Lincoln Electric INVERTEC STT Service Manual Download Page 6 | Manualshive

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MASTER TABLE OF CONTENTS FOR ALL SECTIONS

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INVERTEC STT

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Safety

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Installation

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Section A

Operation

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Section B

Accessories

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Section C

Maintenance

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Section D

Theory of Operation

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Section E

Troubleshooting and Repair

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Section F

Electrical Diagrams

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Section G

STT Parts .......................................................................................................................................P257
STT II Parts ....................................................................................................................................P294

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Summary of Contents for INVERTEC STT

Page 1: ...hink before you act and be careful For use with machine code numbers 10151 10152 10153 10309 10381 10382 10383 11090 11091 11092 11115 11116 INVERTEC STT TM STT II TM Return to Master TOC Return to Ma...

Page 2: ...NJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strong...

Page 3: ...ver 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 o...

Page 4: ...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 Av...

Page 5: ...soudage l aide d crans appropri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gant...

Page 6: ...INVERTEC STT 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 Diagr...

Page 7: ...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 Connect...

Page 8: ...ER RATING ON COPPER COPPER SIZE NAMEPLATE SUPPLY WIRE GROUND WIRE IN CONDUIT IN CONDUIT AWG IEC SIZES AWG IEC SIZES 208 60 40 32 230 60 40 30 460 60 30 16 200 50 60 40 33 220 50 60 40 30 10 6 mm2 10 6...

Page 9: ...T VOLTAGE FUSE SUPER LAG INPUT AMPERE TYPE 75 C TYPE 75 C AND FREQUENCY OR BREAKER RATING ON COPPER COPPER SIZE NAMEPLATE SUPPLY WIRE GROUND WIRE IN CONDUIT IN CONDUIT AWG IEC SIZES AWG IEC SIZES 200...

Page 10: ...ines 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 ra...

Page 11: ...round cover of the Invertec STT II 2 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...

Page 12: ...60V position 3 Move lead A to 380 415 Terminal 380 400 or 415 VAC 1 Open reconnect panel Codes 11115 and access door on wrap around 11116 2 Move input voltage switch to Voltage 380 460V position 3 Mov...

Page 13: ...TENTS 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 O...

Page 14: ...ar dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep fla...

Page 15: ...lent welding performance light weight and compact design Twist Mate output terminals Digital meters for procedure settings are standard Automatic Inductance or Pinch Control Solid state circuitry for...

Page 16: ...lows preset adjust ment of the amplitude of the peak current up to 450 amperes 3B PEAK CURRENT DISPLAY METER This is a digital meter for displaying the preset Peak Current This meter displays in 1 amp...

Page 17: ...rce by the wire feeder Refer to the Accessories section of this manual for wire feeder connection instructions 11 ARC SENSE RECEPTACLE This is a four pin MS type connector for WORK and ELECTRODE sense...

Page 18: ...with Peak Current Note In 100 CO2 shielding gas applications the peak current level should be set greater than in a corre sponding application using a gas blend with a high per centage of Argon Longe...

Page 19: ...trical Stickout 1 4 3 8 mm 6 4 10 Plate Thickness mm 20 ga 14 ga 10 ga 0 9 2 0 3 25 Electrode size mm 0 035 0 045 0 045 0 9 1 1 1 1 WFS min m min 100 100 120 2 5 2 5 3 0 Peak Current 225 270 310 Backg...

Page 20: ...NOTES B 8 B 8 INVERTEC STT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 21: ...ster TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS ACCESSORIES Accessories Section C Options Accessories C 2 LN 742 Wire Feeder Connection Instructions C 3 Connection Diagram C 4 Sec...

Page 22: ...ill show preset values in both local and remote operation OPTIONS ACCESSORIES K940 SENSE LEADS These leads are used to accu rately sense arc voltage One set is required for each STT II power source A...

Page 23: ...rmance 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...

Page 24: ...SHOULD BE LOCATED AS CLOSE AS POSSIBLE FEEDER REMOTE REMOTE ELECTRODE LEAD TO THE WELDING ARC WORK LEAD WIRE FEEDER WIRE FEEDER CONTACT ELECTRODE SENSE LEAD IS BOLTED TOGETHER WITH ELECTRODE LEAD ON T...

Page 25: ...TOC Return to Master TOC Return to Master TOC Section D 1 Section D 1 INVERTEC STT TABLE OF CONTENTS MAINTENANCE Maintenance Section D Input Filter Capacitor Discharge Procedure D 2 Preventive Mainten...

Page 26: ...h wattage resistor 25 1000 ohms and 25 watts minimum This resistor is not sup plied with machine NEVER USE A SHORTING STRAP FOR THIS PROCE DURE 5 Locate the two capacitor terminals large hex head cap...

Page 27: ...the following components thoroughly Power Switch Driver Protection and Control printed circuit boards Power Switch Main Transformer Input Rectifier Heat Sink Fins Input Filter Capacitors Output Termi...

Page 28: ...1 3 2 FIGURE D 2 MAJOR COMPONENT LOCATIONS 1 BASE ASSEMBLY 2 REAR NAMEPLATE 3 RESISTORS 4 FAN SHROUD ASSEMBLY 5 PROTECTION PC BOARD 6 DRIVER PC BOARD 7 CONTROL BOX 8 CONTROL PC BOARD 9 BLEEDER RESIST...

Page 29: ...OUTPUT NEGATIVE CONTROL BOARD IGBT DRIVER BOARD P O W E R B O A R D FAN TRANS T1 TRANS T4 S W I T C H B O A R D S W I T C H B O A R D R E C O N N E C T P R O T E C T I O N INPUT RECTIFIER LINE SWITCH...

Page 30: ...ard THEORY OF OPERATION E 2 E 2 INVERTEC STT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retu...

Page 31: ...TOC Return to Master TOC NOTE Unshaded areas of Block Logic Diagram are the subject of discussion FIGURE E 3 RECONNECT PROTECTION BOARD RECTIFICATION AND PRECHARGE POSITIVE OUTPUT TERMINAL TERMINAL OU...

Page 32: ...former primary windings with DC current flow See Field Effect Transistor FET Operation discussion and diagrams See Figure E 4 POSITIVE OUTPUT TERMINAL TERMINAL OUTPUT NEGATIVE CONTROL BOARD IGBT DRIVE...

Page 33: ...uration 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...

Page 34: ...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 dis...

Page 35: ...oard provides noise suppres sion and by pass filtering to protect the internal circuit ry of the STT machine NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POSITIVE OUTPUT TE...

Page 36: ...relative to the source is applied to the gate terminal of the FET it is capable of conducting current A voltage supply con nected to the drain terminal will allow the FET to con duct and henceforth s...

Page 37: ...dwell time off time is 48 microseconds both FET groups off Since only 2 microseconds of the 50 microsecond time peri od is devoted to conducting the output power is mini mized MAXIMUM OUTPUT By holdin...

Page 38: ...s of time 2 Line surges over 500 VAC 3 Internal Component damage 4 Improper connections THERMAL PROTECTION Thermostats protect the machine from excessive oper ating temperatures Excessive temperatures...

Page 39: ...ransformer 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...

Page 40: ...TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub...

Page 41: ...hich could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag If the PC Board uses protective shorting jumpers don t remove them until installa...

Page 42: ...Department 1 888 935 3877 Machine has no open circuit volt age Wire feeds OK 1 Check the control cable between the feeder and the STT unit Make sure the 2 and 4 leads are intact 2 Put a jumper wire b...

Page 43: ...ot feed wire when the gun trigger is pulled 1 The 42VAC circuit breaker CB1 may be tripped Reset if neces sary 2 Check the 4 amp slow blow fuse located on the reconnect panel Replace if faulty 3 Put a...

Page 44: ...play 1 The power switch must be in the ON position 2 Check the input voltage Make sure all three phases are applied to the machine 3 With input power removed check that the input voltage set up switch...

Page 45: ...input power removed inspect input leads for possible shorts or grounds or miscon nections 2 Install new fuses and reapply power If fuses open again contact your local Lincoln Authorized Field Service...

Page 46: ...oubleshooting assistance before you proceed Call 1 888 935 3877 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Machine loses output while weld ing The...

Page 47: ...he test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTME...

Page 48: ...heck the Background Peak Current Tailout STT II Only and Wire Speed controls for proper set tings Adjust for optimum weld ing performance 2 Make sure the Wire Type and Wire Size switches are in the co...

Page 49: ...coln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION WELDI...

Page 50: ...like a standard MIG process 1 Check the Arc Sense leads for loose or faulty connections 2 Make sure the Arc Sense WORK lead is as close as possible to the welding arc 3 Make sure the machine and wire...

Page 51: ...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 conta...

Page 52: ...ROCEDURE 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...

