICAL DIAGRAMS S Return to Section TOC G-20 150K Q1 4A R7 900V 1 100 J16 FROM DZ1 PROTECTION
PC Board Assembly - Driver - All Codes - (L9134) XXXX R2 R14 ITEM REQ'D PART NO.
+5V +5V 10K R18 FROM (+) UPPER CAPACITOR 10 B52 D1 R8 6 R32 10K (Over Voltage) 4 J8 681K D5 R20 R37 5K 1 332 1 5 OCI3 1.82K R9 56.2K 1W R26 35V 10V 3 J15 TO DRIVER BD. CNY17-3V 27 GND TO POWER BD. CNY17-3V 2 C2 1.82K DZ1 OCI2 CW R3 B14 OUT 7 X1 6 1 5 C6 100K R10 X2 IN 475 R19 R14 56.2K +5V R16 Return to Master TOC D7 FROM BLEEDER RESISTOR 1 3.32K 150K 56.2K J8 R15 9 15.0K R2 R4 R27 56.2K 8 X1 150K R21 R5 56.
Return to Master TOC Return to Section TOC G-23 ELECTRICAL DIAGRAMS PC Board Assembly - Protection - Codes 10151 - 11092 - (L7915) C6 OCI2 R12 D3 D8 B51 R23 R24 R21 R33 R13 D4 R20 R4 B52 R14 R7 X1 D5 C1 R15 52 R8 R27 R10 R6 D6 R9 53 R35 R32 R37 R19 R22 R28 R18 B53 C2 B14 DZ1 14 Return to Master TOC R11 D1 R3 H5 R31 R30 PROTECTION R26 R25 R29 R5 Return to Section TOC L7915-[ ] Return to Master TOC R2 OCI1 51 Return to Section TOC J8 R1 C5 B5 R16 X2
Return to Master TOC ELECTRICAL DIAGRAMS G-24 Schematic - Protection PC Board - Codes 11115 - 11116 - (M20352) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-24 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty.
Return to Master TOC ELECTRICAL DIAGRAMS G-25 PC Board Assembly - Protection - Codes 11115 - 11116 - (L12235) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-25 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty.
+15V 681K EXCITATION CURRENT MIN OFF SET 100A/V CURRENT OUT R10 R5 1014 R8 Q1 R4 100V C1 20K 6.81K CW C2 150p +IC 50V 4 -VH +VH HALL EFFECT SENSOR 3 10 +15V 2 -IC 1 R14 0.1 REF 100 R12 Return to Master TOC C3 6 X1 50V J18 2.94K 12 X1 C5 50 50V R13 Return to Section TOC 4 C4 13 J18 11 1 4 3 THE LINCOLN ELECTRIC CO. NOTES : N.A.
NOTE: ITEM STT CURRENT SENSE C3 C4 R14 R15 R3 X3 R16 C2 PART NO.
Return to Master TOC G-28 ELECTRICAL DIAGRAMS Schematic - Remote Protection PC Board - All Codes - (M17609) 10 PIN REMOTE M 17609 Return to Section TOC G-28 AMPHENOL .39mH 3 J 2 B 1 C 10 G 9 A 12 D 4 F 11 H 14 B 13 C 5 D 8 I 41 16 K 42 7 J 31 J36 REMOTE INTERFACE I J33 1 OPTIONAL E L1 L2 J33 6 .39mH J36 J33 2 .39mH J36 10K L3 BG POT .39mH J36 10K L4 J33 7 PB POT L5 J33 .
Return to Master TOC ELECTRICAL DIAGRAMS G-29 PC Board Assembly - Remote Protection - All Codes - (L9657) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-29 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty.