Invertec STT PDF

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SVM129-B
OCTOBER, 2006
TM
View Safety Info
INVERTEC STT
11115,11116
TM
& STT II
For use with machine code numbers:10151,10152,10153,10309,10381,10382,10383,11090,11091,11092,
Safety Depends on You

View Safety Info View Safety Info 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.
SERVICE MANUAL
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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
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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.
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.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.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
____________________________________________________ 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.
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.
___________________________________________________ 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.
Mar 95
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SAFETY
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits are electrically hot when the welder is on. Do not touch these hot parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
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ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays. 4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground. In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while 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. 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.
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. 5.e. Read and understand the manufacturers instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employers safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
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.
5.f. Also see item 1.b.
AUG 06
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SAFETY
WELDING SPARKS can cause fire or explosion. CYLINDER may explode if damaged.
iii
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. 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.
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.
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.
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 manufacturers recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturers recommendations.
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.
Mar 95
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SAFETY
PRCAUTIONS DE SRET
zones o lon pique le laitier.
iv
Pour votre propre protection lire et observer toutes les instructions et les prcautions de sret specifiques qui parraissent dans ce manuel aussi bien que les prcautions de sret gnrales suivantes: Sret Pour Soudage A LArc 1. Protegez-vous contre la secousse lectrique: a. Les circuits llectrode et la pice sont sous tension quand la machine souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vtements mouills. Porter des gants secs et sans trous pour isoler les mains. b. Faire trs attention de bien sisoler 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse. c. Maintenir le porte-lectrode, la pince de masse, le cble de soudage et la machine souder en bon et sr tat defonctionnement. d.Ne jamais plonger le porte-lectrode dans leau pour le refroidir. e. Ne jamais toucher simultanment les parties sous tension des porte-lectrodes connects deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines. f. Si on utilise la machine souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-lectrode sapplicuent aussi au pistolet de soudage. 2. Dans le cas de travail au dessus du niveau du sol, se protger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le cble-lectrode autour de nimporte quelle partie du corps. 3. Un coup darc peut tre plus svre quun coup de soliel, donc: a. Utiliser un bon masque avec un verre filtrant appropri ainsi quun verre blanc afin de se protger les yeux du rayonnement de larc et des projections quand on soude ou quand on regarde larc. b. Porter des vtements convenables afin de protger la peau de soudeur et des aides contre le rayonnement de larc. c. Protger lautre personnel travaillant proximit au soudage laide dcrans appropris et non-inflammables. 4. Des gouttes de laitier en fusion sont mises de larc de soudage. Se protger avec des vtements de protection libres de lhuile, tels que les gants en cuir, chemise paisse, pantalons sans revers, et chaussures montantes.
6. Eloigner les matriaux inflammables ou les recouvrir afin de prvenir tout risque dincendie d aux tincelles. 7. Quand on ne soude pas, poser la pince une endroit isol de la masse. Un court-circuit accidental peut provoquer un chauffement et un risque dincendie. 8. Sassurer que la masse est connecte le plus prs possible de la zone de travail quil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dautres endroits loigns de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, cbles de grue, ou autres circuits. Cela peut provoquer des risques dincendie ou dechauffement des chaines et des cbles jusqu ce quils se rompent. 9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particulirement important pour le soudage de tles galvanises plombes, ou cadmies ou tout autre mtal qui produit des fumes toxiques. 10. Ne pas souder en prsence de vapeurs de chlore provenant doprations de dgraissage, nettoyage ou pistolage. La chaleur ou les rayons de larc peuvent ragir avec les vapeurs du solvant pour produire du phosgne (gas fortement toxique) ou autres produits irritants. 11. Pour obtenir de plus amples renseignements sur la sret, voir le code Code for safety in welding and cutting CSA Standard W 117.2-1974.
PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR

1. Relier la terre le chassis du poste conformement au code de llectricit et aux recommendations du fabricant. Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre. 2. Autant que possible, Iinstallation et lentretien du poste seront effectus par un lectricien qualifi. 3. Avant de faires des travaux linterieur de poste, la debrancher linterrupteur la boite de fusibles. 4. Garder tous les couvercles et dispositifs de sret leur place.
5. Toujours porter des lunettes de scurit dans la zone de soudage. Utiliser des lunettes avec crans lateraux dans les
Mar. 93
MASTER TABLE OF CONTENTS FOR ALL SECTIONS