Page 53: ...igure F 2 6 Disconnect plugs J30 and J31 from the wiring harness ELECTRIC SHOCK can kill With input power ON there are high voltages inside the machine Do not reach into the machine or touch any inter...

Page 54: ...ssembly 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...

Page 55: ...ine Do not reach into the machine or touch any internal part 15 Apply the correct input power and carefully test for the correct primary voltages at plug J21 See Table F 1 16 If the correct AC input v...

Page 56: ...NOTES F 18 F 18 INVERTEC STT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 57: ...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 electr...

Page 58: ...nvertec 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...

Page 59: ...UXILIARY TRANSFORMER TEST continued 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 FIGUR...

Page 60: ...fully lift and tilt the Invertec STT machine onto its right side See Figure F 6 8 Using the 7 16 wrench remove the five bolts holding the lower tray assembly to the case bottom 9 Carefully slide out a...

Page 61: ...nd remove leads 32A 32B and 33A 33B from the T4 transformer tabs See Figure F 8 ELECTRIC SHOCK can kill With input power ON there are high voltages inside the machine Do not reach into the machine or...

Page 62: ...e control PC board Reconnect lead splice from the output choke to the IGBT module Reposition insulating sleeve 16 Install the case wraparound cover TROUBLESHOOTING REPAIR F 24 F 24 INVERTEC STT Return...

Page 63: ...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...

Page 64: ...n 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 M...

Page 65: ...ent to determine component integrity 9 Perform the Switch Board Test 10 After all tests are completed install the case wraparound cover TROUBLESHOOTING REPAIR F 27 F 27 INVERTEC STT Return to Section...

Page 66: ...NOTES F 28 F 28 INVERTEC STT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 67: ...c trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs saf...

Page 68: ...al part 3 Carefully apply the correct input power to the machine NOTE This test should only be conducted when the machine reconnect switch and jumper are set for high voltage above 380VAC and the prop...

Page 69: ...ea sured 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 8 After all tests are completed remove the jumper b...

Page 70: ...NOTES F 32 F 32 INVERTEC STT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 71: ...his manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing...

Page 72: ...former primary windings input rectifier and reconnect switches 1 Turn off Invertec STT and disconnect main AC input power to the machine 2 Using the 5 16 nut driver remove the case wraparound cover 3...

Page 73: ...rted Replace both Snubber Test 100 ohms switch boards 4 5 9 Less than OK None Continue 100 ohms Greater than Open Replace both Snubber Test 1K ohm switch boards 1 8 9 Less than OK None Continue 100 oh...

Page 74: ...00 ohms Greater than Open Replace both Snubber Test 1K ohm switch boards 9 402 404 Less than OK None Continue 100 ohms Greater than Open Replace both Snubber Test 1K ohm switch boards 402 404 9 Greate...

Page 75: ...elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs...

Page 76: ...RE 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 t...

Page 77: ...ured 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 wr...

Page 78: ...NOTES F 40 F 40 INVERTEC STT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 79: ...afety 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 Se...

Page 80: ...t 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...

Page 81: ...Secure and insulate the front panel assembly for POWER ON testing ELECTRIC SHOCK can kill With input power ON there are high voltages inside the machine Do not reach into the machine or touch any inte...

Page 82: ...rom 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 a...

Page 83: ...avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test r...

Page 84: ...harge Procedure See the Maintenance section ELECTRIC SHOCK can kill Before continuing with the test procedure per form the capacitor dis charge procedure to avoid electric shock 4 Locate the protectio...

Page 85: ...itor Discharge Procedure See the Maintenance section ELECTRIC SHOCK can kill Before continuing with the test procedure per form the capacitor dis charge procedure to avoid electric shock 10 Locate and...

Page 86: ...NOTES F 48 F 48 INVERTEC STT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 87: ...led 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 t...

Page 88: ...J31 LOCATION PLUG J31 TEST PROCEDURE 1 Turn off the Invertec STT and disconnect main AC input power to the machine 2 Using the 5 16 nut driver remove the case wraparound cover 3 Perform the Input Filt...

Page 89: ...A 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 FIGUR...

Page 90: ...ken or loose wires connections or open ther mostats Also check the small inductors on the Remote Protection Board See Figure F 22 Simplified Trigger Circuit Diagram ELECTRIC SHOCK can kill With input...

Page 91: ...nual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assist...

Page 92: ...f 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 Maint...

Page 93: ...OVAL AND REPLACEMENT continued FIGURE F 24 PLUG J1 DISCONNECTION LOWER TRAY AREA OUTPUT CHOKE IGBT MODULE SPLICED CONNECTION J1 CURRENT SENSING PLUG 5 Disconnect the current sensing plug J1 from the c...

