Download Lincoln Electric INVERTEC SVM129-B User's Manual
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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 . . . and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful. View Safety Info Return to Master TOC SERVICE MANUAL 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 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. 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 Return to Master TOC 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 & 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 powered equipment. 1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ____________________________________________________ 1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling 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. ____________________________________________________ 1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment. ____________________________________________________ 1.e. 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 or idler by pushing on the throttle control rods while the engine is running. ___________________________________________________ 1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate. ELECTRIC AND MAGNETIC FIELDS may be dangerous 2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines 2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding. 2.c. Exposure to EMF fields in welding may have other health effects which are now not known. 2.d. 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. 2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded. 2.d.5. Do not work next to welding power source. Mar ‘95 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. Headshield and filter lens should conform to ANSI Z87. I standards. 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. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays. In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while 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. 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. 3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”. 3.d. 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. 3.e. Ground the work or metal to be welded to a good electrical (earth) ground. 3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation. Return to Master TOC ii SAFETY 3.g. Never dip the electrode in water for cooling. 3.h. 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. 3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock. 3.j. Also see Items 6.c. and 8. 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. Worker exposure level should be checked upon installation and periodically 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 products. 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. Return to Master TOC 5.e. Read and understand the manufacturer’s instructions for this 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. 5.f. Also see item 1.b. AUG 06 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. 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. Return to Master TOC 6.c. 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. 6.d. 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 “Recommended 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). 6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode. 6.f. 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. Return to Master TOC iii SAFETY 6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework 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. 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. 7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support. 7.c. Cylinders 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. 7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder. 7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. 7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use. 7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from 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. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. Return to Master TOC Mar ‘95 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. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains. b. Faire trés attention de bien s’isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse. c. Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement. d.Ne jamais plonger le porte-électrode dans l’eau pour le refroidir. e. Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines. f. Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage. 2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps. 3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc: zones où l’on pique le laitier. 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. 7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie. 8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent. 9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques. 10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants. 11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974. PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR a. Utiliser un bon masque avec un verre filtrant approprié ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc. b. Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de l‘arc. c. Protéger l’autre personnel travaillant à proximité au soudage à l’aide d’écrans appropriés et non-inflammables. 1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre. 4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes. 3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles. 2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié. 4. Garder tous les couvercles et dispositifs de sûreté à leur place. 5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les Mar. ‘93 v MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Page Safety .................................................................................................................................................i-iv Installation.............................................................................................................................Section A Operation...............................................................................................................................Section B Accessories ..........................................................................................................................Section C Maintenance ..........................................................................................................................Section D Theory of Operation .............................................................................................................Section E Troubleshooting and Repair ................................................................................................Section F Electrical Diagrams ..............................................................................................................Section G STT Parts .......................................................................................................................................P257 STT II Parts ....................................................................................................................................P294 INVERTEC STT v 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.......................................................................................................................................A-4 Stacking.......................................................................................................................................A-4 Tilting...........................................................................................................................................A-4 Machine Grounding and High Frequency Interference Protection..............................................A-4 Input Connections .......................................................................................................................A-4 Supply Connections..............................................................................................................A-4 Ground Connection...............................................................................................................A-5 Input Voltage Reconnect Procedure ...........................................................................................A-6 Output Connections ....................................................................................................................A-6 Wire Feeder Output Connections .........................................................................................A-6 Return to Master TOC Return to Master TOC Return to Master TOC Input Cable Installation and Connection...............................................................................A-5 INVERTEC STT 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 Amps Background 0 - 125 Amps AUXILIARY POWER 85 VDC Maximum 115 2 VAC @ 4 Amps 42 VAC @ 4 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC INPUT VOLTAGE AND FREQUENCY FUSE(SUPER LAG) OR BREAKER SIZE INPUT AMPERE RATING ON NAMEPLATE 208/60 230/60 460/60 200/50/60 40 40 30 40 32 30 16 33 220/50/60 380/50/60 415/50/60 440/50/60 40 30 30 30 30 18 17 16 TYPE 75 C COPPER SUPPLY WIRE IN CONDUIT AWG (IEC) SIZES 10 (6 mm2) TYPE 75 C COPPER GROUND WIRE IN CONDUIT AWG (IEC) SIZES 10 (6 mm2) PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 23.2 in 13.2 in. 24.4 in. 100 lbs. 589 mm 336 mm 620 mm 46 kg 1 At low input voltages (below 208 VAC) and input voltages of 380 VAC through 415 VAC there may be a 15% reduction in Peak Current. 2 115 VAC not present on European Models. INVERTEC STT 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 Background 0 - 125 Amps AUXILIARY POWER 88 VDC Maximum 115 1 VAC @ 4 Amps 42 VAC @ 4 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES Return to Master TOC Return to Section TOC INPUT VOLTAGE AND FREQUENCY Return to Master TOC INPUT AMPERE RATING ON NAMEPLATE 200/50/60 208/50/60 40 40 36 34 380/50/60 400/50/60 415/50/60 30 30 30 20 19 18 TYPE 75 C COPPER SUPPLY WIRE IN CONDUIT AWG (IEC) SIZES TYPE 75 C COPPER GROUND WIRE IN CONDUIT AWG (IEC) SIZES 10 (6 mm2) 10 (6 mm2) PHYSICAL DIMENSIONS 1 Return to Section TOC FUSE(SUPER LAG) OR BREAKER SIZE HEIGHT WIDTH DEPTH WEIGHT 23.2 in 13.2 in. 24.4 in. 100 lbs. 589 mm 336 mm 620 mm 46 kg 115 VAC not present on European Models. INVERTEC STT 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. • Only qualified personnel should perform this installation. • Turn the input power OFF at the disconnect switch or fuse box before installing this equipment. 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 connections or welding arcs of high frequency units. Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC • Turn the power switch on the Invertec STT “OFF” before connecting or disconnecting input power lines, output cables, or control cables. • Do not touch electrically hot parts. Return to Master TOC Provide proper electrical ground to the machine per local and national electrical codes. • Always connect the ground terminal to a good electrical earth ground. SELECT SUITABLE LOCATION INPUT CONNECTIONS Locate the machine where there is free circulation of clean air. Place the machine so that air can freely circulate 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 II. This machine carries an enclosure rating of IP21S. It should not be placed in extremely damp or dirty locations. It should not be exposed to rain or snow. STACKING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE IMMEDIATE FAILURE OF COMPONENTS 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. See figure A.1 for location of the rating plate. The Invertec STT II cannot be stacked. TILTING Place the machine on a secure, level surface otherwise the unit may topple over. Return to Section TOC A-4 The Invertec STT II should be connected only by a qualified electrician. Installation should be made in accordance with local and national codes. Refer to the “Technical Specifications” at 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 INSTALLATION AND CONNECTION”. INVERTEC STT 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). 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 section for the proper input cable sizes. Refer to Figure A.1 and perform the following steps: 1. Return to Master TOC Return to Section TOC 2. Remove the wraparound cover of the Invertec STT II. 5. Connect the three phase line conductors to the power switch terminals labeled U, V and W. Tighten the connections to 3.0 Nm. (27 in.-lb.) torque. 6. Securely tighten the cable strain relief located on the case back of the machine. GROUND CONNECTION 1. Connect the ground terminal to earth ground per National Electrical Code. Feed the input cable through the input cable entry access hole at the right rear of the machine. 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. 2. Replace the wraparound cover of the Invertec STT II. INVERTEC STT 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.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 (380415 VAC), for Codes 11115 and 11116. 1. For Connections to 440 or 460 VAC verify the internal configurations to the procedures shown below and refer to Figure A.2. Return to Master TOC Return to Section TOC 2. For Connections to 200,208,220,230,380,400 or 415 VAC follow the procedure shown below and refer to figure A.2. NOTE: Turn main power to the machine OFF before performing the reconnect procedure. Failure to do so will result in damage to the machine. DO NOT switch the reconnect bar with machine power ON. ------------------------------------------------------------------------ 460 or 440 VAC (Codes 11092 and around. below) Return to Master TOC 1. Open reconnect panel access door on wrap- 220 or 230 VAC (Codes 11092 and around. below) 1. Open reconnect panel access door on wrap- 200 or 208 VAC (Codes 11092 and around. below) 1. Open reconnect panel access door on wrap- 200 or 208 VAC (Codes 11115 and 11116) 1. Open reconnect panel access door on wrap-around. 2. Move input voltage switch to Voltage = 200 -230V position. 3. Move lead “A” to 200-208 Terminal. WARNING To Operate at Return to Section TOC 380,400 or 415 VAC (Codes 11115 and around. 11116) 380 or 415 VAC (Codes 11092 and around. below) Procedure 1. Open reconnect panel access door on wrap2. Move input voltage switch to Voltage = 380 -460V position. 3. Move lead “A” to 440-460 Terminal. 1. Open reconnect panel access door on wrap- 2. Move input voltage switch to Voltage = 380-460V position. 3. Move lead “A” to 380-415 Terminal. 2. Move input voltage switch to Voltage = 200 -230V position. 3. Move lead “A” to 220-230 Terminal. 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 the Accessories section of this manual for instructions on connecting a wire feeder to the Invertec STT II. The LN-742 or STT-10 wire feeder is the recommended feeder for use with the Invertec STT II. INVERTEC STT II Return to Master TOC Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION Operation...............................................................................................................................Section B Safety Precautions ......................................................................................................................B-2 General Description ....................................................................................................................B-3 Recommended Equipment..........................................................................................................B-3 Operating Controls ......................................................................................................................B-3 Design Features..........................................................................................................................B-3 Welding Capability ......................................................................................................................B-3 Limitations ...................................................................................................................................B-3 Welding Operation ......................................................................................................................B-5 Welding Parameters and Guidelines ..........................................................................................B-6 Recommended Settings for STT II..............................................................................................B-7 Return to Master TOC Return to Master TOC Return to Master TOC Operational Features and Controls.............................................................................................B-4 INVERTEC STT 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 Section TOC • 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. ARC RAYS can burn. Return to Master TOC Return to Section TOC • Wear eye, ear and body protection. Observe additional Safety Guidelines detailed in the beginning of this manual. INVERTEC STT B-2 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. The process is optimized for shortcircuiting GMAW welding. • Protection circuits and ample safety margins prevent damage to the solid state components from transient voltages and high currents. • Preset welding current capability. Return to Master TOC Return to Master TOC Return to Section TOC • STT II offers improvements over the previous model. Approximately 40% increase in deposition rate capability, and a significant increase in travel speed. RECOMMENDED EQUIPMENT WELDING CAPABILITY The LN-742 or STT-10 wire feeder is recommended for use with the STT II. The LN-7 GMA, LN-9 GMA, NA-5, and NA-5R can all be used with the STT II. However, these units can only be used to feed wire since these feeders have no provision for control of the STT output. The Invertec STT II 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. OPERATING CONTROLS LIMITATIONS The Invertec STT II has the following controls as standard: On/Off switch, Peak Current adjustment, Background Current adjustment, Hot Start adjustment, Tailout, and 2 toggle switches; one for wire size selection and one for wire type selection. DESIGN FEATURES AND ADVANTAGES Return to Section TOC B-3 • State of the art inverter technology yields high power efficiency, excellent welding performance, lightweight 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 temperatures, or loss of air flow. • May not be suitable for use in an environment with High Frequency present. (“See Machine Grounding and High Frequency Protection” in the Installation section of this manual) • Suitable for indoor use only (IEC IP21S). INVERTEC STT 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. This switch also controls auxiliary power available through the 14-pin Wire Feeder Receptacle. V ON OFF 2A. BACKGROUND CURRENT OUTPUT CONTROL: The output current is switched to the Background level at the conclusion of the preceding Peak Current pulse. This knob allows preset adjustment of the amplitude of the background current up to 125 amperes. 