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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
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 Input Cable Installation and Connection...............................................................................A-5
Ground Connection...............................................................................................................A-5 Input Voltage Reconnect Procedure ...........................................................................................A-6 Output Connections ....................................................................................................................A-6 Wire Feeder Output Connections .........................................................................................A-6
INVERTEC STT
A-2
INSTALLATION
INPUT- THREE PHASE ONLY
STANDARD VOLTAGE 208/230/460/3/60 HZ 200/220/380/415/440/3/50/60 HZ INPUT CURRENT AT RATED OUTPUT 32/30/16 33/30/18/17/16
A-2
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TECHNICAL SPECIFICATIONS Invertec STT & STT II (For Codes 11092 and BELOW)
RATED OUTPUT
DUTY CYCLE 60% Duty Cycle Return to Section TOC Return to Master TOC 100% Duty Cycle AMPS 225 200 VOLTS AT RATED AMPS 29 28
OUTPUT
CURRENT RANGE Peak Current 1 0 - 450 Amps Background 0 - 125 Amps OPEN CIRCUIT VOLTAGE 85 VDC Maximum AUXILIARY POWER 115 2 VAC @ 4 Amps 42 VAC @ 4 Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES

INPUT VOLTAGE AND FREQUENCY
FUSE(SUPER LAG) OR BREAKER SIZE INPUT AMPERE RATING ON NAMEPLATE TYPE 75 C COPPER SUPPLY WIRE IN CONDUIT AWG (IEC) SIZES TYPE 75 C COPPER GROUND WIRE IN CONDUIT AWG (IEC) SIZES
208/60 230/60 460/60 200/50/60 220/50/60 380/50/60 415/50/60 440/50/60
40 40 30 40 40 30 30 30
32 30 16 33 30 18 17 16 10 (6 mm2) 10 (6 mm2)
PHYSICAL DIMENSIONS
HEIGHT 23.2 in 589 mm WIDTH 13.2 in. 336 mm DEPTH 24.4 in. 620 mm WEIGHT 100 lbs. 46 kg
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. 115 VAC not present on European Models.
INVERTEC STT
A-3
INSTALLATION
INPUT- THREE PHASE ONLY
STANDARD VOLTAGE 200/208/3/50/60 HZ 200/208/380/400/415/3/50/60 HZ INPUT CURRENT AT RATED OUTPUT 36/34 36/34/20/19/18
A-3
TECHNICAL SPECIFICATIONS Invertec STT II (For Codes 11115 AND 11116)
RATED OUTPUT
DUTY CYCLE 60% Duty Cycle Return to Section TOC Return to Master TOC 100% Duty Cycle AMPS 225 200 VOLTS AT RATED AMPS 29 28
OUTPUT
CURRENT RANGE Peak Current 0 - 450 Amps Background 0 - 125 Amps OPEN CIRCUIT VOLTAGE 88 VDC Maximum AUXILIARY POWER 115 1 VAC @ 4 Amps 42 VAC @ 4 Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES

INPUT VOLTAGE AND FREQUENCY
FUSE(SUPER LAG) OR BREAKER SIZE INPUT AMPERE RATING ON NAMEPLATE TYPE 75 C COPPER SUPPLY WIRE IN CONDUIT AWG (IEC) SIZES TYPE 75 C COPPER GROUND WIRE IN CONDUIT AWG (IEC) SIZES
200/50/60 208/50/60 380/50/60 400/50/60 415/50/60
40 40 30 30 30
36 34 20 19 18 10 (6 mm2) 10 (6 mm2)
PHYSICAL DIMENSIONS
HEIGHT 23.2 in 589 mm WIDTH 13.2 in. 336 mm DEPTH 24.4 in. 620 mm WEIGHT 100 lbs. 46 kg
115 VAC not present on European Models.
INVERTEC STT
A-4
INSTALLATION
A-4
Read and understand entire Installation Section before starting installation.
WARNING
Only qualified personnel should perform this installation. Turn the input power OFF at the disconnect switch or fuse box before installing this equipment. Turn the power switch on the Invertec STT OFF before connecting or disconnecting input power lines, output cables, or control cables.
MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION

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: 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. Provide proper electrical ground to the machine per local and national electrical codes.
Do not touch electrically hot parts. Always connect the ground terminal to a good electrical earth ground.
SELECT SUITABLE LOCATION

Locate the machine where there is free circulation of clean air. Place the machine so that air can freely 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.
INPUT CONNECTIONS
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 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.
STACKING
The Invertec STT II cannot be stacked.
TILTING
Place the machine on a secure, level surface otherwise the unit may topple over.
INVERTEC STT
A-5
INSTALLATION
CASE BACK
A-5
Return to Section TOC Return to Section TOC
RATING PLATE INPUT CABLE ENTRY ACCESS & CABLE STRAIN RELIEF
FIGURE A.1 CASE BACK INPUT CABLE INSTALLATION AND CONNECTION
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.
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. Remove the wraparound cover of the Invertec STT II. Feed the input cable through the input cable entry access hole at the right rear of the machine. 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. Strip away 102 mm (4 in.) of the outer jacket. Trim fillers and strip conductor jackets to connect to the power switch.
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. 2. Replace the wraparound cover of the Invertec STT II.
2.
3. Return to Section TOC Return to Master TOC
4.
INVERTEC STT
A-6
Return to Section TOC Return to Master TOC
INSTALLATION
A-6
380-415 OR
4A
*
OR 200-208
2. Move input voltage switch to Voltage = 380-460V position. 3. Move lead A to 380-415 Terminal. 380,400 or 415 VAC (Codes 11115 and around. 11116) 1. Open reconnect panel access door on wrap2. Move input voltage switch to Voltage = 380-460V position. 3. Move lead A to 380-415 Terminal. 1. Open reconnect panel access door on wrap2. Move input voltage switch to Voltage = 200 -230V position. 3. Move lead A to 220-230 Terminal. 1. Open reconnect panel access door on wrap2. Move input voltage switch to Voltage = 200 -230V position. 3. Move lead A to 200-208 Terminal. 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.
*(NOT PRESENT ON ALL MODELS)

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. 2. For Connections to 200,208,220,230,380,400 or 415 VAC follow the procedure shown below and refer to figure A.2.
220 or 230 VAC (Codes 11092 and around. below)
NOTE: Turn main power to the machine OFF
WARNING
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. -----------------------------------------------------------------------To Operate at
460 or 440 VAC (Codes 11092 and around. below) 200 or 208 VAC (Codes 11115 and 11116)
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-
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
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 Operational Features and Controls.............................................................................................B-4
Welding Operation ......................................................................................................................B-5 Welding Parameters and Guidelines ..........................................................................................B-6 Recommended Settings for STT II..............................................................................................B-7
INVERTEC STT
B-2
OPERATION
OPERATING INSTRUCTIONS
Read and understand entire section before operating machine.
B-2
GENERAL WARNINGS
SAFETY PRECAUTIONS WARNING

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. 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. Wear eye, ear and body protection.
Observe additional Safety Guidelines detailed in the beginning of this manual.
INVERTEC STT
B-3
OPERATION

B-3
GENERAL DESCRIPTION
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.
High temperature Class H insulation. Protection circuits and ample safety margins prevent damage to the solid state components from transient voltages and high currents. Preset welding current capability.
STT II offers improvements over the previous model. Approximately 40% increase in deposition rate capability, and a significant increase in travel speed.
RECOMMENDED EQUIPMENT
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.
WELDING CAPABILITY
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
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.
LIMITATIONS
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).
DESIGN FEATURES AND ADVANTAGES
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.
INVERTEC STT
B-4
OPERATION
B-4
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.
6 7
3 8
10 9 11 14 13 1
15
12
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. 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.
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
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
B-5
OPERATION
B-5
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. 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.
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.
INVERTEC STT
B-6
OPERATION
B-6
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. 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
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
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
B-7
OPERATION
(Stainless Steel) Horizontal Fillet (See Table B.3 and B.4)
DIRECTION OF TRAVEL
B-7
WELDING PROCEDURES FOR STT II (Steel) Horizontal Fillet (See Table B.1 and B.2)
DIRECTION OF TRAVEL
75
75
TOP VIEW
TOP VIEW
DIRECTION OF TRAVEL
45
DIRECTION OF TRAVEL
45
75
75
END VIEW
FRONT VIEW
END VIEW
FRONT VIEW
Table B.3 90% He, 7.5% Ar, 2.5% 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 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) 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) 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) 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.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) 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) 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)
INVERTEC STT
Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC B-8
NOTES
INVERTEC STT
B-8
Section C-1
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
INVERTEC STT
C-2
ACCESSORIES
C-2
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. REMOTE RECEPTACLE (For optional remote interface, Connection to the STT-10 Wire Feeder or Robotic Control) 1. The 10 pin MS connector labeled Remote Control located on the front panel of the STT is used for remote control of the power source. Control for the PEAK (PB pot) and BACKGROUND (BG pot) 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
REMOTE PROTECTION BOARD
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.
+ ARC
J19 VOLTAGE SENSE CONNECTION
1 J37 2 3 4
290 291
1 (+) 2 3 (-) 4
- ARC
J38 3 2 1 212C 43A 33C 32C 212B 6 1 4 8 5 3 2 223 7 8 290A J38 10 9 12 4 11 J B C G A D F H E I OPTIONAL REMOTE INTERFACE WIRE FEEDER J39 N ELECTRODE SENSE LEAD TRIGGER GND BG 10K PB 10K
PORTION OF G3136 WIRING DIAGRAM REFER TO ACTUAL DIAGRAM PASTED INSIDE YOUR MACHINE
INVERTEC STT
C-3
ACCESSORIES
C-3
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.
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. 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
Only qualified personnel should perform this installation. 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.
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 CAN KILL
Only qualified persons should install, use or service this machine.
REMOTE RECEPTACLE
CONTROL, ELECTRODE, ARC SENSE "ELECT" AND ARC SENSE "WORK" CABLES SHOULD BE TAPED TOGETHER.
WIRE FEEDER LN 742 LN7 GMA LN9 GMA NA5R NA5
WORK LEAD
WIRE FEEDER CONTROL CABLE ELECTRODE LEAD
ARC SENSE LEAD ELECT"
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
WARNING
Turn off input power to the Welding Power source using the disconnnect switch at the fuse box before connecting the wire feeder.
C-4
ELECTRIC SHOCK CAN KILL
Only qualified persons should install, use or service this machine.
WIRE FEEDER
REMOTE
WORK LEAD
CABLES AND LEADS SHOULD BE TAPED TOGETHER. WIRE FEEDER STT-10
ELECTRODE LEAD
ELECTRODE LEAD
ELECTRODE SENSE LEAD IS BOLTED TOGETHER WITH ELECTRODE LEAD ON THE WIRE FEEDER CONTACT BLOCK
WIRE FEEDER REMOTE ARC SENSE LEAD "WORK"

WORK
(SHOULD BE LOCATED AS CLOSE AS POSSIBLE TO THE WELDING ARC)

4-9-99 M17657-3
FIGURE C.3 STT-10 to STT II CONNECTION Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC
INVERTEC STT
Section D-1
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
INVERTEC STT
D-2
MAINTENANCE
WARNING
Failure to follow this capacitor discharge procedure can result in electric shock. 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.
D-2
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE

1. Turn off input power or disconnect input power lines. 2. Remove hex head screws from side and top of machine and remove wrap-around machine cover. 3. Be careful not to make contact with the capacitor terminals that are located in the center of the Switch Boards. 4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This resistor is not supplied with machine. NEVER USE A SHORTING STRAP FOR THIS PROCEDURE.
FIGURE D.1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS. Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC
INVERTEC STT
D-3
MAINTENANCE
PREVENTIVE MAINTENANCE
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. 2. Remove the machine wraparound cover and perform the input filter capacitor discharge procedure (detailed at the beginning of this chapter). Input Filter Capacitors Output Terminals 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. 7. Replace machine cover and screws. Heat Sink Fins
D-3
3. Clean the inside of the machine with a low pressure airstream. Be sure to clean the following components thoroughly. Power Switch, Driver, Protection, and Control printed circuit boards Power Switch Main Transformer Input Rectifier
INVERTEC STT
D-4
MAINTENANCE
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. 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
D-4
12
4 9 6 5
8 10 7 17 15 16
18 13 19 3
14
11
INVERTEC STT
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
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 S W I T C H
FET CAP FET 1 OHM
B O A R D
PRE CHARGE
CURRENT SENSOR
IGBT MODULE
NEGATIVE OUTPUT TERMINAL
CHOKE R E M O T E P R O T E C T I O N VOLTAGE SENSING RECEPTACLE
LINE SWITCH
INPUT RECTIFIER CR1
"A" LEAD
R E C O N N E C T
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
CURRENT TRANS T3
D R I V E S I G N A L
B O A R D
REMOTE CONTROL RECEPTACLE
CR2 FAN
TRANS T1
115 VAC
18 VAC
PRE CHARGE
TRANS T4
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
S W I T C H
FET CAP FET
B O A R D
WIRE FEEDER RECEPTACLE
LESS THAN 1VDC PULSE TRANSFORMER SIGNAL PWM SIGNAL 15VDC GUN TRIGGER
CURRENT FEEDBACK
CONTROL BOARD
36VAC
IGBT DRIVER BOARD