Page 94: ...ift and tilt the Invertec STT machine onto its right side See Figure F 26 8 Using the 7 16 wrench remove the five bolts holding the lower tray assembly to the case bottom 9 Carefully slide out and sup...

Page 95: ...module to the heat sink 18 Carefully remove the IGBT module 19 Upon reassembly use Dow Corning 340 Heat Sink Compound Lincoln E1868 between the module and the heat sink 20 Mount the new module using...

Page 96: ...NOTES F 58 F 58 INVERTEC STT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 97: ...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 Electr...

Page 98: ...owing conditions exist 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 i...

Page 99: ...mount the new switch board on the heat sink by first lining up the mounting holes Then press the switch board into place 11 Insert each of the four socket head screws into the mounting holes Thread th...

Page 100: ...ntinuing with the test procedure perform the capacitor discharge procedure to avoid electric shock 3 Connect a shorting conductor across termi nals 14 and 53 of the protection PC board See Figure F 29...

Page 101: ...e 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 9 Wit...

Page 102: ...NOTES F 64 F 64 INVERTEC STT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 103: ...ical 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...

Page 104: ...urn 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 Mai...

Page 105: ...EMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 31 PLUG J1 DISCONNECTION LOWER TRAY AREA OUTPUT CHOKE IGBT MODULE SPLICED CONNECTION J1 CURRENT SENSING PLUG 5 Disconnect the current sensing plug J...

Page 106: ...tilt the Invertec STT machine onto its right side See Figure F 33 8 Using the 7 16 wrench remove the five bolts holding the lower tray assembly to the case bottom 9 Carefully slide out and support the...

Page 107: ...t 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 mode...

Page 108: ...its side as shown in Figure F 35 Slide the plastic retaining insu lators that go through the base of the machine to one side Pull the through bolts out of the machine being careful to save all the in...

Page 109: ...witch 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 FIGURE F 36 REMOVING CAPACITOR NUTS CAPACITOR REMOVAL AND R...

Page 110: ...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 Po...

Page 111: ...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 Linco...

Page 112: ...HOCK can kill Before continuing with the test procedure per form the capacitor dis charge procedure to avoid electric shock 4 Using the slot head screw driver loosen the input cable strain relief 5 Us...

Page 113: ...PAIR F 75 F 75 INVERTEC STT OUTPUT RECTIFIER REMOVAL AND REPLACEMENT continued FIGURE F 40 MAIN TRANSFORMER DIODE CONNECTIONS MAIN TRANSFORMER SECONDARY LEADS 9 Remove the two sleevings from the diode...

Page 114: ...bottom tabs from the lower hori zontal 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 replace...

Page 115: ...TEC 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 compo...

Page 116: ...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 condition...

Page 117: ...8 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 Cod...

Page 118: ...0 C8 287 288A 288B 289A 289B 364 365 366 368 369 372 376 9 13 96 G2773 N O O ORANGE N BROWN 1 2 3 4 5 6 1 2 3 4 5 6 354 355 356 357 10K 2W CW MAX CONTROL HOT START R13 WIRE SIZE WIRE FEEDER CB2 BOARD...

Page 119: ...E A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE N E D1 THRU D5 OUTPUT DIODES ARE A MATCHED SET D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET 9 N F R1 R9 BLEEDER RESISTORS ARE A MATCHED SET J21 1 N...

Page 120: ...urn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Wiring Diagram Entire Machine Codes 11090 11092 G4500 NOTE This diagram is for reference only It may not be accurate fo...

Page 121: ...ANGE N BROWN 1 2 3 4 5 6 1 2 3 4 5 6 354 355 356 357 10K 2W CW MAX CONTROL HOT START R13 WIRE SIZE WIRE FEEDER CB2 BOARD 12 C1 R4 R5 25 25W 25 25W 9 5 8 12 25 25W 25 25W 9 C2 R6 R7 4 1 R1 7500 25W 9A...

Page 122: ...1 13 2 LOCAL 5 6 2 K R 3 0 7 P BOOST X21 3 5 4 X24 7 6 5 10K 294V C 1014 PINCH FAST RAMP ENABLE 2901 C PINCH LIMIT 500A MAX PINCH BREAKPOINT PINCH KNEE D PINCH COMMAND 2901 B PT PINCH COMMAND LM224 C...