2B. BACKGROUND CURRENT DISPLAY METER: This is a digital meter for displaying the preset Background Current. This meter displays in 1 amp increments. This meter A does not indicate the actual welding current, only the preset current. 3A. PEAK CURRENT OUTPUT CONTROL: beginning portion of the welding arc is a pulse of current referred to as Peak Current. This knob allows preset adjustment of the amplitude of the peak current up to 450 amperes. The 3B. PEAK CURRENT DISPLAY METER: This is a digital meter for displaying the preset Peak Current. This meter displays in 1 amp increments. This meter does not indicate actual welding current only the preset current. A 4. HOT START CONTROL POTENTIOMETER: “Hot Start” provides approximately 25% to 50% more current during the initial start of the weld for improved arc starting and bead appearance. This control adjusts the duration of this “Hot Start” current. The control range is from 0 to 10, where 0 corresponds to the zero or no “Hot Start”, and 10 is maximum for a “Hot Start” lasting for about four (4) seconds. 5. TAILOUT: Alters the current waveform to increase deposit rate and travel speed. The Minimum setting sets STT II to the original STT waveform. As tailout is increased peak and Background current may need to be reduced to maintain optimum performance. INVERTEC STT 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. WIRE TYPE SELECT SWITCH: This toggle switch selects between mild or stainless steel. In the stainless 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 thermostat(s) or the FET over current sensor has 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 connector is automatically sensed, disabling the front panel Peak and Background Current controls. Refer to “REMOTE CONTROL CONNECTOR” in the ACCESSORIES Section of this manual for more information. 10. WIRE FEEDER RECEPTACLE: This is 14 pin MS-type connector for the wire feeder connection. 115 and 42 VAC along with the trigger switch connections are provided. (Only 42 VAC is available on European models). 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. B-5 13. 115V AUXILIARY POWER CIRCUIT BREAKER (Not on European Models): The 115 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. 14. WORK TERMINAL: This twist-mate connection is the negative output terminal for connecting 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 beginning to weld. Set the Wire Size and Wire Type selection switches per the appropriate wire. Refer to “Operational Features and Controls” in this section for the function of these switches. 11. ARC SENSE RECEPTACLE: This is a four pin MStype connector for WORK and ELECTRODE sense leads. The STT requires a WORK sense and ELECTRODE 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 connection 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. INVERTEC STT 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”). Wire sizes below .035” are unnecessary for most applications. The Invertec STT II is a current controlled machine which is capable of changing the electrode current quickly in order to respond 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. B-6 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 Note: Background Current levels for applications using 100% CO2 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% CO2 arc. (100% CO2 is 35 volts/cm and 100% Argon is 20 volts/cm. 75% Argon, 25% CO2 is about 24 volts/cm. Contact Tip to Work Distance 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 puddle agitation. Adjust Arc Length with Peak Current HOT START The Hot Start control can be set to enhance establishing 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. Note: In 100% CO2 shielding gas applications the peak current level should be set greater than in a corresponding application using a gas blend with a high percentage of Argon. Longer initial arc lengths with 100% CO2 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 transfer to occur resulting in increased spatter. 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 concentrated on the puddle. INVERTEC STT 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.2) DIRECTION OF TRAVEL DIRECTION OF TRAVEL 75° 75° TOP VIEW TOP VIEW DIRECTION OF TRAVEL Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 45° DIRECTION OF TRAVEL 45° 75° FRONT VIEW END VIEW END VIEW 14 ga 10 ga (2.0) (3.25) 0.045 0.045 (1.1) (1.1) 100 170 (2.5) (4.2) 260 280 40 65 7 5 105 120 12 12 (0.3) (0.3) 25 (12) 1/4 - 3/8 (6.4 - 10) Table B.2 75% CO2 - 25% Ar Gas Shield (Set for Steel Mode) Plate Thickness “ (mm) 20 ga (0.9) Electrode size “ (mm) 0.035 (0.9) WFS “/min (m/min) 100 (2.5) Peak Current 225 Background Current 40 Tailout setting 8 Average Amperage 70 Travel Speed “/min 12 (m/min) (0.3) Gas Flow cfh (L/min) Electrical Stickout “ (mm) Table B.3 90% He, 7.5% Ar, 2.5% CO2 FRONT VIEW Table B.1 100% CO2 Gas Shield (Set for Steel Mode) Plate Thickness “ (mm) 20 ga (0.9) Electrode size “ (mm) 0.035 (0.9) WFS “/min (m/min) 100 (2.5) Peak Current 220 Background Current 30 Tailout setting 3 Average Amperage 60 Travel Speed “/min 12 (m/min) (0.3) Gas Flow cfh (L/min) Electrical Stickout “ (mm) 75° 14 ga 10 ga (2.0) (3.25) 0.045 0.045 (1.1) (1.1) 100 120 (2.5) (3.0) 270 310 65 70 4 6 110 130 12 12 (0.3) (0.3) 25 (12) 1/4 - 3/8 (6.4 - 10) Gas Shield (Set for Steel Mode) Plate Thickness “ (mm) 20 ga (0.9) Electrode size “ (mm) 0.035 (0.9) WFS “/min (m/min) 100 (2.5) Peak Current 165 Background Current 35 Tailout setting 7 Average Amperage 40 Travel Speed “/min 12 (m/min) (0.3) Gas Flow cfh (L/min) Electrical Stickout “ (mm) 14 ga 10 ga (2.0) (3.25) 0.045 0.045 (1.1) (1.1) 130 170 (3.3) (4.2) 210 250 60 85 7 4 95 120 16 16 (0.4) (0.4) 25 (12) 1/4 - 3/8 (6.4 - 10) Table B.4 98% Ar, 2% O2 Gas Shield (Set for Stainless Steel Mode) Plate Thickness “ (mm) 20 ga (0.9) Electrode size “ (mm) 0.035 (0.9) WFS “/min (m/min) 100 (2.5) Peak Current 145 Background Current 45 Tailout setting 7 Average Amperage 60 Travel Speed “/min 12 (m/min) (0.3) Gas Flow cfh (L/min) Electrical Stickout “ (mm) INVERTEC STT 14 ga 10 ga (2.0) (3.25) 0.045 0.045 (1.1) (1.1) 130 170 (3.3) (4.2) 190 280 95 95 8 7 120 150 12 12 (0.3) (0.3) 25 (12) 1/4 - 3/8 (6.4 - 10) 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 ...................................................................................................................C-4 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section C-1 INVERTEC STT 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 REMOTE RECEPTACLE (For optional remote interface, Connection to the STT-10 Wire Feeder or Robotic Control) Return to Section TOC C-2 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) current 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 “B” are shorted together This “short circuit” tells the STT control board to accept PEAK and BACKGROUND inputs on this connector rather than from the front panel controls. If this short is removed, the front panel controls will be active. By adding a switch between pins “J” and “B” a “LOCAL/REMOTE” control 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 “G” with + applied to pin “G”. The BACKGROUND CURRENT is controlled with a similar signal applied between pins “A” and “C” with + applied to pin “C”. 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 “F”. 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 + ARC Return to Master TOC Return to Section TOC J19 1 J37 - ARC 223 Return to Master TOC 1 (+) 2 291 3 (-) 2 3 SENSE CONNECTION 4 4 J38 3 J 2 B 1 C 10 G 9 A 4 12 D 8 4 F 5 11 H 212C 6 43A 1 33C 32C 212B Return to Section TOC 290 VOLTAGE J38 3 E 2 I 7 8 290A BG 10K PB TRIGGER 10K GND OPTIONAL REMOTE INTERFACE WIRE FEEDER J39 N ELECTRODE SENSE LEAD PORTION OF G3136 WIRING DIAGRAM REFER TO ACTUAL DIAGRAM PASTED INSIDE YOUR MACHINE INVERTEC STT 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. Connect the electrode lead (Twist-Mate) to (+) output terminal on STT II. 4. Connect the other end of electrode lead (Step #3) and 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. ELECTRIC SHOCK can kill. Return to Section TOC C-3 • Turn the input power OFF at the disconnect switch or fuse box before connecting the wire feeder 1. Turn the Invertec STT II power off. 2. Connect the ARC SENSE LEAD MS connector to the mating connector on STT II front panel. 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 II. 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 II. WARNING Turn off input power to the Welding Power source using the disconnnect switch at the fuse box before connecting the wire feeder. Return to Master TOC Return to Section TOC ELECTRIC SHOCK CAN KILL CONTROL, ELECTRODE, ARC SENSE "ELECT" AND ARC SENSE "WORK" CABLES SHOULD BE TAPED TOGETHER. REMOTE RECEPTACLE Only qualified persons should install, use or service this machine. WIRE FEEDER LN 742 LN7 GMA LN9 GMA NA5R NA5 WIRE FEEDER CONTROL CABLE WORK LEAD ELECTRODE LEAD ARC SENSE LEAD ’ELECT" Return to Master TOC Return to Section TOC WORK 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.) CRM after 6-10-96 M17657 FIGURE C.2 LN-742 to STT II CONNECTION INVERTEC STT 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. ELECTRODE LEAD Return to Master TOC ELECTRODE LEAD Return to Section TOC WIRE FEEDER STT-10 ELECTRODE SENSE LEAD IS BOLTED TOGETHER WITH ELECTRODE LEAD ON THE WIRE FEEDER CONTACT BLOCK WIRE FEEDER REMOTE ARC SENSE LEAD "WORK" WORK (SHOULD BE LOCATED AS CLOSE AS POSSIBLE TO THE WELDING ARC) 4-9-99 M17657-3 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FIGURE C.3 STT-10 to STT II CONNECTION INVERTEC STT Section D-1 TABLE OF CONTENTS -MAINTENANCEMaintenance .........................................................................................................................Section D Input Filter Capacitor Discharge Procedure................................................................................D-2 Preventive Maintenance .............................................................................................................D-3 Major Component Locations .......................................................................................................D-4 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 INVERTEC STT 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. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This resistor is not supplied with machine. NEVER USE A SHORTING STRAP FOR THIS PROCEDURE. 5. Locate the two capacitor terminals (large hex head cap screws) shown in Figure D.1. 6. 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. 7. Repeat discharge procedure for capacitor on other side of machine. 8. 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 capacitor discharge procedure. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS. INVERTEC STT D-2 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. Remove the machine wraparound cover and perform the input filter capacitor discharge procedure (detailed at the beginning 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 • Lower base compartment 4. Examine capacitors for leakage or oozing. Replace if needed. 5. 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. 6. Check electrical ground continuity. Using an ohmmeter, measure resistance between either output stud and an unpainted 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. • Input Rectifier 7. Replace machine cover and screws. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC • Heat Sink Fins INVERTEC STT D-3 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 12 Return to Section TOC D-4 MAINTENANCE Return to Master TOC Return to Section TOC D-4 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 4 6 9 5 8 10 17 15 Return to Master TOC Return to Section TOC 7 16 2 18 13 19 3 Return to Master TOC Return to Section TOC 14 1 11 INVERTEC STT 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 Reconnect, Protection Board, Rectification and Precharge ..................................................E-3 Switch Boards........................................................................................................................E-4 Main Transformer, Output Rectification and Choke...............................................................E-5 Control Board, IGBT Drive and Module.................................................................................E-6 Power Board ..........................................................................................................................E-7 Remote Protection Board ......................................................................................................E-7 Field Effect Transistor (FET) Operation.................................................................................E-8 Return to Master TOC Pulse Width Modulation .........................................................................................................E-9 Minimum Output ..............................................................................................................E-9 Maximum Output .............................................................................................................E-9 Protective Circuits................................................................................................................E-10 Overload Protection.......................................................................................................E-10 Thermal Protection ........................................................................................................E-10 POSITIVE OUTPUT TERMINAL MAIN TRANSFORMER T2 Return to Master TOC S W I T C H LINE SWITCH FET CAP FET B O A R D INPUT RECTIFIER R E C O N N E C T "A" LEAD 115 VAC TRANS T4 18 VAC 2 4 V A C T H E R M O S T A T P O W E R B O A R D B O A R D D R I V E R B O A R D D R I V E CURRENT TRANS T3 S I G N A L PRE CHARGE S W I T C H FET CAP FET B O A R D CURRENT FEEDBACK LESS THAN 1VDC PULSE TRANSFORMER SIGNAL PWM SIGNAL 15VDC GUN TRIGGER IGBT DRIVER BOARD CONTROL BOARD 36VAC VOLTAGE FEEDBACK Return to Master TOC IGBT MODULE BACKPEAK TAILOUT CURRENT GROUND CONTROL METER METER (STT II ONLY) NEGATIVE OUTPUT TERMINAL CHOKE P R O T E C T I O N CR2 TRANS T1 CURRENT SENSOR PRE CHARGE CR1 FAN 1 OHM WIRE BACKPEAK HOT SIZE GROUND CURRENT START CONTROL CONTROL CONTROL SWITCH WIRE TYPE SWITCH 10VAC AND 6VAC 42VAC FIGURE E.1 – INVERTEC STT INVERTEC STT R E M O T E P R O T E C T I O N VOLTAGE SENSING RECEPTACLE B O A REMOTE CONTROL RECEPTACLE R D WIRE FEEDER RECEPTACLE E-2 THEORY OF OPERATION Return to Master TOC Return to Section TOC E-2 FIGURE E.2 – INPUT VOLTAGE POSITIVE OUTPUT TERMINAL MAIN TRANSFORMER T2 S W I T C H LINE SWITCH Return to Master TOC FET B O A R D CURRENT SENSOR INPUT RECTIFIER R E C O N N E C T "A" LEAD TRANS T1 115 VAC TRANS T4 18 VAC 2 4 V A C T H E R M O S T A T P O W E R B O A R D P R O T E C T I O N B O A R D D R I V E R B O A R D D R I V E CURRENT TRANS T3 S I G N A L PRE CHARGE S W I T C H FET CAP FET NEGATIVE OUTPUT TERMINAL CHOKE CR2 FAN IGBT MODULE PRE CHARGE CR1 Return to Section TOC FET CAP 1 OHM B O A R D R E M O T E P R O T E C T I O N VOLTAGE SENSING RECEPTACLE B O A REMOTE CONTROL RECEPTACLE R D WIRE FEEDER RECEPTACLE CURRENT FEEDBACK LESS THAN 1VDC PULSE TRANSFORMER SIGNAL PWM SIGNAL 15VDC GUN TRIGGER IGBT DRIVER BOARD CONTROL BOARD 36VAC VOLTAGE FEEDBACK BACKPEAK TAILOUT CURRENT GROUND CONTROL METER METER (STT II ONLY) WIRE BACKPEAK HOT SIZE GROUND CURRENT START CONTROL CONTROL CONTROL SWITCH WIRE TYPE SWITCH 10VAC AND 6VAC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 42VAC GENERAL DESCRIPTION INPUT VOLTAGE The Invertec STT is a 225 ampere, inverter based, arc welding power supply specifically designed for the Surface Tension Transfer (STT) welding process. It cannot be classified as either a constant current (CC) or a constant voltage (CV) machine. The STT produces current of a desired waveform to reduce spatter and fumes. The STT process is optimized for short circuit GMAW welding only. 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 external wire feeder. 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 Return to Master TOC Return to Section TOC E-3 E-3 THEORY OF OPERATION FIGURE E.3 – RECONNECT, PROTECTION BOARD, RECTIFICATION AND PRECHARGE POSITIVE OUTPUT TERMINAL MAIN TRANSFORMER T2 S W I T C H LINE SWITCH Return to Master TOC FET B O A R D INPUT RECTIFIER R E C O N N E C T "A" LEAD TRANS T1 115 VAC TRANS T4 18 VAC 2 4 V A C T H E R M O S T A T IGBT MODULE P O W E R B O A R D B O A R D D R I V E R B O A R D D R I V E CURRENT TRANS T3 S I G N A L PRE CHARGE S W I T C H FET CAP FET NEGATIVE OUTPUT TERMINAL CHOKE P R O T E C T I O N CR2 FAN CURRENT SENSOR PRE CHARGE CR1 Return to Section TOC FET CAP 1 OHM B O A R D R E M O T E P R O T E C T I O N CURRENT FEEDBACK LESS THAN 1VDC PULSE TRANSFORMER SIGNAL PWM SIGNAL 15VDC GUN TRIGGER IGBT DRIVER BOARD CONTROL BOARD 36VAC VOLTAGE FEEDBACK BACKPEAK TAILOUT CURRENT GROUND CONTROL METER METER (STT II ONLY) WIRE BACKPEAK HOT SIZE GROUND CURRENT START CONTROL CONTROL CONTROL SWITCH WIRE TYPE SWITCH 10VAC AND 6VAC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 energized, connecting full input power to the input filter capacitors. The protection board monitors the capacitors for voltage balance and/or overvoltage and will deenergize the input relays and precharge circuitry if either occurs. The machine output will be disabled. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. INVERTEC STT VOLTAGE SENSING RECEPTACLE B O A REMOTE CONTROL RECEPTACLE R D WIRE FEEDER RECEPTACLE FIGURE E.4 – SWITCH BOARDS POSITIVE OUTPUT TERMINAL MAIN TRANSFORMER T2 S W I T C H LINE SWITCH FET CAP FET Return to Master TOC B O A R D R E C O N N E C T "A" LEAD TRANS T1 115 VAC TRANS T4 18 VAC 2 4 V A C T H E R M O S T A T CURRENT SENSOR IGBT MODULE P O W E R B O A R D B O A R D D R I V E R B O A R D D R I V E CURRENT TRANS T3 S I G N A L PRE CHARGE S W I T C H FET CAP FET NEGATIVE OUTPUT TERMINAL CHOKE P R O T E C T I O N CR2 FAN 1 OHM PRE CHARGE INPUT RECTIFIER CR1 Return to Section TOC E-4 THEORY OF OPERATION Return to Master TOC Return to Section TOC E-4 B O A R D R E M O T E P R O T E C T I O N CURRENT FEEDBACK LESS THAN 1VDC PULSE TRANSFORMER SIGNAL PWM SIGNAL 15VDC GUN TRIGGER IGBT DRIVER BOARD CONTROL BOARD 36VAC VOLTAGE FEEDBACK BACKPEAK TAILOUT CURRENT GROUND CONTROL METER METER (STT II ONLY) WIRE BACKPEAK HOT SIZE GROUND CURRENT START CONTROL CONTROL CONTROL SWITCH WIRE TYPE SWITCH 10VAC AND 6VAC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 42VAC 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 flow. See Field Effect Transistor (FET) Operation discussion and diagrams. See Figure E.4. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. INVERTEC STT VOLTAGE SENSING RECEPTACLE B O A REMOTE CONTROL RECEPTACLE R D WIRE FEEDER RECEPTACLE FIGURE E.5 – MAIN TRANSFORMER, OUTPUT RECTIFICATION AND CHOKE POSITIVE OUTPUT TERMINAL MAIN TRANSFORMER T2 S W I T C H LINE SWITCH Return to Master TOC FET CAP FET B O A R D INPUT RECTIFIER R E C O N N E C T "A" LEAD TRANS T1 115 VAC TRANS T4 18 VAC 2 4 V A C T H E R M O S T A T CURRENT SENSOR IGBT MODULE P O W E R B O A R D B O A R D D R I V E R B O A R D D R I V E CURRENT TRANS T3 S I G N A L PRE CHARGE S W I T C H FET CAP FET NEGATIVE OUTPUT TERMINAL CHOKE P R O T E C T I O N CR2 FAN 1 OHM PRE CHARGE CR1 Return to Section TOC E-5 THEORY OF OPERATION Return to Master TOC Return to Section TOC E-5 B O A R D R E M O T E P R O T E C T I O N VOLTAGE SENSING RECEPTACLE B O A REMOTE CONTROL RECEPTACLE R D WIRE FEEDER RECEPTACLE CURRENT FEEDBACK LESS THAN 1VDC PULSE TRANSFORMER SIGNAL PWM SIGNAL 15VDC GUN TRIGGER IGBT DRIVER BOARD CONTROL BOARD 36VAC VOLTAGE FEEDBACK BACKPEAK TAILOUT CURRENT GROUND CONTROL METER METER (STT II ONLY) WIRE BACKPEAK HOT SIZE GROUND CURRENT START CONTROL CONTROL CONTROL SWITCH WIRE TYPE SWITCH 10VAC AND 6VAC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 42VAC 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 transformer. The opposite directions of current 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 transformer. 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 stabilizer output choke, current sensor, IGBT module and remote protection board to the output terminals. 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 needed due to the inductance of the transformer primary windings. The cross coupling of the primaries along with the clamping action of the diode maintain capacitor balance when they are connected in the series (high voltage) input configuration. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. INVERTEC STT FIGURE E.6 – CONTROL BOARD, IGBT DRIVE AND MODULE POSITIVE OUTPUT TERMINAL MAIN TRANSFORMER T2 S W I T C H LINE SWITCH Return to Master TOC FET CAP FET B O A R D R E C O N N E C T "A" LEAD TRANS T1 115 VAC TRANS T4 18 VAC 2 4 V A C T H E R M O S T A T CURRENT SENSOR IGBT MODULE P O W E R B O A R D B O A R D D R I V E R B O A R D D R I V E CURRENT TRANS T3 S I G N A L PRE CHARGE S W I T C H FET CAP FET NEGATIVE OUTPUT TERMINAL CHOKE P R O T E C T I O N CR2 FAN 1 OHM PRE CHARGE INPUT RECTIFIER CR1 Return to Section TOC E-6 THEORY OF OPERATION Return to Master TOC Return to Section TOC E-6 B O A R D R E M O T E P R O T E C T I O N VOLTAGE SENSING RECEPTACLE B O A REMOTE CONTROL RECEPTACLE R D WIRE FEEDER RECEPTACLE CURRENT FEEDBACK LESS THAN 1VDC PULSE TRANSFORMER SIGNAL PWM SIGNAL 15VDC GUN TRIGGER IGBT DRIVER BOARD CONTROL BOARD 36VAC VOLTAGE FEEDBACK BACKPEAK TAILOUT CURRENT GROUND CONTROL METER METER (STT II ONLY) WIRE BACKPEAK HOT SIZE GROUND CURRENT START CONTROL CONTROL CONTROL SWITCH WIRE TYPE SWITCH 10VAC AND 6VAC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 42VAC 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 data is processed and the suitable PWM signal is sent to the power board. (See Pulse Width Modulation discussion). The control board also determines when the IGBT module should be switched OFF to reduce weld spatter and fumes. The appropriate signal is sent to the IGBT drive board which then applies, or removes, the gate drive signal to the IGBT module. When the IGBT module is in the OFF state, the welding current must pass through the one ohm resistance. This reduces the current and, subsequently, spatter and fumes. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. INVERTEC STT FIGURE E.7 – POWER BOARD AND REMOTE PROTECTION BOARD POSITIVE OUTPUT TERMINAL MAIN TRANSFORMER T2 S W I T C H LINE SWITCH Return to Master TOC FET CAP FET B O A R D R E C O N N E C T "A" LEAD TRANS T1 115 VAC TRANS T4 18 VAC 2 4 V A C T H E R M O S T A T CURRENT SENSOR IGBT MODULE P O W E R B O A R D B O A R D D R I V E R B O A R D D R I V E CURRENT TRANS T3 S I G N A L PRE CHARGE S W I T C H FET CAP FET NEGATIVE OUTPUT TERMINAL CHOKE P R O T E C T I O N CR2 FAN 1 OHM PRE CHARGE INPUT RECTIFIER CR1 Return to Section TOC E-7 THEORY OF OPERATION Return to Master TOC Return to Section TOC E-7 B O A R D R E M O T E P R O T E C T I O N VOLTAGE SENSING RECEPTACLE B O A REMOTE CONTROL RECEPTACLE R D WIRE FEEDER RECEPTACLE CURRENT FEEDBACK LESS THAN 1VDC PULSE TRANSFORMER SIGNAL PWM SIGNAL 15VDC GUN TRIGGER IGBT DRIVER BOARD CONTROL BOARD 36VAC VOLTAGE FEEDBACK BACKPEAK TAILOUT CURRENT GROUND CONTROL METER METER (STT II ONLY) WIRE BACKPEAK HOT SIZE GROUND CURRENT START CONTROL CONTROL CONTROL SWITCH WIRE TYPE SWITCH 10VAC AND 6VAC Return to Master TOC Return to Section TOC 42VAC POWER BOARD REMOTE PROTECTION BOARD The power board creates a pulse transformer drive signal, which is derived from the PWM signal received from the control board. See Pulse Width Modulation 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) Operation. The remote protection board provides noise suppression and by-pass filtering to protect the internal circuitry of the STT machine. Return to Master TOC Return to Section TOC The power board supplies a 15VDC supply voltage for the control board and also powers the input relays (CR1 and CR2). NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. INVERTEC STT 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. FETs are semiconductors well suited for high-frequency switching. Return to Section TOC E-8 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 connected to the drain terminal will allow the FET to conduct 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 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. 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 output signal possible over a 50-microsecond time period. 1 The positive portion of the signal represents one FET group1 conducting for 1 microsecond. The negative portion is the other FET group1. The dwell time (off time) is 48 microseconds (both FET groups off). Since only 2 microseconds of the 50-microsecond time period is devoted to conducting, the output power is minimized. 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. A FET group consists of the sets of FET modules grouped onto one switch board. INVERTEC STT 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. 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 thermostat will prevent output voltage or current. The meter will remain on during this time. (In addition, the yellow thermo LED will light.) Return to Master TOC Return to Section TOC 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 protection 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. In the event that the capacitor voltage is too high, the protection circuit will prevent output. The protection circuit may prevent output, if any of these circumstances occur: 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. 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 Return to Section TOC Return to Master TOC Return to Master TOC 4. Improper connections Return to Section TOC E-10 INVERTEC STT 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 .................................................................................................F4 - F-12 Test Procedures ...................................................................................................................F-13 T1 Auxiliary Transformer Test........................................................................................F-13 T4 Auxiliary Transformer Test........................................................................................F-19 Input Rectifier Test.........................................................................................................F-25 Capacitor Balance Test .................................................................................................F-29 Switch Board Test..........................................................................................................F-33 Snubber Resistors Test .................................................................................................F-37 Power Board Test ..........................................................................................................F-41 Protection Board Test ....................................................................................................F-45 Trigger Circuit Test ........................................................................................................F-49 Replacement Procedures ....................................................................................................F-53 IGBT Module Removal and Replacement.....................................................................F-53 Switch Board Replacement ...........................................................................................F-59 Capacitor Removal and Replacement Procedure.........................................................F-65 Output Rectifier Removal and Replacement.................................................................F-73 Return to Master TOC Return to Master TOC Retest After Repair...............................................................................................................F-77 INVERTEC STT 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. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into two main categories: Output Problems, and Welding Problems. Return to Master TOC Return to Section TOC 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 subject 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. All of the referred to test points, components, terminal strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram. OSCILLOSCOPE WARNING WARNING Return to Master TOC Return to Section TOC 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 present, 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. INVERTEC STT F-2 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. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure: Return to Master TOC Return to Section TOC • If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete. • If you return a PC Board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis. 4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board. NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature. 2. Check for loose connections at the PC board to assure that the PC board is properly connected. 5. Remove the replacement PC board and substitute it with the original PC board to recreate the original problem. a. If 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 terminal strips. PC Board can be damaged by static electricity. ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations Reusable Container Do Not Destroy Return to Master TOC • 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. 1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom. 3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures: Return to Section TOC F-3 • Remove your body’s static charge before opening the static-shielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame. • If you don’t have a wrist strap, touch an unpainted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time. b. If the original problem is recreated by substitution of the original board, then PC board was the problem. Reinstall replacement PC board and test machine. the the the the 6. Always indicate that this procedure was 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 PROBLEM,” will help avoid denial of legitimate PC board warranty claims. • Tools which come in contact with the PC Board must be either conductive, anti-static or static-dissipative. INVERTEC STT 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. Contact the Lincoln Electric Service Department, 1-888-9353877. Machine has no open circuit voltage. Wire feeds OK. 1. Check the control cable between the feeder and the STT unit. Make sure the #2 and #4 leads are intact. 1. Perform the T1 Transformer Test. Auxiliary 2. Perform the T4 Transformer Test. Auxiliary 2. Put a jumper wire between Pins "C" and "D" on the 14 pin amphenol. If normal open circuit voltage (85VDC) is restored, the problem is in the feeder control cable or the wire feeder. 3. Make sure the reconnect switch S7 is in the correct position for the three-phase input voltage being applied. Return to Section TOC F-4 CAUTION Do not switch reconnect switch with input power applied to machine. 3. Perform the Power Board Test. 4. Perform the Trigger Circuit Test. 5. Perform Capacitor Balance Test. 6. Perform the Protection Board Test. 7. Perform the Switch Board Test. 8. Check for loose or broken connections on the heavy current carrying conductors (i.e., main transformer, choke, output diodes, IGBT module and output terminals). 9. 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, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. INVERTEC STT 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. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Machine has no welding output (no open circuit voltage), and the wire feeder does not feed wire when the gun trigger is pulled. 1. The 42VAC circuit breaker CB1 may be tripped. Reset if necessary. 2. Check the 4 amp slow blow fuse located on the reconnect panel. Replace if faulty. 3. 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. 4. 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. 1. If 42VAC is NOT present at pins "K" and "I" on the 14 pin amphenol, perform the T1 Auxiliary Transformer Test. 2. Check leads #43 and #212C for loose or faulty connections between the T1 auxiliary transformer and the remote protection board. See the Wiring Diagram. Also check the continuity through the remote protection board to the 14 pin amphenol. 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, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. INVERTEC STT 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. With input power removed, check the continuity of the 4 amp slow blow fuse located on the reconnect panel. No output or reduced output the first time power is applied to the machine. Return to Section TOC 1. The input power switch (S1) may be faulty. Check or replace. 3. With input power removed, check that the input voltage setup switch and jumper "A" (the reconnect auxiliary jumper) are in the proper position for the input voltage being used. Return to Master TOC Return to Section TOC 2. Check the input voltage. Make sure all three phases are applied to the machine. Return to Section TOC F-6 1. Check input voltages, fuses and input voltage reconnect procedures. See the Installation section. 1. Contact the Lincoln Electric Service Department. 1-888-9353877. 2. If high input voltage (380VAC or higher) is applied, the capacitors may need conditioning. Let the "unloaded" machine idle for 30 minutes. 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. Call 1-888-935-3877. INVERTEC STT 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. Machine output returns after a few seconds and trigger is pulled again. The thermal indicator light is lit. 1. With the input power removed, inspect input leads for possible shorts or grounds or misconnections. 1. Check the input power switch (S1) and the reconnect switch for "shorted" or "grounded" wires or connections. 2. Install new fuses and reapply power. If fuses open again, contact your local Lincoln Authorized Field Service Facility. 2. Perform the Input Rectifier Test. 1. The overcurrent sensor is activated, indicating that too much output current is being drawn from the machine. Reduce welding current demands or remove the "fault" in welding cables. 1. The current sensor may be faulty. 3. Perform the Switch Board Test. 2. The control PC board may be faulty. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 2. Make sure that the gun tip is not "shorted" to the work surface and that the proper welding procedures are being used. 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. Call 1-888-935-3877. INVERTEC STT 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 Section TOC F-8 1. Check to make sure the fan is running and operating correctly. 2. Welding application exceed recommended cycle. may duty 1. The IGBT heat sink thermostat or fan thermostat may be defective. Check or replace. 3. Dirt and dust may have clogged the cooling channels. Blow out the unit with clean, dry compressed air. 4. Air intake and exhaust louvers may be blocked due to inadequate clearance around the machine. 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. Call 1-888-935-3877. INVERTEC STT 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 Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 2. Check the gun and nozzle for leaks or obstructions. 3. 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 perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. INVERTEC STT 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. Adjust for optimum welding performance. 2. Make sure the Wire Type and Wire Size switches are in the correct position for the electrode wire being used. 1. Check for the correct open circuit voltage (approximately 85VDC). If the correct open circuit 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 current carrying conductors (i.e., main transformer, choke, output diodes, IGBT module and output terminals). 2. If the correct open circuit voltage is NOT present, perform the Switch Board Test. 3. The output diodes may be faulty. Check or replace if necessary. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4. The driver PC board and or control PC board may be faulty. 5. 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, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. INVERTEC STT 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 Master TOC Return to Section TOC Return to Section TOC 2. The Peak Current or Background Setting may be too high. Adjust for optimum welding performance. Return to Section TOC F-11 1. The IGBT module may be faulty. Check or replace. 2. The IGBT driver PC board may be faulty. 3. The control PC board may be faulty. 3. The Tailout may not be set correctly for the process. (STT II Only) 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. Call 1-888-935-3877. INVERTEC STT 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. 2. Make sure the Arc Sense "WORK" lead is as close as possible to the welding arc. 2. The IGBT driver PC board may be faulty. 3. Make sure the machine and wire feed settings are correct for the process and wire being used. Poor welding, weld settings drift, or output power is low. 3. The control PC board may be faulty. 1. Make sure the machine settings are correct for the welding process being used. 1. The current sensor may be faulty. Check associated leads for loose or faulty connections. 2. Check the welding cables for loose or faulty connections. 2. The control PC board may be faulty. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 3. Make sure the reconnect 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. 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. Call 1-888-935-3877. INVERTEC STT 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. 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. Call 1-888-935-3877 Return to Master TOC Return to Section TOC Return to Section TOC F-13 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. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 II models INVERTEC STT F-13 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. Perform the Input Filter Discharge Procedure. Maintenance section. 4. Locate the T1 auxiliary transformer and secondary lead molex plugs (J30 and J31) on the left side, just in front of the main transformer assembly. Check for broken or loose wires. See Figure F.1. Capacitor See the WARNING Return to Master TOC Return to Section TOC ELECTRIC SHOCK can kill. • Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. INVERTEC STT F-14 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. See Figure F.2. 6. Disconnect plugs J30 and J31 from the wiring harness. 7. Apply the correct input power to the machine and test for the correct secondary voltages at plugs J30 and J31. (Make sure the reconnect panel is configured properly for the input voltage being applied.) 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. INVERTEC STT F-15 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. 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 Figure F.2. 14. Before applying input power make certain the reconnect panel assembly is insulated and supported for safe operation. Return to Master TOC Return to Section TOC WARNING ELECTRIC SHOCK can kill. • Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TABLE F.1 – T1 AUXILIARY TRANSFORMER VOLTAGES TEST POINTS NORMAL VOLTAGE PLUG J30 PINS 1 TO 2 (LEADS 32 TO 33) 115VAC PLUG J31 PINS 1 TO 4 (LEADS 501 TO 504) 18VAC PLUG J31 PINS 2 TO 3 (LEADS 212 TO 503) 24VAC PLUG J31 PINS 2 TO 5 (LEADS 212 TO 43A) 42VAC PLUG J21 PINS 1 TO 4 (LEADS H1 TO H2) 200/208VAC PLUG J21 PINS 1 TO 2 (LEADS H1 TO H3) 220/230VAC PLUG J21 PINS 1 TO 3 (LEADS H1 TO H4) 380/415VAC PLUG J21 PINS 1 TO 6 (LEADS H1 TO H5) (H6) 440/460VAC NOTE: If the main AC input supply voltage varies, the auxiliary transformer voltages will vary by the same percentages. INVERTEC STT F-16 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. If the correct AC input voltages are applied to the primary windings and any or all of the secondary voltages are missing or not correct, the T1 auxiliary transformer may be faulty. 17. After all tests are complete, reconnect plugs J30 and J31. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 18. Install the case wraparound cover. INVERTEC STT F-17 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 Master TOC Return to Section 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 troubleshooting 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 Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt/Ohmmeter (Multimeter) Invertec STT Wiring Diagrams Isolated 115VAC supply 5/16" Nut driver 7/16" Wrench Note: Component locations and disassembly procedures may vary slightly on STT II models INVERTEC STT F-19 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. • Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. Using the 5/16" nut driver, remove the case wraparound cover. Return to Master TOC 3. Perform the Input Filter Capacitor Discharge Procedure. See the Maintenance section. Return to Section TOC F-20 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, disconnect the lead splice. Thread the lower lead down into the lower tray assembly area. See Figure F.3. INVERTEC STT 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.5 – PLUG J22 LOCATION Return to Master TOC Return to Section TOC PLUG J22 6. Locate and disconnect plug J22 from the wiring harness. See Figure F.5. INVERTEC STT F-21 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. Using the 7/16" wrench, remove the five bolts holding the lower tray assembly to the case bottom. 10. Locate and remove plug J13 from the IGBT drive board. See Figure F.7. FIGURE F.7 – PLUG J13 LOCATION IGBT DRIVE BOARD PLUG J13 T4 AUXILIARY TRANSFORMER STT II INVERTEC STT F-22 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. Carefully apply the 115VAC isolated supply to the T4 transformer at the #32 and #33 tabs. WARNING ELECTRIC SHOCK can kill. Return to Master TOC Return to Section TOC • With input power ON, there are high voltages inside the machine. Do not reach into the machine or touch any internal part. INVERTEC STT F-23 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.2 – T4 AUXILIARY TRANSFORMER VOLTAGES TEST POINTS NORMAL VOLTAGES PLUG J13 PINS 5 TO 6 6VAC PLUG J13 PINS 2 TO 3 10VAC PLUG J22 PINS 1 TO 2 (LEADS 240 TO 241) 18VAC PLUG J22 PINS 2 TO 9 (LEADS 241 TO 242) 18VAC PLUG J22 PINS 3 TO 4 (LEADS 243 TO 244) 18VAC PLUG J22 PINS 12 TO 13 (LEADS 245 TO 246) 18VAC 13. Check the secondary AC voltages according to Table F.2. 15. After all tests are completed, reconnect the following: 14. With the correct 115VAC applied to the primary winding (#32 to #33), if any or all of the secondary voltages are missing or low, the T4 auxiliary transformer may be faulty. Replace the T4 auxiliary transformer. Leads #32A, #32B, #33A, #33B to the T4 transformer tabs Plug J13 to the IGBT drive board 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. Return to Master TOC Return to Section TOC 16. Install the case wraparound cover. INVERTEC STT F-24 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. Return to Master TOC Return to Section 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 troubleshooting 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. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5/16" Nut driver Analog Voltmeter/ohmmeter (Multimeter) Inverter STT Wiring Diagrams Note: Component locations and disassembly procedures may vary slightly on STT II models INVERTEC STT F-25 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. Using the 5/16" nut driver, remove the case wraparound cover. 6. Use an ANALOG ohmmeter to perform the tests shown in Table F.3. 3. Perform the Input Filter Discharge procedure. Maintenance section. Capacitor See the WARNING ELECTRIC SHOCK can kill. Return to Master TOC Return to Section TOC • Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. INVERTEC STT F-26 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.3 – INPUT RECTIFIER TEST TEST POINTS +PROBE -PROBE ACCEPTABLE METER READING 9 9 9 A B C Greater than 100K ohms Greater than 100K ohms Greater than 100K ohms A B C 9 9 9 Less than 100 ohms Less than 100 ohms Less than 100 ohms 12 12 12 A B C Less than 100 ohms Less than 100 ohms Less than 100 ohms A B C 12 12 12 Greater than 100K ohms Greater than 100K ohms Greater than 100K ohms 6. Replace the input rectifier when any of the tests are NOT OK. 8. Test capacitors C1 and C2 and replace both capacitors if either is faulty. NOTE: When installing a new input rectifier, torque the mounting nuts (in a cross-tightening pattern) to 6 inch-pounds (.7 Nm). Torque terminals to 26 inch-pounds (3 Nm). PROCEED TO STEP 7 TO CHECK RELATED COMPONENTS. NOTE: Faulty capacitors could be the reason for input rectifier failure. 7. Inspect main power switch S1 and replace if faulty. Go to step 8. Visually inspect the capacitors for leakage, damage, etc., and use appropriate test equipment to determine component integrity. 9. Perform the Switch Board Test. 10. After all tests are completed, install the case wraparound cover. INVERTEC STT F-27 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 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 troubleshooting 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 functioning properly. MATERIALS NEEDED 5/16" Nut driver Analog Volt/ohmmeter (Multimeter) Note: Component locations and disassembly procedures may vary slightly on STT II models INVERTEC STT F-29 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. • 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. SWITCH 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 measured between each switch board, the capacitive balance is OK. This indicates that capacitors C1, C2, and resistors R1 and R9 are functioning properly. Proceed to Step #5. B. If more than 25VDC difference is measured between each switch board, test each of the following components: Capacitors C1, C2 and resistors R1 and R9. See the Invertec STT Wiring Diagram. INVERTEC STT F-30 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. After all tests are completed, remove the jumper between pins C and D on the 14-pin amphenol. 6. Jumper together pins "C" and "D" on the 14 pin amphenol. This will energize the output terminals. 9. Install the case wraparound cover. 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. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC A. If less than 15VDC difference is measured between each switch board, the test is OK. B. If more than 15VDC difference is measured between each switch board, the switch board(s) and or power PC board may be faulty. Perform the Switch Board Test. Perform the Power Board Test. INVERTEC STT F-31 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 Master TOC Return to Section 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 troubleshooting 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. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Analog Volt/ohmmeter (Multimeter) 5/16" Nut driver Note: Component locations and disassembly procedures may vary slightly on STT II models INVERTEC STT F-33 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). The internal board circuitry processes the signals and outputs them to the FETs. The switch board circuitry contains snubber circuitry to protect the FETs. This protection is supplemented by offboard resistors. The switch board design accommodates the connection point(s) for the capacitor(s), main transformer primary windings, input rectifier, and reconnect switches. 1. Turn off Invertec STT and disconnect main AC input power to the machine. Return to Master TOC Return to Section TOC 2. Using the 5/16" nut driver, remove the case wraparound cover. 3. Perform the Input Filter Discharge Procedure. Maintenance section. Capacitor See the ELECTRIC SHOCK can kill. • 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 resistance tests detailed in Table F.5 and shown in Figure F.11. If any test fails, replace both switch boards. See the Switch Board Removal and Replacement procedure. 7. If the switch boards appear to be burned or 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 F-34 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-35 SWITCH BOARD TEST (continued) TABLE F.5 – SWITCH BOARD RESISTANCE TEST Apply Positive Test Probe to Terminal 1/8 12 9 4/5 Return to Master TOC Return to Section TOC 1/8 9 12 Return to Master TOC 4/5 Return to Section TOC TROUBLESHOOTING & REPAIR F-35 Apply Negative Test Probe to Terminal Test Result Conclusion Repair Action 12 Greater than OK None 1K ohm 1/8 4/5 9 9 1/8 4/5 12 Next Procedure Notes Continue Less than 100 ohms Shorted Replace both switch boards Snubber Test Less than 100 ohms OK None Continue Greater than Open 1K ohm Replace both switch boards Snubber Test Greater than OK 1K ohm None Continue Less than 100 ohms Shorted Replace both switch boards Snubber Test Less than 100 ohms OK None Continue Greater than Open 1K ohm Replace both switch boards Snubber Test Less than 100 ohms None Continue Greater than Open 1K ohm Replace both switch boards Snubber Test Greater than OK 1K ohm None Continue Less than 100 ohms Shorted Replace both switch boards Snubber Test Less than 100 ohms OK None Continue Greater than Open 1K ohm Replace both switch boards Snubber Test Greater than OK 1K ohm None Continue Less than 100 ohms Replace both switch boards Snubber Test OK Shorted 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). INVERTEC STT 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.5 – SWITCH BOARD RESISTANCE TEST (continued) Apply Positive Test Probe to Terminal 12 401/403 9 Return to Section TOC Return to Master TOC Return to Master TOC Apply Negative Test Probe to Terminal Test Result Conclusion Repair Action 401/403 Greater than OK None 1K ohm 12 402/404 402/404 Return to Section TOC F-36 9 Next Procedure Notes Continue Less than 100 ohms Shorted Replace both switch boards Snubber Test Less than 100 ohms OK None Continue Greater than Open 1K ohm Replace both switch boards Snubber Test Less than 100 ohms None Continue Greater than Open 1K ohm Replace both switch boards Snubber Test Greater than OK 1K ohm None Continue Less than 100 ohms Replace both switch boards Snubber Test OK Shorted 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). 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 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 Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 troubleshooting assistance before you proceed. Call 1-888-935-3877. DESCRIPTION This test will determine if the snubber resistors (R4, R5, R6, R7) are functioning properly. MATERIALS NEEDED Analog Volt/ohmmeter (Multimeter) STT Wiring Diagrams 5/16” Nut driver Note: Component locations and disassembly procedures may vary slightly on STT II models INVERTEC STT F-37 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. Using the 5/16" nut driver, remove the case wraparound cover. 3. Perform the Input Filter Discharge Procedure. Maintenance section. Capacitor See the WARNING Return to Master TOC Return to Section TOC ELECTRIC SHOCK can kill. • Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. INVERTEC STT F-38 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. If 30 ohms or more is measured, resistor R4 is faulty and must be replaced. 7. Repeat the same procedures to test R5, R6, and R7 according to Table F.6. 8. Reconnect leads 401/403 and 402/404 to the switch board. 9. Install the case wraparound cover. c. If 20 ohms or less is measured, resistor R4 is faulty and must be replaced. TABLE F.6 – SNUBBER RESISTORS TEST Check Test Result Conclusion Next Test Step Lead 401 to Terminal 12 25 ohms >30 ohms <20 ohms OK R4 open R4 faulty Continue Lead 402 to Terminal 9 25 ohms >30 ohms <20 ohms OK R5 open R5 faulty Continue Lead 403 to Terminal 12 25 ohms >30 ohms <20 ohms OK R6 open R6 faulty Continue Lead 404 to Terminal 9 25 ohms >30 ohms <20 ohms OK R7 open R7 faulty Continue > = GREATER THAN < = LESS THAN INVERTEC STT Repair Action Replace R4 Replace R5 Replace R6 Replace R7 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 Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 troubleshooting 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 Note: Component locations and disassembly procedures may vary slightly on STT II models INVERTEC STT F-41 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. Locate relays CR1 and CR2 just to the front of the fan motor. WARNING Return to Master TOC VOLTAGE TEST PROCEDURE 1. Remove input power to the Invertec STT. 2. Perform the Input Filter Capacitor Discharge Procedure. See the Maintenance section. 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. Return to Section TOC OK. If the relays are NOT being activated, the power PC board could be faulty. Continue with the voltage tests. 4. Apply the correct input power and turn ON the Invertec STT machine. 5. After about a 5 second delay the relays should activate. This can be determined by an audible click which can be heard when the relays are activated. If the relays are being activated, the power PC board is most likely ELECTRIC SHOCK can kill. • Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 3. Using the 5/16" nut driver, loosen the front control panel by removing the four sheet metal screws from the top and bottom of the front panel. Carefully move the front panel assembly to the right to gain access to the power PC board. See Figure F.14. INVERTEC STT F-42 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. Carefully test for 18VAC input from the T1 Auxiliary Transformer between plug J7 pin 5 (lead#501) and plug J7 pin 6 (lead #504) at the power PC board. See Figure F. 15. 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. NOTE: If the 18VAC is NOT present, perform the T1 Auxiliary Transformer Test. Also check associated wiring. See the Wiring Diagram. INVERTEC STT 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 3.5 ohms #210 6J4 9J4 #223 8J33 13J36 #413 C 5J4 3.5 ohms 2J31 #212 6J34 12J4 5J36 #405 D #212C Return to Master TOC Return to Section TOC 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 Figure F.15. 