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 42VAC
FIGURE E.1 INVERTEC STT
INVERTEC STT
E-2
THEORY OF OPERATION
FIGURE E.2 INPUT VOLTAGE
E-2

FET CAP FET 1 OHM
B O A R D
PRE CHARGE
CURRENT SENSOR
IGBT MODULE
LINE SWITCH
INPUT RECTIFIER CR1
"A" LEAD
R E C O N N E C T
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
CURRENT TRANS T3
B O A R D
CR2 FAN
TRANS T1
115 VAC
18 VAC
PRE CHARGE
TRANS T4
P O W E R
B O A R D
S W I T C H
FET CAP FET
B O A R D
CURRENT FEEDBACK
CONTROL BOARD
36VAC
IGBT DRIVER BOARD

VOLTAGE FEEDBACK
WIRE TYPE SWITCH
GENERAL DESCRIPTION
The Invertec STT is a 225 ampere, inverter based, arc welding power supply specifically designed for the Surface Tension Transfer (STT) welding process. 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.
INPUT VOLTAGE
The Invertec STT can be connected for a variety of three-phase voltages. The initial input power is applied to the STT through a line switch located on the front of the machine. The AC input voltage is applied to the input rectifier and the T1 auxiliary transformer. The T1 transformer develops the appropriate AC voltages to operate the cooling fan, the power and control boards. The T1 transformer also supplies primary voltage to the T4 auxiliary transformer as well as 42 VAC to an 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
E-3
THEORY OF OPERATION
FIGURE E.3 RECONNECT, PROTECTION BOARD, RECTIFICATION AND PRECHARGE
E-3

FET CAP FET 1 OHM
B O A R D
PRE CHARGE
CURRENT SENSOR
IGBT MODULE
LINE SWITCH
INPUT RECTIFIER CR1
"A" LEAD
R E C O N N E C T
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
CURRENT TRANS T3
B O A R D
CR2 FAN
TRANS T1
115 VAC
18 VAC
PRE CHARGE
TRANS T4
P O W E R
B O A R D
S W I T C H
FET CAP FET
B O A R D
CURRENT FEEDBACK
CONTROL BOARD
36VAC
IGBT DRIVER BOARD

VOLTAGE FEEDBACK
WIRE TYPE SWITCH
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.
E-4
THEORY OF OPERATION
FIGURE E.4 SWITCH BOARDS
E-4

FET CAP FET 1 OHM
B O A R D
PRE CHARGE
CURRENT SENSOR
IGBT MODULE
LINE SWITCH
INPUT RECTIFIER CR1
"A" LEAD
R E C O N N E C T
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
CURRENT TRANS T3
B O A R D
CR2 FAN
TRANS T1
115 VAC
18 VAC
PRE CHARGE
TRANS T4
P O W E R
B O A R D
S W I T C H
FET CAP FET
B O A R D
CURRENT FEEDBACK
CONTROL BOARD
36VAC
IGBT DRIVER BOARD

VOLTAGE FEEDBACK
WIRE TYPE SWITCH
Return to Master TOC Return to Master TOC
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.
E-5
THEORY OF OPERATION
FIGURE E.5 MAIN TRANSFORMER, OUTPUT RECTIFICATION AND CHOKE
E-5

FET CAP FET 1 OHM
B O A R D
PRE CHARGE
CURRENT SENSOR
IGBT MODULE
LINE SWITCH
INPUT RECTIFIER CR1
"A" LEAD
R E C O N N E C T
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
CURRENT TRANS T3
B O A R D
CR2 FAN
TRANS T1
115 VAC
18 VAC
PRE CHARGE
TRANS T4
P O W E R
B O A R D
S W I T C H
FET CAP FET
B O A R D
CURRENT FEEDBACK
CONTROL BOARD
36VAC
IGBT DRIVER BOARD