Page 123: ...2 400 SERIES ANALOG LOGIC CIRCUIT SHEET 1 ELECTRICAL SYMBOLS PER E1537 UNLESS OTHERWISE SPECIFIED 300 SERIES DIGITAL LOGIC CIRCUIT SHEET 1 EQUIP DIODES t 56 R238 CAPACITORS 1A 400V UNLESS OTHERWISE SP...

Page 124: ...409 C405 X31 X34 C466 C457 R403 R533 C402 DZ10 C403 C406 X22 R340 Q3 R333 X32 C429 R308 R309 D305 X17 C444 C456 X12 X20 X15 X10 X13 X14 X9 X11 X18 X16 X19 X21 X23 X24 R 3 0 1 R302 R 3 1 3 R312 C304 C4...

Page 125: ...s 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 fro...

Page 126: ...es 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 fr...

Page 127: ...ity 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 Electr...

Page 128: ...MPLETE BOARD THIS RESISTORS Ohms CAPACITORS MFD NOTES 1A 400V DIODES POWER BD SCHEMATIC POWER SUPPLY SOURCE POINT UNUSED SCALE CLEVELAND OHIO U S A THE LINCOLN ELECTRIC CO FILENAME M16018_6JA M TO CON...

Page 129: ...tion TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PC Board Assembly Power All Codes L8033 NOTE Lincoln Electric assumes no responsibili...

Page 130: ...INTED CIRCUIT BOARD MAY CHANGE 10VAC R 6VAC R 6 1 3 4 J13 NOTES 15V 1 3 J12 4 2 WINDING TRANSFORMER AUXILLARY OFF Darlington OFF M 17581 STT CONTROL BOARD 1K ON Darlington ON 1 50K R2 V 50V 0 1 C6 1 0...

Page 131: ...o Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PC Board Assembly Darlington Drive Codes 10151 10383 G2778 NOTE Lincoln Electric assumes no responsibi...

Page 132: ...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 Lin...

Page 133: ...ility 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 Elec...

Page 134: ...H E L I N C O L N E L E C T R I C C O CHK C D 8 S C A L E D A T E SUPPLY VOLTAGE NET FRAME CONNECTION COMMON CONNECTION I N V E R T E C V 3 0 0 EQUIP L SHT 42 10 SUP S D G CLEVELAND OHIO U S A T Y P E...

Page 135: ...T12705 34 1N4936 2 DZ1 DZ2 DZ3 DZ12 DZ4 DZ7 T12702 27 1N4740 4 T12702 29 1N4744A T12702 40 1N4735 Q4 Q12 2 T12704 68 6 T12704 69 2N4403 2N4401 Q1 Q2 Q3 Q10 4 T12704 73 IC PKG MOSFET R1 R3 R5 R24 4 S1...

Page 136: ...3 7 10 4 9 8 5 1 12 J9 1 J9 4 J9 3 J11 1 J10 4 150K R6 100 R7 4A 900V Q1 20W 250 R1 1W 12V DZ1 150K R3 150K R4 20W 250 R2 150K R 5 J9 6 J10 6 J16 3 J10 1 J10 3 20W 250 R14 J16 1 1W 12V DZ2 150K R10 1...

Page 137: ...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 compr...

Page 138: ...A SHT EARTH GROUND CONNECTION M M SUP S D G NONE TYPE _ R LAST NO USED INVERTEC V300 PROTECTION SCALE POWER SUPPLY SOURCE POINT _ _ Over Voltage C TO DRIVER BD D VOLTAGE NET COMMON CONNECTION FRAME C...

Page 139: ...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 compro...

Page 140: ...o 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 L...

Page 141: ...ility 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 Elec...

Page 142: ...V 100V 3A Q1 J18 4 CURRENT CAL FILE S21410_1BA SENSOR 3 8V 38 mA EXCITATION CURRENT MIN OFF SET ADJUSTMENT HALL EFFECT 100A V CURRENT OUT 1014 S 1014 1 6V 16 mA VREF SOURCE 21410 1014 THE LINCOLN ELEC...

Page 143: ...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 m...

Page 144: ...05 C16 J33 4 J36 6 39mH L4 39mH L7 J33 8 J36 9 J34 1 STUD STUD 5W 1200 R2 TYPE SUBJECT NONE CHASSIS CHASSIS CHASSIS 04 20 94 3000V 0047 C14 J37 3 332 R4 J37 1 3000V 0047 C13 J33 10 332 R8 332 R3 332 R...

Page 145: ...lity 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 Elect...

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