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. Return to Master TOC Return to Section TOC 9. Carefully test for 24VDC at the power PC board at plug J7 pin 2 (lead #309)(+) to plug J14 pin2 (lead #313)(-). See Figure F.15. NOTE: If the 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 (lead#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 (lead#313)(-). See Figure F.15. NOTE: If more than 1VDC is measured, perform the Protection Board Test. NOTE: If 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 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 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 troubleshooting 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 II models INVERTEC STT F-45 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. Do not reach into the machine or touch any internal part. 2. Using the 5/16" nut driver, remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure. See the Maintenance section. WARNING 5. Apply the correct input power and turn the machine ON. Return to Master TOC Return to Section TOC ELECTRIC SHOCK can kill. • Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 4. Locate the protection PC board just in front of the input rectifier and relay mountings. 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 properly. B. If more than 5 VDC is measured, perform the Capacitor Balance Test. INVERTEC STT 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. The capacitor 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 the Invertec STT machine. 9. Perform the Input Filter Capacitor Discharge Procedure. See the Maintenance section. WARNING Return to Master TOC ELECTRIC SHOCK can kill. Return to Section TOC F-47 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-47 • Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 10. Locate and remove leads #309 and #309A from CR1 and CR2 relays. See Figure F.18. 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. 11. Apply correct input power and turn ON the machine. 12. Check for approximately 12VDC from plug J15 pin 1 (lead #314)(+) to plug J15 pin 4 (lead#315) (-). See Figure F.17. 13. Check for approximately 12VDC from plug J15 pin 3 (lead #316)(+) to plug J15 pin 6 (lead#317) (-). See Figure F.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 #309A onto the CR1 and CR2 relays. 17. After all tests are completed, install the case wraparound cover. INVERTEC STT 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. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. 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. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5/16" Nut driver Volt/ohmmeter (Multimeter) Wiring Diagram and board Schematics Note: Component locations and disassembly procedures may vary slightly on STT II models INVERTEC STT F-49 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. • Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. Using the 5/16" nut driver, remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure. See the Maintenance section. 4. Locate plug J31 at the left side of the machine. See Figure F.19. INVERTEC STT F-50 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. STT CONTROL G2782-[ ] Return to Master TOC Return to Section TOC FIGURE F.21 – CONTROL PC BOARD MOLEX PLUG 223 Return to Master TOC Return to Section TOC J5 J17 J27 J28 J2 J3 J4 J1 210 6. Using the ohmmeter, check for approximately 3.5 ohms resistance from pin "C" of the 14 pin amphenol (see Figure F.20) to plug J4 pin 9 (lead#223) at the control PC board. See Figure F.21 and Figure F.22, Simplified Trigger Circuit Diagram. INVERTEC STT 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 3.5 ohms #210 6J4 9J4 #223 8J33 13J36 #413 C 5J36 #405 D #503A 2 4 V A C TO POWER BOARD 5J4 3.5 ohms 2J31 #212 6J34 12J4 Return to Master TOC Return to Section TOC #212C 7. Using the ohmmeter check for continuity (zero ohms) from plug J31 pin 3 (lead#503A) to plug J4 pin 6 (lead#210). See Figure F.22, Simplified Trigger Circuit Diagram. 8. If any of the resistance checks are abnormally high in steps 5, 6 or 7, check for broken or loose wires, connections or "open" thermostats. Also check the small inductors on the Remote Protection Board. See Figure F.22, Simplified Trigger Circuit Diagram. WARNING Return to Master TOC Return to Section TOC 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. 9. Apply the correct input power to the machine and turn ON. 10. Locate plug J6 on the power PC board. See Figure F. 15. in 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 trigger circuit to operate. If the correct DC voltage is NOT present, perform the Protection Board Test and the Power Board Test. 12. Test to make sure the T1 auxiliary transformer is producing 24VAC. See Figure F.22, Simplified Trigger Circuit Diagram. 13. 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. INVERTEC STT 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 Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section 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 troubleshooting 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) Note: Component locations and disassembly procedures may vary slightly on STT II models INVERTEC STT F-53 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. Perform the Input Filter Capacitor Discharge Procedure. See the Maintenance 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.23. WARNING ELECTRIC SHOCK can kill. Return to Master TOC Return to Section TOC • Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. INVERTEC STT F-54 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. Disconnect the current sensing plug J1 from the control PC board. Carefully remove plug Return to Master TOC Return to Section TOC PLUG J22 6. Locate and disconnect plug J22 from the wiring harness. See Figure F.25. INVERTEC STT F-55 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. Using the 7/16" wrench, remove the five bolts holding the lower tray assembly to the case bottom. 12. Carefully remove the lower tray assembly clear from the machine. 9. Carefully slide out and support the lower tray assembly. 13. Remove the rubber RTV coating from the IGBT module. 10. Using the needle nose pliers, remove the strain relief holding the J22 lead harness to the case bottom. INVERTEC STT F-56 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. Using the 12mm wrench, remove the large lead and the #289 lead from the large "E" terminal. Note lead placement for reassembly. 16. Using the 12mm wrench, remove the large lead and the #287 lead from the large "C" terminal. Note lead placement for reassembly. 21. Using the 12mm wrench, assemble the large lead and the smaller #289 lead to the large "E" terminal. Torque to 86 inch pounds. 22. Using the 12mm wrench, assemble the large lead and the smaller #287 lead to the large "C" terminal. Torque to 86 inch pounds. 23. Using the phillips head screw driver, reassemble the small leads to the small "E" and "G" terminals. Torque to 13 inch pounds. 17. Using the 3/16" Allen type wrench, remove the four socket head cap screws that mount the module to the heat sink. 24. Apply the Silicone Rubber RTV Coating (Lincoln E2861 or Dow 3140) to the terminals and lead connections as was previously removed. 18. Carefully remove the IGBT module. 25. Replace the lower tray assembly. 19. Upon reassembly, use Dow Corning 340 Heat Sink Compound (Lincoln E1868) between the module and the heat sink. 26. Connect plug J22 to the wiring harness and plug J1 to the control PC board. 20. Mount the new module using the socket head cap screws and torque to 35 inch pounds. 27. Connect the lead splice between the output choke and the IGBT module. 28. Install the case wraparound cover. Note: The torque should be rechecked after three hours. INVERTEC STT F-57 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 Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 troubleshooting 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 Note: Component locations and disassembly procedures may vary slightly on STT II models INVERTEC STT F-59 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. In addition to replacing the switch boards, replace capacitors C1 and C2 if the following conditions exist: WARNING ELECTRIC SHOCK can kill. • Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. a. The machine was operating from 380 VAC or higher when the failure occurred. b. Burned areas are visible on the switch boards. 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. 4. Carefully disconnect the leads at the top of the switch board. 5. Using the 3/16" socket wrench, remove the four cap screws from the switch board. See Figure F.28. Return to Master TOC Return to Section TOC 3. Perform the Input Filter Capacitor Discharge Procedure. See the Maintenance section. INVERTEC STT F-60 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. (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. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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. 13. Torque both sets of screws in 10 inch-pound increments. Use a 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). CAUTION Failure to connect the switch board leads correctly 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 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) with new style (new part number). 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. INVERTEC STT F-61 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. Connect a shorting conductor across terminals 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 12 (–) of one switch board. The meter will show the capacitors charging up and may take a minute or so to stabilize. The final meter reading should not exceed 8600 ohms (8.6 on the scale). 5. Test the other switch board the same way. Return to Master TOC NOTE: Repeat the Input Filter Capacitor Discharge Procedure. 1. Turn main power OFF. 2. Perform Input Filter Capacitor Discharge Procedure. See the Maintenance section. Return to Section TOC Return to Master TOC Return to Master TOC 6. Remove the shorting conductor set up in step 3. 7. Replace 20 amp fuses with 5-amp fuses in the input supply fuse holders. WARNING ELECTRIC SHOCK can kill. • Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. Return to Section TOC Return to Section TOC TEST PROCEDURE NOTE: These fuses should be installed to protect against excessive current flow caused by a short circuit during the procedure. FIGURE F.29 — SHORTING TERMINALS 14 AND 53 OF PROTECTION BOARD L7915-[ ] PROTECTION 53 14 JUMPER TERMINALS INVERTEC STT F-62 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. Do not reach into the machine or touch any internal part. 8. With the machine connected for 440/460 volt operation and the proper input voltage applied, turn on input power to the machine. 10. Remove input power. Then remove the 5-amp fuses from the input supply fuse holders. 11. Install 20-amp fuses and test under load. NOTE: A resistive-type grid load bank is recommended. 14. Perform Retest After Repair. INVERTEC STT F-63 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 Master TOC Return to Section 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 troubleshooting 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 capacitors C1 and C2. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5/16" Nut driver Slot head screw driver 7/16" Wrench Needle nose pliers 1/2" Wrench Note: Component locations and disassembly procedures may vary slightly on STT II models INVERTEC STT F-65 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. • Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 2. Using the 5/16" nut driver, remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure. See the Maintenance 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. INVERTEC STT 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.32 – PLUG J22 DISCONNECTION Return to Master TOC PLUG J22 Return to Section TOC F-67 6. Locate and disconnect plug J22 from the wiring harness. See Figure F.32. INVERTEC STT 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. 8. Using the 7/16" wrench, remove the five bolts holding the lower tray assembly to the case bottom. 12. Carefully remove the lower tray assembly clear from the machine and set aside. 9. Carefully slide out and support the lower tray assembly. 13. Carefully disconnect the leads at the top of the switch board. 10. Using the needle nose pliers, remove the strain relief holding the J22 lead harness to the case bottom. INVERTEC STT 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 Section TOC F-69 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 properly. 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 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. Pull the through-bolts out of the machine, being careful to save all the insulation and standoff material. Set aside for reassembly. 16. Remove the switch board and capacitor assembly from the machine. INVERTEC STT 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 FIGURE F.37 – LOOSENING THE CLAMP RING SET SCREW 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. INVERTEC STT 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. 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. . . Return to Master TOC Return to Section TOC CAUTION Proper capacitor polarity must be noted when attaching the capacitor to the switch board assembly. The Input Filter Capacitor Protection Circuit could have been activated and prevented output. This means the Input Filter Capacitors must be conditioned. 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. The Input Filter Capacitor Protection Circuit monitors the voltage across input filter capacitors C1 and C2. When it senses an overvoltage condition, the protection circuit will prevent the machine from operating. 21. Install the lower tray assembly and all previously disconnected loads and plugs. To condition the Input Filter Capacitors: 22. Perform the Test After Repair of Switch Boards and/or Capacitors. Return to Master TOC 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). Return to Section TOC F-72 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 capacitor voltage has reached the acceptable operating level. INVERTEC STT 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. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. DESCRIPTION This procedure will aid the technician in the removal and replacement of the output diode heat sink assembly. MATERIALS NEEDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 II models INVERTEC STT F-73 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. See the Maintenance section. WARNING Return to Master TOC Return to Section TOC ELECTRIC SHOCK can kill. • Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 4. Using the slot head screw driver, loosen the input cable strain relief. 5. Using the 5/16" nut driver, remove the four screws securing the case back to the internal horizontal baffles. 6. Carefully pull the case back away from the output rectifier assembly. NOTE: The case back will NOT detach from the case bottom. 7. 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. Note 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 tab. See Figure F.39. INVERTEC STT 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. Using the 7/16" wrench, remove the diode leads from the main transformer secondary leads. Note washer and lead placement for reassembly. INVERTEC STT F-75 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. 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. 12. Using the 3/8" nut driver, loosen the front nuts from the switch board/capacitor assembly through-bolts. 18. 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. 13. Carefully lift the horizontal baffle away from the upper tabs of the output rectifier heat sink assembly. Return to Master TOC Return to Section TOC 14. Slide the heat sink assembly to the right (facing the back of the machine) to disengage the bottom tabs from the lower horizontal baffle. 15. Carefully remove the output rectifier heat sink assembly and leads from the STT machine. 16. Remove the nut that secures each diode that is to be replaced. NOTE: The output diodes must be replaced in matched sets. INVERTEC STT 19. Insert the diode sets into the mounting hole and tighten the diode mounting nuts to a torque of 25 inch-pounds (3 Nm). 20. Replace the rectifier heat sink assembly, leads and connections that were previously removed. Install the fan and motor assembly (note insulation placement). Install the case back and the case wraparound cover. 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 3.5 AMPS Return to Master TOC Return to Section TOC 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 73 TO 85 VDC INVERTEC STT 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 Return to Section TOC The Input Filter Capacitor Protection Circuit could have been activated and prevented output. This means the Input Filter Capacitors must be conditioned. 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 noncorrosive, 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. The Input Filter Capacitor Protection Circuit monitors the voltage across input filter capacitors C1 and C2. When it senses an overvoltage condition, 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. 3. Turn main power ON. 4. Let the unloaded machine sit for 30 minutes. 5. Turn main power OFF. Return to Section TOC Return to Master TOC Return to Master TOC 6. Turn main power ON. Return to Section TOC F-78 NOTE: The machine should be ready to operate, and the protection circuit should have automatically reset once the capacitors have been conditioned and capacitor voltage has reached the acceptable operating level. INVERTEC STT 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) . . . . . . . . . . . . . .G-4 Wiring Diagram - Entire Machine - Codes 11115-11116 - (G4557) . . . . . . . . . . . . . . .G-5 Schematic - Control PC Board - Codes 10151-11092 - (G2781 Sheet 1) . . . . . . . . .G-6 Return to Master TOC Schematic - Control PC Board - Codes 10151-11092 - (G2781 Sheet 2) . . . . . . . . .G-7 PC Board Assembly - Control - Codes 10151-11092 - (G2782) . . . . . . . . . . . . . . . . .G-8 Schematic - Control PC Board - Codes 11115-11116 - (G4649 Sheet 1) . . . . . . . . . .G-9 Schematic - Control PC Board - Codes 11115-11116 - (G4649 Sheet 2) . . . . . . . . .G-10 PC Board Assembly - Control - Codes 11115-11116 - (G4648) . . . . . . . . . . . . . . . . .G-11 Schematic - Power PC Board - All Codes - (M16018) . . . . . . . . . . . . . . . . . . . . . . .G-12 PC Board Assembly - Power - All Codes - (L8033) . . . . . . . . . . . . . . . . . . . . . . . . . .G-13 Schematic - Darlington Drive Board - Codes 10151-10383 - (M17581) . . . . . . . . . .G-14 PC Board Assembly - Darlington Drive - Codes 10151-10383 - (G2778) . . . . . . . . .G-15 Schematic - IGBT Drive Board - Codes 11090-11116 - (L12144) . . . . . . . . . . . . . . .G-16 PC Board Assembly - IGBT Drive - Codes 11090-11116 - (L12145) . . . . . . . . . . . . .G-17 Return to Master TOC Schematic - Switch Board - All Codes - (L8440) . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-18 PC Board Assembly - Switch - All Codes - (L8441) . . . . . . . . . . . . . . . . . . . . . . . . .G-19 Schematic - Driver Board - All Codes - (S20799) . . . . . . . . . . . . . . . . . . . . . . . . . . .G-20 PC Board Assembly - Driver - All Codes - (L9134) . . . . . . . . . . . . . . . . . . . . . . . . . .G-21 Schematic - Protection PC Board - Codes 10151-11092 - (M16097) . . . . . . . . . . . .G-22 PC Board Assembly - Protection - Codes 10151-11092 - (L7915) . . . . . . . . . . . . . .G-23 Schematic - Protection PC Board - Codes 11115-11116 - (M20352) . . . . . . . . . . . .G-24 PC Board Assembly - Protection - Codes 11115-11116 - (L12235) . . . . . . . . . . . . . .G-25 Schematic - Current Sense PC Board - All Codes - (S21410) . . . . . . . . . . . . . . . . .G-26 PC Board Assembly - Current Sense - All Codes - (M17591) . . . . . . . . . . . . . . . . . .G-27 Schematic - Remote Protection PC Board - All Codes - (M17609) . . . . . . . . . . . . . .G-28 Return to Master TOC PC Board Assembly - Remote Protection - All Codes - (L9657) . . . . . . . . . . . . . . . .G-29 INVERTEC STT 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. 9B R5 25 25W C1+ 25 2200 F 12B 12B 25W450V 51 R4 12B 12B 9B 7500 25W W R 9 FAN MOTOR 4 AMP SLOW BLOW B B V R C C W J21 220230V H3 200208V INPUT PER N.A. 6 H4 3 H4 H3 H2 2 4 1 B N.D. J5, J7, J34 J16, J28 J30 R 1 32 11 5 V R 2 33 J31 4 2 V5 43A U 2 4 V3 N J22 15 32A 32C 16 32B 7 33C 8 33A 33B P. C . B O A R D C O N N E C TO R C AV I T Y N U M B E R I N G S E Q U E N C E N.A. (VIEWED FROM COMPONENT SIDE OF BOARD) J19 P I N O U T O F F R O N T PA N E L C O N N E C TO R S ( R E A R V I E W ) P30 P29, P31 J30 P22 P21 J29. J31 J21 J22 I N L I N E C O N N E C TO R C AV I T Y N U M B E R I N G S E Q U E N C E ( V I E W E D F R O M W I R E S I D E O F C O N N E C TO R ) Y Y I 8 N.E. 5F S BOTTOM OUTSIDETOP S F S TOP INSIDE 8F H2 H1 0V W 2 Y 4 504 18V Y 1 501 R13 2 300W E 3 1 J18 4 2 1 J12 2 3 4 R B W 241 503A J22 W 14 242 243 224 W 6 244 N 224A 224 210A 150 5W 212A B W 1 4 2 J13 3 5 6 R B W DARLINGTON DRIVEBOARD W B R B 240 241 242 307 308 309 310 501 504 7 8 2 4 5 J7 6 1 3 311 313 1 2 J14 3 4 POWER BOARD 5 3 6 8 J6 1 10 2 7 9 4 303 302 304 275 212 305 301 212A 211A 371A 374A 243 244 303 302 304 275 210 T4 AUXILIARY TRANSFORMER ELECTRICAL SYMBOLS PER E1537 COLOR CODE: B = BLACK G = GREEN N = BROWN O = ORANGE R = RED W = WHITE Y = YELLOW U = BLUE NOTES: 1. FOR MACHINES SUPPLIED WITH INPUT CABLE FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT. WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. 2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. CONNECT TERMINALS U & W TO SUPPLY CIRCUIT. FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT. N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. 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 BLEEDER 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. N.I. DENOTES A TWISTED WIRE PAIR OR GROUP. N.J. NOT PRESENT ON EUROPEAN VERSIONS. N.K. NOT PRESENT ON EUROPEAN VERSIONS, CODE 10309 AND HIGHER. N.L. PRESENT ON EUROPEAN VERSIONS, CODE 10309 AND HIGHER. D7 287 - ARC 1 4 J1 2 3 J27 Y Y 301 305 245 223 211A 212C 210 246 502 5 6 7 2 1 4 8 3 9 10 212C 43A 33C 32C 212B E B 370 371 372 374 376 3 2 1 10 9 12 4 11 8 1 7 14 3 11 10 6 4 2 5 9 12 13 1 2 3 4 5 6 J17 7 8 9 J28 10 11 12 9 6 12 8 2 1 13 4 J2 15 16 2 10 8 7 11 14 3 3 1 5 9 J4 11 5 12 6 7 4 10 B R W B 370 371 372 374 376 6 1 4 8 5 3 2 7 J34 8 9 10 J36 5 4 6 J33 2 3 7 1 14 6 3 6 2 J35 5 1 4 VOLTAGE SENSE CONNECTION 1 (+) 2 3 (-) 4 J38 J B BG C 10K G A PB D 10K TRIGGER F H GND E I OPTIONAL REMOTE INTERFACE WIRE FEEDER N 414 B 406 H L M 405 D 413 C 416 K 408 I 415 A 407 J E F G SPARE GND 21 82 81 4 TRIGGER 2 43B 42 CB1 42 6AMP VAC 33D 31A CB2 115 6AMP VAC 353 352 42 41 32 31 77 76 75 42 VAC 115 VAC N.J. J23 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 PEAK CURRENT METER 351 350 J25 J26 357 356 BACKGROUND METER 355 354 358 359 364 365 366 367 368 369 362 CW (MAX) 10KR11 2W PEAK CURRENT CONTROL CW (MAX) 10KR12 2W BACKGROUND CONTROL CW (MAX) 10K R13 2W HOT START CONTROL 363 364 365 CONTROL BOARD 403 402 401 410 409 412 404 411 J24 350 351 352 353 354 355 356 357 358 359 360 361 362 363 360 361 2 5 6 J3 1 4 3 291 J39 5 13 16 8 15 7 3 1 7 5 6 J5 8 2 4 290 C 223 371 374 N N O O FAN THERMOSTAT 503A 212B J19 1 2 J37 3 4 DARLINGTON MODULE W B 503B DARLINGTON HEATSINK THERMOSTAT + ARC 288 289 1 0 R2 2W .001/400 240 6V O U 12 245 18V U 13 246 212 J23 J25 R 1 18V 2 11 5 V W 18V R 9 B 3 18V B 4 N O H3 289A CHOKE D1 D2 D3 D4 D5 C3 10V 503 288B R14 2 300W 288A CURRENT SENSE BOARD L3 12 METER PINOUT (VIEWED FROM BACK OF METER) J39 5 1, 8 J2, J36 J38 T3 CURRENT TRANSFORMER I 402, 404 SWITCH + BOARD (RIGHT) 401, 403 T1 AUXILIARY TRANSFORMER J24 J26 J6, J27, J33 H5 H6 H1 G J1, J8, J3, J9, J 11 , J 1 2 , J 1 4 J 1 0 , J 1 3 , J18, J37 J15, J35 440460V A 380415V S1 POWER ON OFF W U WR 4,5 289B N.E. J22 371 10 371A 374 11 374A A J4, J17 307308 H1 H3 A 4 F TOP 10 .001/400 OUTSIDE 2 W R3 S C4 S F D11 BOTTOM BOTTOM D10 INSIDE S D9 1F D8 D7 1 51 12D A T2 MAIN TRANSFORMER SWITCH BOARD (LEFT) 401, 403 R W R W 1, 8 12 311 313 52 PROTECTION 2 BOARD 5 J15 1 4 3 H5 51 6 N.H. N.K. Return to Master TOC 1 53 3 J8 2 4 14 N.L. POWER LINE FILTER ASSEMBLY + 309 310 53 14 REMOTE PROTECTION BOARD C8 20/400 4 4, 5 402, 404 52 309 309A 310 CR1 310A LINE Return to Master TOC 53 9A B Return to Section TOC 7500 25W R1 9 9A 9A R7 25 25W C2+ 25 2200 F 25W450V R6 12A 12A N.F. C Return to Section TOC N.L. TOROIDAL CORE N.G. 9A Return to Section TOC G-2 ELECTRICAL DIAGRAMS R9 Return to Master TOC Return to Section TOC G-2 366 367 367A .045 368 367A S2 WIRE SIZE .035 STAINLESS S3 MILD 369 (-) 502 Y 503 503A WIRE TYPE THERMAL OVERLOAD INDICATOR (+) 9-13-96 G2773 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 & STT II 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. 9B R5 25 25W C1+ 25 2200 F 12B 12B 25W450V 51 R4 12B 12B 9B 7500 25W W R 9 WR 4,5 5 440460V A J21 220230V H3 200208V INPUT PER N.A. H5 H6 6 H4 3 H4 H2 H3 2 H2 4 H1 1 H3 H1 B N.D. 1, 8 8 12 J31 4 2 V5 43A U 2 4 V3 N J22 15 32A 32C 16 32B 7 33C 8 33A 33B R 1 18V 2 11 5 V W 18V R 9 B 3 18V B 4 0V W 2 Y 4 504 18V Y 1 501 J6, J27, J33 J16, J28 J39 J19 P I N O U T O F F R O N T PA N E L C O N N E C TO R S ( R E A R V I E W ) 1 2 3 4 2 1 4 3 1 2 3 4 5 6 N.E. 240 241 503A J22 W 14 242 243 224 W 6 224A FA N T H E R M O S TAT C H O K E 379 T H E R M O S TAT 244 N 224 503A 212B 1 4 2 J13 3 5 6 R B W DARLINGTON DRIVEBOARD W B R B 240 241 242 307 308 309 310 501 504 7 8 2 4 5 J7 6 1 3 311 313 1 2 J14 3 4 210A 150 5W 212A J24 J26 J23 J25 POWER BOARD 5 3 6 8 J6 1 10 2 7 9 4 303 302 304 275 212 305 301 212A 211A J29. J31 P21 J21 3 2 1 6 5 4 1 2 3 4 5 6 3 2 1 6 5 4 P22 J22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 I N L I N E C O N N E C TO R C AV I T Y N U M B E R I N G S E Q U E N C E ( V I E W E D F R O M W I R E S I D E O F C O N N E C TO R ) 371A 374A 243 244 303 302 304 275 210 COLOR CODE: B = BLACK G = GREEN N = BROWN O = ORANGE R = RED W = WHITE Y = YE LLOW U = BLUE CASE TR AY CASE FRONT BOTTOM NOTES: N.M. 1. FOR MACHINES SUPPLIED WITH INPUT CABLE FOR SINGLE PHASE INPU T: CONNEC T GREEN LEAD TO GROUND PER NATIONA L E LECTRIC CODE. CONNEC T BLACK & WHI T E LEADS TO SUPP LY CIRCUI T. WRA P RED LEAD WITH TAP E TO PROVIDE 600V. INSUL ATION. FOR THREE PHASE INPU T: CONNEC T GREEN LEAD TO GROUND P ER NATIONA L EL ECTRIC CODE. CONNEC T BLACK, RED & WHI T E LEADS TO SUPPLY CIRCUI T. 2. FOR MACHINES NO T SUPPLIED WI T H INPU T CABLE FOR SINGLE PHASE INPU T: GROUND MACHINE PER NATIONA L AND LOCAL ELECTRICAL CODES. CONNEC T TERMINALS U & W TO SUPPLY CIRCUI T. FOR THREE PHASE INPU T: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRIC A L CODES. CONNEC T TERMINALS U, V & W TO SUPP LY CIRCUI T. N.B. SINCE COMPONENTS OR CIRCUITRY O F A PRINTED CIRCUIT BOARD MAY C HANGE WITHOUT AF FECTING THE INTERCHANGEABILIT Y OF A C OMPLETE BOARD, THIS DIAGRAM MAY N O T SHOW THE EXACT COMPONENTS OR CIRCUITRY H AVI NG A COMMON CODE NUMBER. N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VO LTAGE. CONNECTION SHOWN IS FOR 440-460V O PERATION. N.E. D1 THRU D5 OUTPUT DIODES ARE A M ATCHED SET. D7 THRU D 11 OUTPUT DIODES ARE A M ATCHED SET. N.F. R1, R9 BLEEDER RESISTORS ARE A M ATCHED SET. N.G. C1, C2 CA PACITORS ARE A M ATCHED SET. N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VO LTAGE. CONNECTION SHOWN IS FOR 380-460V O PERATION. N.I. DENOTES A T WISTED WIRE PAIR OR GROU P. N.J. NO T PRESENT ON EUROPEAN VERSION. - ARC FAN SHROUD CASE BACK 1 2 J37 3 4 1 4 J1 2 3 J27 Y Y 301 305 245 223 211A 212C 210 246 502 5 6 7 2 1 4 8 3 9 10 212C 43A 33C 32C 212B E B 370 371 372 374 376 8 1 7 14 3 11 10 6 4 2 5 9 12 13 1 2 3 4 5 6 J17 7 8 9 J28 10 11 12 9 6 12 8 2 1 13 4 J2 15 16 2 10 8 7 11 14 3 3 1 5 9 J4 11 5 12 6 7 4 10 B R W B 370 371 372 374 376 6 1 4 8 5 3 2 7 J34 2 5 6 J3 1 4 3 8 9 10 J36 5 4 6 J33 2 3 7 1 J39 14 6 3 6 2 J35 5 1 4 BG 10K PB 10K TRIGGER GND OPTIONAL REMOTE INTERFACE ELECTRODE SENSE LEAD GND 21 82 81 4 TRIGGER 2 42 41 32 31 77 76 75 42 VAC 115 VAC N.J. 43B 42 CB1 42 6AMPVAC 33D 31A CB2 115 6AMP VAC 353 352 J23 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 PEAK CURRENT METER 351 350 J25 J26 357 356 BACKGROUND METER 355 354 358 359 364 365 366 367 368 369 J38 J B C G A D F H E I WIRE FEEDER N 414 B 406 H L M 405 D 413 C 416 K 408 I 415 A 407 J E F G J24 350 351 352 353 354 355 356 357 358 359 360 361 362 363 377 378 362 CW (MAX) 10KR11 2W PEAK CURRENT CONTROL CW (MAX) 10KR12 2W BACKGROUND CONTROL 363 CW 377 378 364 365 CONTROL BOARD 403 402 401 410 409 412 404 411 290A 360 361 PLATFORM CASE BACK 291 3 2 1 10 9 12 4 11 5 13 16 8 15 7 3 1 7 5 6 J5 8 2 4 VOLTAGE SENSE CONNECTION 1 (+) 2 3 (-) 4 290 C DARLINGTON MODULE W B T4 AUXILIARY TRANSFORMER T1 AUXILIARY TRANSFORMER R B W 1 0 R2 2W .001/400 DARLINGTON HEATSINK THERMOSTAT D12 223 D1 D2 D3 D4 D5 C3 5F S BOTTOM OUTSIDETOP S F S TOP INSIDE 8F 6V O U 12 245 18V U 13 246 J2, J36 J38 P29, P31 1 J12 2 3 4 J19 287 E B W 503B N O 212 3 1 J18 4 2 + ARC 288 R15 2 300W CHOKE 371 374 N N O O 10V 503 289A CURRENT SENSE BOARD L3 ELECTRICAL SYMBOLS PER E1537 J5, J7, J34 P. C . B O A R D C O N N E C TO R C AV I T Y N U M B E R I N G S E Q U E N C E N.A. (VIEWED FROM COMPONENT SIDE OF BOARD) J30 Y I Y METER PINOUT (VIEWED FROM BACK OF METER) P30 T3 CURRENT TRANSFORMER I 402, 404 SWITCH + BOARD (RIGHT) 401, 403 J30 R 1 32 11 5 V R 2 33 288B R16 2 300W 288A N.E. J22 371 10 371A 374 11 374A 380415V G J1, J8, J3, J9, J 11 , J 1 2 , J 1 4 J 1 0 , J 1 3 , J18, J37 J15, J35 307308 6 3 2 51 4 1 2 3 4 8 J11 J10 1 2 J16 7 DRIVER 3 BOARD 1 J9 2 14 3 6254 1 13 A TOP FAN MOTOR H3 4 F TOP 10 .001/400 OUTSIDE 2 W R3 S C4 S F D11 BOTTOMBOTTOM D10 INSIDE S D9 1F D8 D7 1 289B 289 T2 MAIN TRANSFORMER SWITCH BOARD (LEFT) 401, 403 R W R W1, 8 12 311 313 52 PROTECTION 2 BOARD 5 J15 1 4 3 H5 51 6 CR2 309A H1 LEFT FAN MOTOR + 51 N.K. N.L. 4 4, 5 309 310 53 14 N.F. H1 H3 C8 20/400 402, 404 52 12D LINE Return to Master TOC 53 9A B Return to Master TOC 7500 25W R1 9 9A 9A R7 25 25W C2+ 25 2200 F 25W450V R6 12A 12A N.F. C Return to Section TOC TOROIDAL CORE N.G. C Return to Section TOC REMOTE PROTECTION BOARD N.L. 9A Return to Section TOC G-3 ELECTRICAL DIAGRAMS R9 Return to Master TOC Return to Section TOC G-3 CW (MAX) 10K R13 2W TAILOUT CONTROL R14 500K 2W HOT START CONTROL 366 367 367A .045 368 367A S2 WIRE SIZE .035 STAINLESS S3 MILD 369 (-) 502 Y 503 503A WIRE TYPE THERMAL OVERLOAD INDICATOR (+) N.K. NO T PRESEN T ON EUROPEAN VERSIONS, CODE 10309 AND HIGHER. N.L. PRESEN T ON EUROPEAN VERSIONS, CODE 10309 AN D HIGHER. N.M. PRESEN T ON EUROPEAN VERSIONS, CODE 10383 AN D HIGHER. D-RW 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. INVERTEC STT & STT II 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. INVERTEC STT & STT II 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. I 5 Y I F BOTTOM OUTSIDE S 8 8 D2 S TOP D3 D4 F D5 S TOP INSIDE 1, 8 } 1 4 2 3 5 6 D1 5 Y SWITCH BOARD (RIGHT) 2 33 15 2 H2 4 5 3 1 H2 0V W Y 1 H1 33C 43A 9 14 1 J F B I G 3 A 4 D L A E K M F J N G I H B H PINOUT OF FRONT PANEL CONNECTORS (REAR VIEW) P29, P31 J30 J21 P21 J29. J31 1 2 2 1 1 2 3 3 2 1 1 2 3 3 2 1 3 4 4 3 4 5 6 6 5 4 4 5 6 6 5 4 P22 4 5 J22 6 7 8 9 10 11 12 13 14 15 16 8 7 6 5 1 240 2 115V W 18V R 9 3 B 18V B 2 212 4 504 1 501 241 503A 242 243 224 DARLINGTON HEATSINK THERMOSTAT J22 W 14 W 224A 6 N O 224 210A 503A 212B 150 5W 6V U 12 18V U 18V 13 O 245 212A ELECTRICAL SYMBOLS PER E1537 1 6 B W 1 2 3 4 210 } COLOR CODE: B = BLACK G = GREEN N = BROWN O = ORANGE R = RED W = WHITE Y = YELLOW U = BLUE 2 1 16 15 14 13 12 11 10 4 9 3 INLINE CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM WIRE SIDE OF CONNECTOR) 1. FOR MACHINES SUPPLIED WITH INPUT CABLE FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT. WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. 2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. CONNECT TERMINALS U & W TO SUPPLY CIRCUIT. FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT. N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR 380-415V 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 BLEEDER 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 380-415V OPERATION. N.I. DENOTES A TWISTED WIRE PAIR OR GROUP. N.J. NOT PRESENT ON EUROPEAN VERSIONS. N.K. NOT PRESENT ON EUROPEAN VERSIONS. N.L. PRESENT ON EUROPEAN VERSIONS. C 212C 43A 33C 32C 212B E G J13 R B W W B R B 240 241 242 POWER BOARD J7 J6 J14 5 3 6 8 1 10 2 7 9 4 303 302 304 275 212 305 301 212A 211A 371A 374A 243 244 303 302 304 275 246 T4 AUXILIARY TRANSFORMER J23 J25 311 313 FAN THERMOSTAT 244 N } 7 8 2 4 5 6 1 3 J37 - ARC 287 223 IGBT DRIVE BOARD 307 308 309 310 501 504 288 2 • • 300W D7 IGBT MODULE W B 1 2 3 4 503B 10V 503 R B W F NOTES: C C 374A J19 288A E C3 R2 .001/400 10 2W N.A. J39 E D 33A 33B R 18V 371A 11 3 1 4 2 Y Y 301 305 245 223 211A 212C 210 246 502 } 1 4 2 3 3 1 7 5 6 8 2 4 J1 J27 } 5 6 7 2 1 4 8 3 9 10 370 371 372 374 376 B R W B 370 371 372 374 376 6 1 4 8 5 3 2 7 } 8 9 10 5 4 6 2 3 7 1 } 1 2 3 4 3 2 1 10 9 12 4 11 J34 291 J38 J B C G A D F H E I 403 402 401 410 409 412 404 411 } } } PB 10K TRIGGER GND INTERFACE REMOTE OPTIONAL J39 J33 J35 14 6 414 406 5 13 16 8 15 7 405 413 416 408 415 407 SPARE GND 21 82 N B H L M D C K 81 4 TRIGGER 2 42 42 41 VAC I A J E 32 31 77 76 75 3 6 2 5 1 4 115 VAC N.J. 43B 42 CB1 6AMP 42 VAC 33D 31A CB2 6AMP 115 VAC J23 J24 350 351 352 353 354 355 356 357 358 359 360 361 362 363 BG 10K FEEDER WIRE J36 F G 1 2 3 8 4 1 5 7 6 14 J17 7 3 8 11 9 10 10 J28 6 11 4 12 2 5 9 9 6 12 12 13 8 2 1 13 4 J2 15 16 2 10 8 7 11 14 3 3 1 5 9 J4 11 5 12 6 7 4 10 VOLTAGE SENSE CONNECTION 1 (+) 2 3 (-) 4 290 J5 353 352 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 PEAK CURRENT METER 351 350 J25 J26 357 356 BACKGROUND METER 355 354 358 CW (MAX) 10K R11 2W 359 PEAK CURRENT CONTROL 360 361 16 J38 J19 8 32A 32B 10 4 T1 AUXILIARY TRANSFORMER 6 8 16 7 10 P.C. BOARD CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD) 3 J11 H3 1 J2, J36 J16, J28 32 METER PINOUT (VIEWED FROM BACK OF METER) 2 J12 1 2 3 4 J22 1 J31 U 24V J24 J26 5 1 7 H3 H1 J6, J27, J33 8 1 6 H4 N.D. 4 5 6 6 Y J5, J7, J34 1 3 4 1 D9 D7 401, 403 32C R 42V 380415V 200208V INPUT PER N.A. G J3, J9, J10, J13, J15, J35 H5 N R V C P30 } J18 D10 S J9 402, 404 115V J21 H6 C 2 F R13 289 CHOKE C4 D11 DRIVER BOARD 3 J30 R B 7 R3 F BOTTOM D8 371 374 4 AMP SLOW BLOW B 1 9 C1 + 4 J10 H3 POWER ON OFF W U A 4 S CURRENT SENSE BOARD L3 .001/400 J22 H1 A 3 3 2 51 J16 1 2 14 13 A 2 7 3 314 315 316 317 FAN MOTOR 1 8 12 52 9B 7500 25W 12B 310A S1 Return to Master TOC 6 9D 12D 12B N.G. R9 CR2 10 2W } Return to Master TOC LOAD F 307 308 52 52 N.F. 12D J1, J8, J11, J12, J14 J18, J37 1 311 313 1 4 3 6 J15 N.L. POWER LINE FILTER ASSEMBLY BOTTOM INSIDE 51 N.K. Return to Master TOC J8 H5 51 12D 12D LINE Return to Section TOC 53 1 3 2 4 PROTECTION 2 BOARD 5 S7 RECONNECT 9B 9B 9C 12A 12C 12A 9B - F TOP OUTSIDE 309 310 53 52 N.H. TP3 TP2 A Return to Section TOC 309 309A 310 310A 9D B A A CR1 TP1 B B 4 1 W 1, 8 2 • • 300W } H1 H1 R S D+ C C 401, 403 R W 12 52 9A C - 289A J3 } 53 T2 MAIN TRANSFORMER } R1 25 2200 F 25W 450V R6 12A 12A SWITCH BOARD (LEFT) } 9A 9A + } 9A C2 + ARC 288B R14 } 7500 25W + 20/400 289B } N.F. C8 4 4, 5 402, 404 REMOTE PROTECTION BOARD TOROIDAL CORE { { { 9 9A 9A R7 25 25W } Return to Master TOC Wiring Diagram - Entire Machine - Codes 11115 - 11116 - (G4557) INPUT RECTIFIER 9D 9D D13 9C Return to Section TOC G-5 ELECTRICAL DIAGRAMS } Return to Section TOC G-5 2 5 6 1 4 3 CONTROL BOARD 364 365 366 367 368 369 362 CW (MAX) 10K R12 2W BACKGROUND CONTROL CW (MAX) 10K R13 2W HOT START CONTROL 363 364 365 366 367 367A .045 368 S2 WIRE SIZE .035 367A STAINLESS 369 S3 WIRE TYPE MILD (-) 502 Y 503 THERMAL OVERLOAD INDICATOR (+) 503A 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. A G4557 INVERTEC STT & STT II +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 0.01 WIRE TYPE POSITION 0.01 W3 0.01 0.01 OPTION 10 COMM J28 6 REM A FOR ENERGY CONTROL PHA OUTPUT J28 W4 OCI4 +15V_REM 7 OCI4 A 4 .0047 HP2231 8 OCI4 2 HP2231 50V Vcc OCI4 B TO C430 POWER 0.1 50V HP2231 BOARD 6 OCI4 B GND 5 ISOLATED HP2231 REM CIRCUIT 3 A 120us OCI5 P BOOST C414 .0047 RAMP P BOOST A 5 B T2 A X10 Q /Q 6 2 OCI5 METER_2 PWM OUTPUT J2 100 R437 ( SHEET 2 ) C413 15.0K R433 3 J2 J2 OUTA -VIN 4 J2 R468 +VIN 13 0.1 50V +15V 3 +PWR 2 TO FRONT END HP2231 7 RST C415 B 2 1 T1 4 HP2231 4 /RAMP -PWR 1 OUTB METER_1 4.75K 6 2 LOCAL R547 R495 2.67K 2.67K 2.67K 12V 1W 35V C455 LM224 A D 10 DZ17 C451 1.0 3 1 X30 R497 150K 11% BACKGROUND INCREASE 11 12 X29 B 10 LM224 C J2 820p 50V RAMP BALL KEEP_ALIVE LEVEL FUSE +PWR 5 C453 KEEP_ALIVE LEVEL NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. +VIN 12 J2 -VIN 8 -PWR 6 R496 1 2 3 4 Input- Current Feedback GENERAL INFORMATION J1 1 5 6 10 Remote Control 1 8 9 16 CAPACITORS = to Control Panel DIODES = Darlington 14 Drive- Output Vac In 1 3 Analog Logic I/O 4 6 to Control Panel UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E-2056 ON 2 PLACE DECIMALS IS + .O2 ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS MFD ( .022/50V RESISTORS = Ohms ( J2 7 LAST NO. USED FILE: G2781_1D1 ELECTRICAL SYMBOLS PER E1537 Analog Logic I/O 1A, 400V 1/4W UNLESS OTHERWISE SPECIFIED) LABELS UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) J3 Ch'ge.Sht.No. 100 SERIES- ARC SENSE CIRCUIT (SHEET 2) 200 SERIES- TRIGGER CIRCUIT (SHEET 2) 300 SERIES- DIGITAL LOGIC CIRCUIT (SHEET 1) 400 SERIES- ANALOG LOGIC CIRCUIT (SHEET 1) DR. MLD DATE 04/12/94 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. X36 117, 211, 310, 424 Q10 W4 VOLTAGE NET FRAME CONNECTION EARTH GROUND CONNECTION STT CONTROL TYPE SCHEMATIC (Sheet 1 of 2) SUBJECT NONE SCALE OCI7 129, 211, 314, 475 D- COMMON CONNECTION EQUIP. CLEVELAND, OHIO U.S.A. 5-24-96E 165, 242, 345, 564 C- POWER SUPPLY SOURCE POINT THE LINCOLN ELECTRIC CO. 5-19-95 DZ20 R- SUPPLY REFERENCE DESIGNATOR SERIES DEFINITIONS NOTES : WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY J2 J2 100K SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE R470 0.1 REMOTE N.A. C411 50V J28 BACKGND R431 SCALED_BGND PINCH FAST RAMP TAILOUT R430 PB_SCALED C416 100 8 P_BOOST BACKGND 10.0K 4 3 DURING HOT START HOT_START 332 9 20.0K OCI6 B 3 J28 RAMP IN +1.42V R498 9 11 D 4 1 50V 11 100 13 H= OPTION PB TIME HP2231 W2 R458 475 100V D404 10 X21 D417 C 8 R342 2 2901 R556 R330 1N4936 1 12V 35V R344 2.21K R343 X23 5 D421 DISABLE OPTION TO START 4.75K 4 +5.1V ARC_START L= OPTION PB TIME R324 6 HP2231 +15V C470 330p 12 4 14 1.00M D419 5 ARC D403 D X36 B D405 +15V D418 100V /RAMP 2.21K L=DISABLE LOCAL PB TIME 10.0K L= NO OPTION START_RESET 10.0K 10 C NAND 8 OCI3 10 X18 C 8 10.0K R329 H= OPTION ENABLED HP2231 4 /PB_OPTION 10.0K A B X18 6 RST 4.75K R454 B R457 C471 D402 511 R326 +15V 9 C474 R553 24.3K 2901 1 R529 /ARC 7 R327 /COUNT 2.21K R317 BALL_OR_FUSE R313 DON_RESET 5 R322 UNTIL ARC STARTS P BOOST 10 13 3.92K X23 8 3 T2 X10 B 4.75K OCI3 3.01K SG3846 1 X22 B START_RESET V=ARC 4 A 11 R557 +15V /PWM_SYNC T1 12 10K /PB_LOCAL +15V PINCH KNEE J28 3 10 KEEP IN P_BOOST MC14013B B X16 1 C +15V R328 CW 4.75K 50V 14 15 A 3.92K R308 3.92K 100K R311 NAND X16 9 8 H = A>100 X17 NAND 9 D2 SET 2 C422 X36 1W +15V_REM "KEEP ALIVE" X30 R548 2.67K COMMAND SIGNAL NOTE: 10 VSS 8 +15V RAMP J28 2 J27 RESET 2 SET 1 5 CURRENT LEVEL D415 R549 J28 4 J28 D1 6 J27 5 J28 10 7 PINCH SLOW RAMP 13 5 7 10K 16 Unused Devices +5.1V 11 NAND R455 14 1us MIN PULSEWIDTH X29 7 J28 CLOCK 2 2 +15V R539 12 C450 REMOTE_POTS 100 LM224 RESET 1 R323 0.1 9 6 B 35V C307 DZ16 C452 1.0 PINCH RAIL X29 SHUT 50V R493 7 /HOT_START 12 ENABLE (SHEET 2) PWM_EN 9 15V 1.0 2 A X31 DZ8 C309 J28 (SHEET 2) R428 B X24 1014 R445 1.00M C449 12V REMOTE BG POT DZ15 13 +15V R492 OUTB RT Verror 1.00K 12 10.0K HOT_START J27 1 PB_START 4 B /PWM_SYNC D414 R491 5 4 /Q2 X16 NAND 5 7 +5.1V BACKGROUND COMMAND +15V LOCAL_POTS 1.00K ENERGY CONTROL OPTION OUTB 11 OUTA COMP R537 INCREASE TAILOUT 10.0K 3 PWM CT 7 9 OUTA 12 GND 6 50V R435 CW D407 C447 1.0 35V J2 14 1014 C417 A 100 ARC_START TIMING 2N4401 NAND 1W R475 R476 R477 2 35V 12V R434 10.0 10K X24 0.1 J2 7 6 H = STAINLESS R345 +15V 13 Vc I+ 50V 330p 5 R444 267K HOT START Q6 1 R469 1.00M 10.0K D406 ARC_START C404 1.0 R478 J3 OFF 35V R480 J3 6 1.00M 5 10K 1.0 R489 100 HOT START TIME J3 CW C 9 DZ11 +15V C446 100 2 Return to Master TOC R472 5.62K 3SEC X31 8 +15V CW 500 2700p R520 R406 .018 15 Vin R426 10.0K A 2 1.00M 2.67K R544 CLOCK 1 13 14 10.0K 2 P BOOST R534 2.67K R545 LOCAL BG POT 2.67K 10K CW 3.32K ERROR AMP R490 J2 11 SHORT OR 500K POT C 100K 1014 D409 R546 1N4936 +15V 1 SS_WIRE 2N4401 10.0K BACKGROUND METER +15V 4 1 CLIM X25 ISYNC R538 10.0K 82.5K 3 6 14 VDD R459 100K CURRENT X22 500K R325 1.3 msec PLASMA X17 15.0K 3 V- 3 10 C418 R427 ON BOARD /PB_OPTION 0.1 3.1V 47.5K 100K 11 X30 PWM_SYNC 3 13 P_BOOST TIME (SHEET 2) 1.00K R425 2 R420 1 R443 11 A X15 C308 ENERGY CONTROL OPTION 2 Vref COMMAND J2 1N4936 ARC 3us MAX DEADTIME R424 X24 V+ 6 100V GENERATOR 100V 475K 5 8 D401 R419 1 D OPTO ISOLATOR DARL. DRIVE HP2231 20V WAVEFORM P_BOOST COMMAND 5 /Q1 CW 47p 47.5K 13 10 PLASMA BOOST METER C406 39.2K R563 X21 COMMAND /HOT_START X15 1 J28 L = MILD D303 C305 12 R554 100p SAWTOOTH 8 C 8 J28 D304 9 R436 LOCAL R407 NAND R441 150K C410 R416 TAIL OUT 2.67K C473 1.00K LM224 NAND 9 ARC_START R439 X21 R421 D 10 50V X19 Q1 2 15.0K C472 R422 CFB X31 11 Q2 NAND 1N4936 1N4936 +5.1V 15.0K PWM_EN 10 R415 12 R /C 8 1.00K C403 R507 35V LM224 10 D 1014 Q9 D420 D301 1 6 9 13 Q1 MC14040 4 /DON_MIN NAND 1 ON TIME COUNTER Q8 R432 12 14 NAND 8 2 BALL_OR_FUSE R320 DARLINGTON 1.00K 1W X34 C 15.0K D NAND 8 10.0K 1V=100A 3 A 10 C 14 Q10 150us MIN +15V 15 Q11 B X15 12 /PWM_SYNC 11 10K Q2 3 AMPS>100 X35 X15 NAND 16 VDD X20 BOOST TIME LIMIT R314 1V R310 6 5 PINCH LATCH B A 100 C402 1.0 X34 X17 R440 100 100 ( SHEET 2 ) 1 A 9 13 5 1 +15V 13 Q9 2N4401 P_BOOST ONLY AFTER 4 4 C 10K R450 10 R404 B 4 12V 17.8K J2 X31 3 DZ10 10.0K VSS /PB_LOCAL PINCH C419 1.8 6 R408 R403 R533 J27 10 J2 16 10K NAND 10K PRI_FB 12 10 PB_SCALED NAND X14 2 /BALL /PINCH +5.1V 1N4936 2N4401 12 D400 CW 100K PINCH COMMAND X13 NAND CFB R532 1.00M LOCAL PB POT J27 R471 8.25K 47.5K 15 2 R530 "ANALOG LOGIC" +15V J2 9 11 2.5V 10.0 R501 8 REF 6 2901 13 X14 56.2K 35V R500 10.0 REMOTE PB POT TL431 10 X23 4.75K 1 X33 C400 1.0 J27 R502 LOCAL_POTS PINCH LIMIT NAND 6 10 B D302 Q4 2 B 9 0.1 50V GND 5 /HOT_START PINCH X23 2901 8 100V 2 6 ( SHEET 2 ) PINCH RAMP 11 1.50K 35V C401 75.0 1W R402 C461 12V R503 DZ18 C460 1.0 C 500A MAX 15.0K D 13 B.PT 14 D X14 X14 4.75K 5 RST R316 R453 8 10K R550 R504 10K +15V 13 9 1 C304 9 /Q R442 R401 75.0 100V PINCH 10 .294V Q2 Q10 8 R414 Q3 7 R318 R446 CONTROL POTS POWER 1.30K R400 1.30K R506 1.30K 1.30K R505 REMOTE_POTS CW 200 C Q4 6 13 NAND 10 Q X9 RESET 4.75K 330p CW FUSE_RESET /RESET X13 8 R306 11 13 1014 R413 10 VDC A X13 B FUSE 4 C A 11 R447 STAINLESS NAND A .0047 X24 5 PINCH DON_MIN 330p B T2 T1 12 26.7K +15V 12 10 D 100K +15V J3 3 9 10K Q7 12 14 13.7K MILD R412 9 C303 13 50V +15V X12 NAND R499 1W 4 A /PINCH C306 330p START /(BALL & SHORT) 2N4401 C407 6.81K X12 NAND 5 3 B 9 /ARC OR RAMP CTRL 15V PINCH FAST RAMP ENABLE R417 DZ12 2.21K R418 35V SS_WIRE R411 9 6 2.21K C409 1.0 100 > .045 DIA WIRE Return to Master TOC 8 X21 1000A/ms B 8 R405 - WIRE TYPE SELECT Return to Section TOC 9 Q5 HP2231 +15V 9 Q1 MC14040 R494 J3 4 NAND 2 /RESET /ARC 2 Q6 3 2 FOR ENERGY 6 B COUNTER 1.00M 15.0K C424 HP2231 6.81K L= .035 X12 1 /ARC PB_START OCI6 Q12 2 R319 CONTROL OPTION /ARC FUSE GEN. PULSE CONTROL OPTION PINCH COMMAND < .035 DIA WIRE 11 A 6 R451 R410 47.5K 10 RESET R334 FAST RAMP - X12 NAND 12 /BALL_DELAYED 4.75K PB_START SIGNAL R409 X22 3 B 1 2N4401 H= .045 X11 NAND BALL_DELAYED 100p HP2231 39 /C VSS 5 /PINCH 20V 2 C301 +15V TO FE (SHEET 2) C465 1 /BALL_RC 13 11 A NAND 12 PINCH BREAKPOINT WIRE SIZE SELECT X11 TRIP TIMING Q8 Q2 8 COMMAND 100 R510 7 8 /RESET 2.67K 4 B /KILLER 10.0K 10.0K X36 NAND 5 35V 13 D423 100A/ms 11 R449 C412 1.0 C R423 6 +t 56 R303 150us FUSE ENTRY SLOW RAMP 12 R PINCH 1ms R452 OVERCURRENT 13 Q9 Q3 ARC & /RAMP CTRL 1N914 Q8 Q4 6 DV/DT ARC KILLER PULSE R525 R526 J3 R523 150K +15V 2901 10 R559 FUSE NAND 5 13 D Q7 5 FUSE 1N914 X28 14 /KILLER 4 R307 1014 9 X11 OCI1 100V 100V 11 50V D424 15.0 33.2K R514 332K 8 C R512 150K X35 75.0 +15V R522 D410 1 C475 100K R524 10 5V 10.0K CR1 12Vdc 6 5.62K ARC R515 7 5 3V 1V/100A R516 X35 B 13 KILL_RC /ARC 332K 4 12 X16 NAND 15 Q10 15 /RESET R562 2700p 6 1014 CURRENT FEEDBACK ( SHEET 2 ) 1N4936 35V J1 TO TRIGGER CIRCUIT OVERCURRENT FAULT 3 A NAND 2 Q7 D 11 Q11 X32 7 /Q ARC 10.0K X36 6 Q 2N4403 D416 C423 1.0 10.0 +15V 33.2K +t .25 J1 4 +15V R466 1 R517 J1 3 2 R518 R467 221K BOARD 1 2 3 R521 SENSE +5.1V OVERCURRENT R509 KILLER 4.75K D300 1 4.75K FOR ENERGY C302 +15V OUTPUT DISABLE D411 2 KILL_START 3 R561 +15V B T2 RST +15V 1 1014 5 A X9 HP2231 200V X35 A A /BALL 2 T1 4 R540 NAND 10 D 12 Q5 R305 C300 10.0K ARC 7 FROM FE (SHEET 2) 10.0K 2 A R560 .33 R513 OCI2 ARC/SHORT DETECT X11 NAND 8 750us R302 CW 9 /KILLER NAND Q6 3 22.1K R301 50K BALL_OR_FUSE 4.75K 11 1 D 13 D 2 R448 375us OCI3 0.1 50V GND 5 TO FE (SHEET 2) ARC 10K BALL +15V 82.5K 68.1K J1 X13 X17 16 VDD 26.7K +15V "DIGITAL LOGIC" PINCH TO BREAK INTO ARC R312 10.0K 1 33.2K 1N914 1 CURRENT D305 3 10V 1W C464 PINCH R333 2.5V CW OVERCURRENT TRIP 68.1K Return to Master TOC Return to Section TOC R519 R309 3 Q3 2N4401 FORCES THIRD CONSECUTIVE Q12 /KILLER 6 C429 HP2231 11 1 33.2K 825 R487 R482 R474 8 REF 20V HP2231 10.0 3.92K R339 825 825 R488 R486 825 X26 TL431 35V 11 PINCH SIGNAL 1 POWER R484 0.1 50V LM224 8 Vcc OCI2 C458 OP AMP 50V 8 Vcc X29 0.1 OP AMP LT1014 12 6 FROM FE (SHEET 2) 56.2K C463 1W DV/DT LEVEL DETECT R564 12V 35V C448 1.0 B 22.1K DZ19 C462 1.0 R511 1.00M C314 1 DZ9 10V 1W 7 C428 X24 0.1 50V LM2901 4 +15V DV/DT METER 10.0 1 LM224 INTEGRATOR 47.5K 7 C427 COMPARATOR 50V 4066B 4 X23 0.1 SWITCH 50V 4066B C459 X30 0.1 SWITCH 7 PINCH LIMITER HP2231 +5 VOLT GROUND PLANE D412 7 C457 X31 0.1 50V REPETITIOUS ADJUST FE (SHEET 2) CURRENT CFB C426 X22 SWITCH 4066B 3 +15V OCI2 B OCI1 R300 X34 A 2.43K R528 100 DZ20 7 DV/DT KILLER PINCH KILLER Varc METER_2 R483 3 500 1N4007 7 0.1 50V 4066B POWER PLANE 14 GROUND PLANE METER_1 2 10.0K C313 REMOTE R473 D413 243 D309 D308 1N4007 7 14 C425 SWITCH 50V 4093B 14 X21 0.1 NAND 50V 4093B C468 X36 0.1 NAND 50V 4 10.0K R337 R338 1400V J28 14 +15V OUT s18395-23 35V 1000 .0047 C438 X18 0.1 NAND 4093B R340 2.21K lm350 2.43K C310 18 VAC C444 X17 0.1 50V 7 +15V 7 +5.1V C311 C437 NAND 7 +15V LM224 5 R527 POWER PLANE C312 4093B 0.1 4.75K X34 B X8 ADJ X16 50V R555 LOCAL D310 J28 7 6 DIGITAL, TRIGGER & ANALOG SECTIONS 7 C436 NAND 100K R508 IN 4093B 0.1 R552 2.67K R541 D307 X15 50V R429 2.67K R542 1N4007 C435 NAND 267K 2.67K R543 +15V D306 4093B 0.1 14 GROUND PLANE 2.67K +15V POWER SUPPLY FOR X14 50V 4093B 7 GROUND PLANE J27 1 C434 NAND 50V 4093B 7 X13 0.1 NAND 50V 14 R341 11 C433 X12 0.1 NAND 14 15.0K 4093B 0.1 14 R332 X11 50V LT1014 11 C432 C467 OP AMP 14 3.92K 8 X35 0.1 50V LM224 14 W1 8 C466 X34 OP AMP MC14538B +15V +15V POWER PLANE 14 R321 8 0.1 50V TIMER 50V MC14538B 14 56.2K 8 C445 X10 0.1 TIMER 50V MC14040 C443 X9 0.1 COUNTER 50V 14 15.0K 7 C456 X32 0.1 COUNTER MC14040 14 CW 35V 12 C442 X20 0.1 50V MC14013B 4 R335 SG3846 C441 DUAL FF C440 4.7 4 R304 X19 0.1 50V PWM 16 R551 X25 16 R456 16 3.01K 16 100K 14 C439 /KILLER 13 (PINCH KNEE) 2781-A Return to Master TOC Schematic - Control PC Board - Codes 10151 - 11092 - (G2781 Sheet 1 of 2) 1N4007 Return to Section TOC G-6 ELECTRICAL DIAGRAMS G Return to Section TOC G-6 CHK. SUP'S'D'G. SHT. NO. G 2781-A INVERTEC STT & STT II 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 1.50K R221 R222 R228 1.30K 1.30K 1.50K R223 R224 1.30K 1.30K R229 D208 DZ6 3.3V 1 1W CNY17-3 OCI7 5 ON=TRIGGER ON D211 OFF=TRIGGER OFF C207 6 2 4 20 50V D209 D210 ISOLATED CIRCUIT 56 TO POWER D207 R238 +t TRIGGER OCI3 = OPTION ENABLED 267 ( UNUSED 9 +t 10.0 D206 CR1 R239 6 4 R230 R216 FAN TSTAT PINCH KILLER B OCI1 BOARD OPTION ENABLE DIODE OFF = OPTION DISABLED 1N4936 HP2231 J17 100V TRIGGER 6 CHOKE TSTAT 1.50K 9 L=PWM OFF 330p 50V CR1 CR 1 FROM SHEET 1 J4 24 VAC OPTION ENABLE H=PWM ON C205 0.1 J4 DIODE ON L=PWM ON INTERFACE 10 OVERHEAT INDICATOR HP2231 D105 H=PWM OFF C204 10K OVERCURRENT FAULT FE 8 R235 R212 8.25K 15.0K R214 DT ENERGY CONTROL ( SHEET 1 ) 14 11 Y 15V R153 C 2901 8 J4 ON PROTECTION BOARD PINCH PULSE J17 10.0 10.0 R209 26.7 26.7 R206 8.25K R141 OPTOCOUPLERS +12VFE 2N4401 681 ( SHEET 1 ) L=ARC 3.92K X28 2 OVERVOLTAGE 1W ARC DETECTOR FOR INITIAL 2 C203 ARC/SHORT DETECT H=SHORT Q1 ADJUSTMENT 2 DZ3 DT HP2231 OCI2 HP2231 D104 1N914 1N4936 A R231 FE DERIVATIVE_TRIP R140 R149 ARC 332 100V X6 B 10K R147 FE 10 1 2901 2901 PWM ENABLE TO ANALOG LOGIC 9 47.5K D X28 4 10K X6 5 D205 X28 B 7 TRIGGER TO DIGITAL LOGIC 5 2.3V PINCH START R146 10K 50V 6 C202 PWM_EN 332K C206 R240 8 47.5K ( SHEET 1 ) +15V R234 8.95V BOARD A J17 2 2901 9 R163 3.6V R211 22.1K +15V 1.7V = 150A PRIMARY +15V 5W PWM DT_DELAYED 330p 820p 1.89V NORMAL D204 1N4936 FAN R C106 NEG_CLAMP D203 1N4936 150 12 7 1N914 +15V ( SHEET 1 ) OPTOCOUPLER 4 X5 A 3.92K 1.00K 13 A OCI5 FROM D115 3.92K DT PHASE B 1 10K SMP04 R208 R210 ON POWER 4 C110 CW D103 1N914 C R148 10 J4 3 1 R150 2 HP2231 X5 2901 6 R134 3 X6 A R136 DT_RC R133 FE 1 4.75K 267K 7 ARC DETECTOR 14 26.7 R207 +12VFE D 12 100V R135 R132 22.1K 3.92K B 6 PWM R131 R130 3.92K Return to Master TOC OCI5 FROM X3 100p +12VFE 47.5K SMP04 Varc SAMPLE ARC_TRIP R128 C201 +15V +12VFE Varc SAMPLE C105 4.75K 26.7 1N4936 PRI_FB L=HIGH DV/DT AMPLIFIER SHORT DETECT 1N914 .33 200V H=LOW DV/DT 10K OLD DV/DT FE TRANS. R152 R164 DV/DT SAMPLE PULSE FE PHASE A R165 825 D C200 J4 8 CURRENT ( SHEET 1 ) 2 DV/DT 100K R145 15 9 2 Y 3 13 2901 10 J4 DV/DT LEVEL DETECT D202 1N4936 DV/DT 10X 5K +12VFE 2901 8 D102 6 FE C X3 1N914 3.92K 14 dv/dt 7 D201 1N4936 OP470 R144 1N914 X5 +12VFE FE 11 9 D116 13.7K SMP_STROBE R122 13.7K R124 SMP04 50V HP2231 D200 R200 Y OCI2 TO DIGITAL LOGIC X5 B X4 B 10K PRIMARY CURRENT FEEDBACK 125:1 RATIO B 11 NEG_CLAMP D117 50V 5 R142 1 7 820p DT_DELAYED OUT R121 R125 13.7K R123 R120 13.7K 68.1K 13.7K R119 1.00M R126 13.7K 51.1K R118 1N4007 CIRCUIT 1.00K 4 0.1 B X3 5 C109 +12VFE FE R127 R117 D100 C107 FE Varc SAMPLE +12VFE FE +12VFE 68.1K 13.7K SMP04 FE 100V R129 R116 13.7K 26.7K J5 R115 C103 100p R114 47.5K R108 20.0K R162 20.0K 12V 1W 1 + STUD DZ2 10K 10 NEW DV/DT R137 D101 1N914 .0047 2 6 4.75K 3 20V .400V CW TURN 3 C104 50V J5 DV/DT A X3 VARC_SCALED R159 1 OP470 C108 1.8 100K 4.75K X4 A R113 2 FE R112 243 SAMPLE 4.75K 400V 3000V 1W 47.5K .001 .0047 SENSE PANEL 4.75K C101 C100 VOLTAGE R111 INPUT FROM DV/DT Varc 47.5K R139 R110 12V R143 C102 DZ1 TRIGGER 1V REF ARC VOLT FILTER 47.5K R109 R138 +12VFE 100p J5 6 +12VFE J17 TO ENERGY CONTROL OPTION FE J5 3 R104 13.7K R102 13.7K R101 13.7K R100 Varc FILTERED J5 7 - STUD 13.7K FRONT END 13.7K 2781-B Return to Master TOC Schematic - Control PC Board - Codes 10151 - 11092 - (G2781 Sheet 2 of 2) 5 Return to Section TOC G-7 ELECTRICAL DIAGRAMS G Return to Section TOC G-7 ( SHEET 1 ) +15V 2 R155 1.50K J17 7 R160 B DIODE ON OCI3 = OPTION P_BOOST TIME OR NOT OPTION P_BOOST TIME HP2231 J17 2 ENERGY CONTROL 3 R161 TIME ( SHEET 1 ) A Return to Master TOC Return to Section TOC H = PINCH L = NOT PINCH H = START PLASMA BOOST TIMING 12 ( SHEET 1 ) WIRE TYPE POSITION OCI6 ENERGY CONTROL OPTION ( SHEET 1 ) HP2231 +12VFE J4 PB_START SIGNAL FOR OCI6 6 ISOLATED CIRCUIT +12VFE +12VFE POS FE POWER PLANE 16 J17 +12V OUT 3 X6 0.1 D108 C111 36 VAC Dgnd Vss 8 13 J5 8 18 VAC C113 CT J5 2 .0047 J5 47 1400V 35V -15V OUT 11 OPTION COMMON OUT 6 27 C118 8 OCI6 0.1 50V C129 0.1 50V HP2231 GND 5 GND 5 FE D113 +12VFE 35V C119 GND C116 7915 IN D111 C120 D114 C124 27 0.1 35V X2 UNUSED GATES 4 3 C126 OUT 50V OP AMP C125 0.1 50V D112 FE FE OP470 V- 6 X5 LM2901 11 12 X6 C 4 NAND 5 COMPARATOR C127 0.1 50V NEG FE POWER NET FILE: G2781_1D1 10 FE J17 -15VFE +12VFE 0.1 X4 -15VFE J17 V+ 50V s15128-12 1N4007 1N4007 CONTROL HP2231 Vcc C128 POS FE POWER PLANE D110 ENERGY C117 243 C115 .0047 4 GND 5 CW 1400V C114 18 VAC 50V 8 OCI1 FE GROUND PLANE R157 500 0.1 HP2231 FE ADJ R156 35V 1000 50V Vcc C123 OCI5 OUT s15128-15k1 1.82K C112 R158 XFMR LM350 IN D109 1N4007 0.1 SMP04 4093B 7 1N4007 C122 X3 NAND 50V 8 Vcc Vdd C121 D107 X1 Return to Master TOC B L = MILD STEEL ON SHEET 1 50V ENERGY CONTROL OPTION H = STAINLESS 14 Return to Section TOC A 7 J17 X28 "D" COMPARITOR C211 0.1 ( SHEET 1 ) HP2231 12 LM2901 ENERGY CONTROL OPTION L = NOT PLASMA BOOST J17 COMPARATOR PINCH SIGNAL FOR OCI1 7 HP2231 5 X28 J4 7 J17 3 J4 1 1.50K 1 4 OPTION P BOOST DIODE OFF = LOCAL P_BOOST TIME D106 1N4936 OPTION P BOOST TIME UNUSED 4 1.50K ENERGY CONTROL X4 C 9 GENERAL INFORMATION 8 OP470 CAPACITORS = POWER SUPPLY FOR "FRONT END" 13 MFD ( .022/50V RESISTORS = Ohms ( 12 X4 D LAST NO. USED ELECTRICAL SYMBOLS PER E1537 -15VFE DIODES = 14 OP470 1/4W 1A, 400V UNLESS OTHERWISE SPECIFIED) LABELS UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) 100 SERIES- ARC SENSE CIRCUIT (SHEET 2) 200 SERIES- TRIGGER CIRCUIT (SHEET 2) 1 4 5 8 J5 Front End Vac and Varc 1 6 7 12 J17 Energy Control Option 1 6 7 12 J4 Trigger Circuit I/O and Vac N.A. 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 + .O2 ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS NOTE: Ch'ge.Sht.No. MLD DATE 04/04/94 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. STT CONTROL TYPE SUBJECT NONE SCALE DR. CHK. W4 EARTH GROUND CONNECTION EQUIP. CLEVELAND, OHIO U.S.A. 5-24-96E Q10 VOLTAGE NET FRAME CONNECTION THE LINCOLN ELECTRIC CO. 5-19-95 X36 117, 211, 310, 424 COMMON CONNECTION 400 SERIES- ANALOG LOGIC CIRCUIT (SHEET 1) SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE OCI7 129, 211, 314, 475 D- POWER SUPPLY SOURCE POINT 300 SERIES- DIGITAL LOGIC CIRCUIT (SHEET 1) NOTES : 165, 242, 345, 564 C- SUPPLY REFERENCE DESIGNATOR SERIES DEFINITIONS FE DZ20 R- FV SCHEMATIC (Sheet 2 of 2) SUP'S'D'G. SHT. NO. G 2781-B INVERTEC STT & STT II 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 R103 R102 R101 R100 R107 R105 J27 D109 C113 R121 R119 D110 D111 R106 R104 R505 D208 R521 C207 C467 R512 R515 DZ9 R509 DZ20 R108 R122 C461 R504 C468 R335 Q10 R522 R518 X35 R311 R524 R316 R517 C464 R162 C460 R400 STT CONTROL X24 R516 C458 DZ12 R418 C125 R111 DZ18 R532 R506 X36 X17 X19 C422 R459 R429 R413 D403 X29 Q7 R556 R500 X15 X16 Q4 R555 X25 R553 C474 C428 X21 C448 R495 C405 R511 DZ11 D409 R469 R406 R319 C425 R450 X22 X30 C411 R431 X34 R407 C406 R324 R333 R341 R332 R329 C424 OCI3 DZ16 OCI4 C123 R165 C430 R345 R344 D115 OCI5 OCI1 R534 DZ8 R334 R541 C457 R343 R152 D414 R432 R473 R155 R454 R456 X6 X10 R328 C434 C418 X13 C440 R529 R330 X23 C439 R457 R339 R337 R540 D405 R318 X18 C438 R530 R471 D300 R309 R308 DZ3 R135 C126 R550 R301 Q1 R153 D104 R149 R147 R129 R132 R126 R123 D303 R320 X11 X9 X12 C302 R151 R140 X14 R474 R545 R508 R159 C102 X31 C413 R436 R472 D105 C454 R437 R482 C127 R300 C311 C309 R144 C104 C101 R544 R548 C308 R487 C446 R547 R416 R430 X26 R417 C409 J1 R124 C305 R486 Q2 R488 R158 R109 R503 R239 J4 C447 R415 R403 R542 R231 R230 R533 C451 C469 R492 R208 D407 DZ15 C402 R520 C122 R110 R340 DZ10 DZ17 R475 C404 R546 R209 R496 C110 Q9 Q3 C462 C403 C455 R493 OCI7 D400 D415 R490 D408 D413 R528 R479 D406 C449 R203 R201 R481 R480 D211 R204 R202 C416 R527 R507 D209 Q6 OCI6 R310 D200 R205 R440 C128 D205 R485 R445 R408 C463 C129 R200 C201 R235 R497 C121 R154 R242 R213 DZ19 C453 R498 R536 D106 C205 C450 W2 C452 R494 R112 R236 R241 R422 W3 C466 R161 R210 C203 C459 C417 R160 R233 C206 C410 R423 W1 D116 R232 R421 R424 R463 W4 R461 C426 C103 R419 R444 D117 D308 R499 R114 C470 R157 R148 D306 DZ2 R561 R211 R420 D401 C202 C105 R163 R131 X8 R448 D112 D107 R156 D103 R137 R514 R237 R212 C106 R133 D309 C211 R214 R136 R134 D307 R425 C475 R215 X5 R146 C312 R427 D424 C117 C443 D419 C407 D310 R338 D402 R428 C313 D418 R551 C314 R411 R449 R127 C429 R412 D404 OCI2 D417 R410 R141 R409 R128 R414 C419 R560 R442 R164 R458 R426 C465 R446 C415 D422 D114 C118 R125 R554 D113 R142 C441 D411 D421 C120 R143 R523 R304 D102 R538 R447 C300 C109 R564 D410 R302 D305 X3 R525 C433 R331 DZ1 R539 R451 R452 R305 C427 R552 C472 C119 IDENTIFICATION PART NO R510 Q8 R317 X1 R453 C107 C306 C124 C444 C473 X4 D301 D420 R455 R314 R150 R113 C445 R312 C304 R145 C307 C112 REQ'D ITEM R325 C303 X2 R323 C108 R130 IDENTIFICATION C414 R138 R313 D101 R322 R468 R139 R303 C111 R439 C471 C301 C432 C116 PART NO C204 C435 R321 C115 D302 R306 Return to Master TOC R307 C437 C114 C100 R117 R115 J17 J5 Return to Master TOC R557 Return to Section TOC REQ'D R441 Return to Master TOC PC Board Assembly - Control - Codes 10151 - 11092 - (G2782) C436 Return to Section TOC G-8 ELECTRICAL DIAGRAMS G 2782-1 Return to Section TOC G-8 CAPACITORS = MFD/VOLTS Return to Master TOC Return to Section TOC RESISTORS = OHMS THIS SHEET CONTAINS PROPRIETARY INFORMATION UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLE SIZES PER E2056 5-19-95 THE LINCOLN ELECTRIC CO. AND IS ON 2 PLACE DECIMALS IS .02 7-28-95C ON 3 PLACE DECIMALS IS .002 5-24-96E ON ALL ANGLES IS .5 OF A DEGREE MATERIAL TOLERANCE t(" ") TO AGREE THE LINCOLN ELECTRIC CO. WITH PUBLISHED STANDARDS. OWNED BY EQUIP. THE LINCOLN ELECTRIC CO. TYPE CLEVELAND, OHIO U.S.A. NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF NOTE: SCALE DR F.V. FULL DATE 6-8-94 CHK 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. FV SUBJECT REF. STT INVERTER WELDER CONTROL P.C. BOARD ASSEMBLY L8441-3 G 2782-1 SHT. SUP'S'D'G NO. INVERTEC STT & STT II 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. 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 II 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. 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 II 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. 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 II 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 26.7K +24V +24V J14 J6 C10 50V 10 ADJ J6 D9 D11 +24V 4 C7 267 Return to Master TOC J14 2 1 J7 4 1 J6 C 4 5 8 6 10 TRIGGER 4 6 100K J6 7 HAVING A COMMON CODE NUMBER. 1 GENERAL INFORMATION UNUSED 12 COM LAST NO. USED ELECTRICAL SYMBOLS PER E1537 MFD ( .022/50V CAPACITORS = 14 RESISTORS = Ohms ( DIODES = 13 1A, 400V 1/4W UNLESS OTHERWISE SPECIFIED) UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) ON HOLES SIZES PER E-2056 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS Ch'ge.Sht.No. 3-29-96L 9-11-92B 9-27-96F 6-25-93A 10-25-96 9-24-93D R- 69 C- 14 D- 16 DZ- 6 VOLTAGE NET POWER SUPPLY SOURCE POINT COM COMMON CONNECTION 4-13-95C 3-22-91 LABELS SUPPLY FRAME CONNECTION FILENAME: M16018_6JA ON 2 PLACE DECIMALS IS + .O2 P6 SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 5 ON 3 PLACE DECIMALS IS + .OO2 NOTE: X4 X4 11 UNLESS OTHERWISE SPECIFIED TOLERANCE 3 2 DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS X4 LM224 COM 1 CONTROL CNY17-3 WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS 3 2 R24 50V 4.75K P6 9 J6 C11 500 15J OCI1 NOTES : N.A. COM R25 TP2 5 20V COM 15.0K OUT LM350 24Vac P6 X5 1 P6 2 COM R14 D10 IN R21 9 33.2K 5.11K 4 J6 X4 C6 1.8 J6 2.21K 8 R13 A D8 10 R19 COM COM J14 10K R17 IRF513 J14 R23 P6 5 D13 33.2K D12 P6 267K S DZ1 39 D RELAY COILS P7 R18 C14 X4 R16 R10 40V 33.2K 4 P7 33.2K R11 2 R22 3 600mA D 5 100 Q40 R43 FROM PROTECTION BD. 2 100 100K 1W J7 1N4936 R12 10K R42 D14 B 475K J14 1 J7 150K R41 10K R9 +24V DZ6 6.2V Return to Master TOC J6 6 P7 7 E Vin + Vc DZ5 P7 8 J7 50V D4 Return to Master TOC Return to Section TOC TRANSFORMER J7 N.I. IN Return to Section TOC TO PULSE 30V F N.I. IN 1W Return to Section TOC 1.0A 30V 0.1 R8 C3 +24V D16 1.0A C8 GND INV IN 267 243 D15 OUT 267 R3 C2 50V D2 t ADJ C1 50V + .24 R4 LM350 J7 6 OUT X1 J7 5 P7 IN 1.50K P7 D3 100K +t D1 R5 R1 R2 Return to Master TOC G-12 ELECTRICAL DIAGRAMS M 16018 Return to Section TOC G-12 EQUIP. THE LINCOLN ELECTRIC CO. DR. MJH DATE POWER BD SCHEMATIC SUBJECT NONE 11/10/92 INVERTEC TYPE CLEVELAND, OHIO U.S.A. SCALE EARTH GROUND CONNECTION CHK. SUP'S'D'G. 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. SHT. NO. M 16018 INVERTEC STT & STT II 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. IDENTIFICATION POWER BOARD J14 D14 R5 REQ'D L8033-[ ] ITEM J7 Return to Section TOC G-13 ELECTRICAL DIAGRAMS C14 Return to Master TOC Return to Section TOC G-13 D5 R23 CAPACITORS = MFD/VOLTS INDUCTANCE = HENRYS 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 II +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 1.50K OCI1 2 7 D5 3 ON 4 267 R5 DZ2 HP2201 12V = Darlington ON OFF = Darlington OFF 3.92K 1K Return to Master TOC Return to Section TOC +15V 1W J13 C5 0.1 50V 1 VS 2 IN 3 NC 4 X2 GND 4429 VS 8 OUT 7 OUT 6 GND 5 R3 Symmetric Gate Drive Layout STT CONTROL BOARD D13 1N5402 1N5402 E .33 D8 D11 B TWISTED R18 R17 1.00K 1.00K D7 1N5402 R16 C10 200V 1N5402 BLUE R14 D12 1N5402 1 R15 1N5402 J12 10W 1.00K D10 C MODULE 2.7 1.00K Return to Master TOC Schematic - Darlington Drive Board - Codes 10151 - 10383 - (M17581) 10VAC Return to Section TOC G-14 ELECTRICAL DIAGRAMS M 17581 Return to Section TOC G-14 J12 C9 3300 D9 50V 1N5402 J12 J12 BLACK 3 4 R8 20 5W D 10.0 R7 100V S C8 DZ3 Q2 4A G 500p 18V 1000V 1W C6 0.1 GND 50V 1.50K GND GENERAL INFORMATION LAST NO. USED ELECTRICAL SYMBOLS PER E1537 +V RESISTORS = Ohms ( Return to Master TOC DIODES = Return to Section TOC MFD ( .022/50V CAPACITORS = 1A, 400V 1/4W UNLESS OTHERWISE SPECIFIED) LABELS UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) C14 0.1 50V 8 J13 1 OCI1 J12 3 1 N.A. 2 GND 4 5 6 3 4 WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY 13 3 VOLTAGE NET FRAME CONNECTION NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E-2056 ON 2 PLACE DECIMALS IS + .O2 ON ALL ANGLES IS + .5 OF A DEGREE NOTE: D- DZ- COMMON CONNECTION SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE ON 3 PLACE DECIMALS IS + .OO2 GND 17 POWER SUPPLY SOURCE POINT Ch'ge.Sht.No. EQUIP. THE LINCOLN ELECTRIC CO. 5-19-95 3-29-96L SCALE DR. MLD DATE SUBJECT NONE 03/23/94 INVERTER WELDERS TYPE CLEVELAND, OHIO U.S.A. MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS EARTH GROUND CONNECTION FILE: M17581_1AB NUMBER. HP2201 18 C- SUPPLY NOTES : Vcc R- CHK. BS SCHEMATIC, DARLINGTON DRIVE SUP'S'D'G. 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. SHT. NO. M17581 INVERTEC STT & STT II 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 Master TOC XXX D2 D1 D12 D11 XXX Return to Section TOC D6 PART NO. J12 G2778-[ ] D10 REQ'D XXX J13 C8 Return to Master TOC Return to Section TOC ITEM CAPACITORS = MFD/VOLTS Return to Master TOC Return to Section TOC RESISTORS = OHMS 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 II 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. 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 II 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. 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 II 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 15.0K 20 1N4936 DZ7 R32 2N4401 R28 40V 40V 2N4403 1 Q12 PRIMARY C4 600mA DZ2 10V 100V TRANSFORMER A 1N4936 1A BYT12P600 C1 R34 10.0 R24 R30 1 8 D10 1.00K C5 C6 12 R NEGATIVE INPUT L 8440 Return to Master TOC A1 A2 1/2W R29 R21 6.2V FILTER CAPACITOR BYT30P600 2N4403 600mA CANADA FRANCE NOTE: AUSTRALIA Return to Section TOC 39.2K WITH PUBLISHED STANDARDS DZ9 40V 39.2K INPUT NOTES : Q11 1.00K 1.50K C2 47.5 1 600mA R23 R40 MATERIAL TOLERANCE ("t") TO AGREE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY 1N4936 R22 22.1K 39.2K R41 D7 1A 100V IRFD110 R37 R1 Q1 R2 Return to Master TOC Return to Section TOC 221 R39 39.2K SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE W R38 N.A. D1 1N4936 ON ALL ANGLES IS + .5 OF A DEGREE A2 BYT30P600 9-11-92 TRANSFORMER PRIMARY A2 100 INVERTEC V300 TYPE DR. 4 5 10-8-93A R5 EQUIP. 1200V C2 1N4936 SUBJECT .047 R D6 SWITCH BOARD SCHEMATIC FRAME CONNECTION C3 10.0 C7 Ch'ge.Sht.No. 50V ON HOLES SIZES PER E-2056 2700p ON 2 PLACE DECIMALS IS + .O2 475 DATE S5 SCALE S4 M. A. P. S3 CLEVELAND, OHIO U.S.A. S1 S2 THE LINCOLN ELECTRIC CO. C1 UNLESS OTHERWISE SPECIFIED TOLERANCE 475 RESISTOR A2 BYT12P600 (UNLESS OTHERWISE SPECIFIED) UNLESS OTHERWISE SPECIFIED) SNUBBER A1 A2 IRFP460 FILE NO. L8440-1AA R13 C2 100 1.50K D5 10.0 R42 D5 1N4936 G5 R6 R10 20 D4 G4 10.0 15.0K D3 NUMBER. 1/2W 1W D2 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE DZ3 10V R11 600mA 40V 2N4401 1W D1 G3 R17 15V 40V 2N4403 1 Q4 R7 DZ4 G2 1A, 400V Q5 600mA G1 10.0 DIODES = 1W R8 UNLESS OTHERWISE SPECIFIED) 1W IRFD110 ELECTRICAL SYMBOLS PER E1537 3.3V 40V 2N4403 10V 100V DZ5 600mA DZ1 1A GENERAL INFORMATION R12 Q6 Q3 C1 POSITIVE INPUT 9 B 1/4W D9 1N4936 MFD ( .022/50V 1W 1.00K R18 R14 6.2V 1/2W RESISTORS = Ohms ( DZ6 40V 2N4403 CAPACITORS = R35 R15 Q7 1.00K Return to Master TOC 47.5 1 600mA R16 EARTH GROUND CONNECTION 1N4936 IRFD110 22.1K COMMON CONNECTION D3 1A 100V ON 3 PLACE DECIMALS IS + .OO2 Q2 R4 100 POWER SUPPLY SOURCE POINT 10 LABELS 221 1N4936 VOLTAGE NET 8 C- D4 1N4936 W SUPPLY 42 R- D- LAST NO. USED Schematic - Switch Board - All Codes - (L8440) D2 Return to Section TOC G-18 ELECTRICAL DIAGRAMS R3 Return to Master TOC Return to Section TOC G-18 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 II 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 3.3V 1W Q1, Q2, Q3, Q10 4 T12704-73 IC PKG MOSFET Q4, Q12 2 T12704-68 2N4401 Q5, Q6, Q7, Q8, Q9, Q11 6 T12704-69 2N4403 4 S19400-1000 100 1/4W 2 S19400-2210 221 1/4W 10 S19400-10R0 10 R7, R30 2 S19400-1501 1.5K 1/4W R10, R32 2 S19400-1502 15K 1/4W R11, R15, R22, R28 4 T14231-20 1 1/2W R12, R14, R20, R21 4 S19400-1001 1K 1/4W R13, R31 2 S19400-20R0 20 1/4W R16, R23 2 S19400-2212 22.1K 1/4W R18, R29, R37, R42 4 S19400-4750 475 R35, R36 2 S19400-47R5 47.5 1/4W R38, R39, R40, R41 4 S19400-3922 39.2K 1/4W R1, R3, R5, R24 DZ12 R22 R28 R24 D7 DZ7 DZ9 C6 R36 R37 R29 R34 R25 R27 R19 DZ2 D10 C8 R32 R26, R27, R33, R34 1/4W 1/4W Return to Master TOC Q6 R6, R8, R9, R17, R19, R25 Q9 R10 Q8 R26 R40 R41 R38 R39 R9 Q5 R8 R6 R33 R18 R17 R35 R42 C7 C2 D9 DZ1 R2 R11 R4 R5 R15 DZ3 D3 DZ6 DZ4 Return to Master TOC Return to Section TOC Return to Section TOC SWITCH IDENTIFICATION S16668-5 R2, R4 L8441-[ ] PART NO. 4 D7, D8, D9, D10 B8 REQ'D C1, C5, C6, C7 D1, D2, D3, D4, D5, D6, Return to Master TOC Return to Section TOC G-19 ELECTRICAL DIAGRAMS D8 Return to Section TOC G-19 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 II 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 12V BD. 1W 2 Power Switch Drive Transformer J16 Capacitor Pre-charging Circuits 3 J16 7 R9 150K 150K J16 150K R10 R13 Return to Master TOC 20W R14 1 2 1 3 1 7 250 20W R11 Return to Section TOC 250 R8 Q2 R12 4A 3 4 J11 4 6 J9,J10 8 900V 14 150K 100 DZ2 J16 14 J16 FROM PROTECTION 12V 1W 13 NOTES : N.A. J16 SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 12 WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY J16 NUMBER. Return to Master TOC Return to Section TOC NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E-2056 ON 2 PLACE DECIMALS IS + .O2 ON 3 PLACE DECIMALS IS + .OO2 FILE: S20799-1AA Ch'ge.Sht.No. 6-25-93C SCALE DR. LC DATE SUBJECT NONE 11-4-92 CHK. INVERTER WELDERS TYPE CLEVELAND, OHIO U.S.A. MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS EQUIP. THE LINCOLN ELECTRIC CO. ON ALL ANGLES IS + .5 OF A DEGREE NOTE: BD. BS SCHEMATIC, DRIVER BOARD SUP'S'D'G. SHT. NO. S 20799 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 II PC Board Assembly - Driver - All Codes - (L9134) XXXX R2 R14 ITEM REQ'D PART NO. IDENTIFICATION XXXX XXXXX XXXXXXX R1 R10 R5 R13 L9134-[ ] DZ1 R7 Q1 DRIVER XXXX XXXX R6 XXXX R8 Return to Master TOC Return to Master TOC G-21 ELECTRICAL DIAGRAMS R9 Return to Section TOC Return to Section TOC G-21 T1 XXXX XXXX R12 XXXX DZ2 R3 Return to Master TOC Return to Master TOC R11 Return to Section TOC Return to Section TOC R4 Q2 XXXXXXX XXXXX XXXX XXXX J10 J9 J11 RESISTORS = OHMS/WATTS CAPACITORS = MFD/VOLTS INDUCTANCE = HENRYS J16 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 II +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 56.2K R6 Return to Master TOC Schematic - Protection PC Board - Codes 10151 - 11092 - (M16097) 5 Return to Section TOC G-22 ELECTRICAL DIAGRAMS M 16097 Return to Section TOC G-22 2 10K 6 4 C3 50V 267K R34 .022 (Over Voltage) 4 J15 B53 FROM (-) UPPER CAPACITOR +5V R22 10K 332K 2 R11 150K 150K R7 6 (Over Voltage) 4 6 C4 .022 50V 267K J15 15.0K R33 D4 J8 1 D8 H5 R31 R29 R25 R24 R23 15.0K 15.0K 15.0K 15.0K 15.0K 15.0K F I L E : M 16097-2F1 OCI1 D3 R30 4 5 1N4007 FROM CENTER LEG OF INPUT CNY17-3V 2 6 4 GENERAL INFORMATION TO CONTROL BD. R1 Return to Master TOC +5V N.A. 12 X1 LM224 11 1A, 400V UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) 2 14 ON HOLES SIZES PER E-2056 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS _ VOLTAGE NET FRAME CONNECTION EARTH GROUND CONNECTION NUMBER. ON 2 PLACE DECIMALS IS + .O2 _ D- COMMON CONNECTION WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY UNLESS OTHERWISE SPECIFIED TOLERANCE _ C- POWER SUPPLY SOURCE POINT NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE X1 13 LABELS R- SUPPLY SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE ON 3 PLACE DECIMALS IS + .OO2 NOTE: DIODES = 1/4W UNLESS OTHERWISE SPECIFIED) NOTES : 4 C1 MFD ( .022/50V CAPACITORS = RESISTORS = Ohms ( J8 LAST NO. USED ELECTRICAL SYMBOLS PER E1537 (Single Phase) 681K C5 Return to Section TOC TO DRIVER BD. 1 X1 2 R12 J15 CNY17-3V R36 B51 OCI4 3 5K 3 5 D6 CW 1.82K FROM (-) LOWER CAPACITOR 1 332 R28 R13 Return to Master TOC Return to Section TOC R35 Ch'ge.Sht.No. EQUIP. THE LINCOLN ELECTRIC CO. 1-25-91 9-11-92B CLEVELAND, OHIO U.S.A. 12-10-93A DR. BS/DB SCALE DATE PROTECTION SUBJECT NONE 9-7-89 INVERTEC V300 TYPE CHK. TJP SUP'S'D'G. 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. SHT. NO. M 16097 INVERTEC STT & STT II 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 D7 OCI3 J15 R34 OCI4 R36 C4 Return to Master TOC C3 Return to Section TOC G-23 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 II 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. 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 II 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. 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 II +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. SINCE COMPONENTS OR CIRCUITRY ON CIRCUIT BOARD MAY CHANGE THE INTERCHANGEABILITY Return to Master TOC THIS DIAGRAM MAY NOT OR CIRCUITRY OF SHOW THE EXACT COMPONENTS ON HOLES SIZES PER E-2056 ON 2 PLACE DECIMALS IS + .O2 ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS CODE NUMBER. Ch'ge.Sht.No. 5-19-95 9-27-96F CAPACITORS = MFD ( .022/50V RESISTORS = Ohms ( DIODES = 1A, 400V 1/4W SUPPLY UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) EQUIP. TYPE CLEVELAND, OHIO U.S.A. SCALE DR. MLD 2 4 THE LINCOLN ELECTRIC CO. FRAME CONNECTION EARTH GROUND CONNECTION COMMON CONNECTION THE LINCOLN ELECTRIC CO. 11-15-96E VOLTAGE NET POWER SUPPLY SOURCE POINT UNLESS OTHERWISE SPECIFIED) J18 FILE: S21410_1BA LABELS ELECTRICAL SYMBOLS PER E1537 BOARD. CONTROLS HAVING A COMMON UNLESS OTHERWISE SPECIFIED TOLERANCE NOTE: A PRINTED OF A COMPLETE AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF GENERAL INFORMATION WITHOUT AFFECTING 14 1014 LT1014 3 THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY 1014 R15 1.50K 8 8 10.0 J18 2 TL431 X1 9 X2 X3 681K 3A 1.00K 1 7 5 13.7K R6 2 1 J18 X1 1014 R9 R7 X1 R1 1.50K 100 3 R2 2K Return to Master TOC VREF 1.6V = 16 mA 1 6 13.7K 10.0K CURRENT CAL CW Return to Section TOC R11 ADJUSTMENT R16 1.00K SOURCE R3 Return to Master TOC Schematic - Current Sense PC Board - All Codes - (S21410) 3.8V = 38 mA Return to Section TOC G-26 ELECTRICAL DIAGRAMS S 21410 Return to Section TOC G-26 DATE SUBJECT NONE 03/21/94 CHK. FV SUP'S'D'G. STT-CURRENT SENSE SCHEMATIC SHT. NO. S 21410 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 II NOTE: ITEM STT CURRENT SENSE C3 C4 R14 R15 R3 X3 R16 C2 PART NO. DESCRIPTION R13 R1 Q1 REQ'D M17591-[ ] XXXXXXX XX X XX X X XX XX Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC X XXX XXXX X2 R2 C5 R4 R12 J18 C1 R8 X XX XXX Return to Section TOC XXX X XX X1 R9 X X Return to Section TOC PC Board Assembly - Current Sense - All Codes - (M17591) XX XX Return to Section TOC G-27 ELECTRICAL DIAGRAMS XXX XX XX Return to Section TOC G-27 R7 R6 R10 R11 R5 CAPACITORS = MFD/VOLTS 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 II 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 .39mH J36 L6 Return to Master TOC Return to Section TOC 3 J33 8 C1 C3 .0047 3KV .0047 3KV C2 .0047 3KV C4 .0047 .39mH C5 C6 J36 .0047 .0047 3KV J36 3KV 3KV J36 C7 J36 .0047 3000V 6 5 L7 J36 J34 .39mH J36 J34 J36 C8 1 3000V J34 J35 J34 J35 C9 Return to Master TOC Return to Section TOC 4 .0047 8 1 4 2 5 3000V J34 TP1 TP3 150V 80J 4 J33 TP2 160J 160J 320V 320V C15 C16 600V 600V R1 R2 1200 1200 5W C14 .0047 R3 R4 R5 332 332 332 R6 R7 R8 332 332 332 3000V NOTES : N.A. 2 4 NOTE: J34 TRIGGER 32 E F L M N H 21 14 PIN WIRE J37 1 SENSE GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 1 3 DIODES = 3 ON HOLES SIZES PER E-2056 CHASSIS 1A, 400V 1/4W UNLESS OTHERWISE SPECIFIED) LABELS UNLESS OTHERWISE SPECIFIED) (UNLESS OTHERWISE SPECIFIED) 8 L- 7 C- 16 TP- 3 D- 0 VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION FILE: M17609_1BA Ch'ge.Sht.No. EQUIP. THE LINCOLN ELECTRIC CO. 5-19-95 ON 3 PLACE DECIMALS IS + .OO2 TYPE CLEVELAND, OHIO U.S.A. ON ALL ANGLES IS + .5 OF A DEGREE SCALE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS R- SUPPLY WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY ON 2 PLACE DECIMALS IS + .O2 CHASSIS MFD ( .022/50V CAPACITORS = RESISTORS = Ohms ( J37 LAST NO. USED SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE UNLESS OTHERWISE SPECIFIED TOLERANCE CHASSIS 4 G NUMBER. J34 J37 A 3000V NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE J34 J37 J36 15 (-) STUD B2 2 115 VAC J35 (+) STUD B1 5W J36 .0047 .0047 GND FEEDER AMPHENOL J33 C13 3000V 2 3000V J35 J35 .05 .0047 3 3000V C12 J36 J36 10 7 C11 GND 42 VAC J35 6 J33 9 C10 .0047 J33 5 VOLTAGE Return to Master TOC 6 .0047 .05 Return to Section TOC 3 TRIGGER DR. MLD DATE SCHEMATIC SUBJECT NONE 04/20/94 STT REMOTE PROTECTION BOARD CHK. F.V. SUP'S'D'G. 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. SHT. NO. M 17609 INVERTEC STT & STT II 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. 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 II