VOLTAGE FEEDBACK
WIRE TYPE SWITCH
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 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. 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.
E-6
THEORY OF OPERATION
FIGURE E.6 CONTROL BOARD, IGBT DRIVE AND MODULE
E-6

FET CAP FET 1 OHM
B O A R D
PRE CHARGE
CURRENT SENSOR
IGBT MODULE
LINE SWITCH
INPUT RECTIFIER CR1
"A" LEAD
R E C O N N E C T
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
CURRENT TRANS T3
B O A R D
CR2 FAN
TRANS T1
115 VAC
18 VAC
PRE CHARGE
TRANS T4
P O W E R
B O A R D
S W I T C H
FET CAP FET
B O A R D
CURRENT FEEDBACK
CONTROL BOARD
36VAC
IGBT DRIVER BOARD

VOLTAGE FEEDBACK
WIRE TYPE SWITCH
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.
E-7
THEORY OF OPERATION
FIGURE E.7 POWER BOARD AND REMOTE PROTECTION BOARD
E-7

FET CAP FET 1 OHM
B O A R D
PRE CHARGE
CURRENT SENSOR
IGBT MODULE
LINE SWITCH
INPUT RECTIFIER CR1
"A" LEAD
R E C O N N E C T
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
CURRENT TRANS T3
B O A R D
CR2 FAN
TRANS T1
115 VAC
18 VAC
PRE CHARGE
TRANS T4
P O W E R
B O A R D
S W I T C H
FET CAP FET
B O A R D
CURRENT FEEDBACK
CONTROL BOARD
36VAC
IGBT DRIVER BOARD

VOLTAGE FEEDBACK
WIRE TYPE SWITCH
POWER 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 power board supplies a 15VDC supply voltage for the control board and also powers the input relays (CR1 and CR2).

The remote protection board provides noise suppression and by-pass filtering to protect the internal circuitry of the STT machine.
E-8
THEORY OF OPERATIONS
FIGURE E-8 FIELD EFFECT TRANSISTOR OPERATION
SOURCE TERMINAL GATE TERMINAL (0 VOLTS) DRAIN TERMINAL
E-8
SOURCE (N)
DRAIN (N)
SUBSTRATE (P)
N CHANNEL
A. PASSIVE
GATE TERMINAL (+ 6 VOLTS)
SOURCE (N)
DRAIN (N)
ELECTRONS
B. ACTIVE
FIELD EFFECT TRANSISTOR (FET) OPERATION

An FET is a type of transistor. FETs are semiconductors well suited for high-frequency switching. 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
E-9
THEORY OF OPERATION
FIGURE E-9 TYPICAL FET OUTPUTS
E-9
sec
48 50
sec sec
sec
MINIMUM OUTPUT
24 sec 2 sec 50 sec MAXIMUM OUTPUT 24 sec
PULSE WIDTH MODULATION

Return to Section TOC Return to Master TOC 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.
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.
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.
A FET group consists of the sets of FET modules grouped onto one switch board.
INVERTEC STT
E-10
THEORY OF OPERATION
THERMAL PROTECTION
E-10
PROTECTIVE CIRCUITS
Protective circuits are designed into the Invertec machine to sense trouble and shut down the machine before the trouble damages the internal machine components. Both overload and thermal protection circuits are included.
OVERLOAD PROTECTION
The machine is electrically protected from producing abnormally high output currents due to short electrode stick-out or the nozzle shorting to the work. Should the output current exceed 500 amps, an electronic 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: 1. Capacitor conditioning is required (Required if machine has been off for prolonged periods of time.) 2. Line surges over 500 VAC 3. Internal Component damage 4. Improper connections Return to Section TOC Return to Master TOC
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.) Thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the Power Switch may be left on and the reset should occur within a 15-minute period. If the fan is not turning or the air intake louvers were obstructed, then the power must be switched off for 15 minutes in order to reset. The fan problem or air obstruction must also be corrected.
INVERTEC STT
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 Retest After Repair...............................................................................................................F-77
INVERTEC STT
F-2
TROUBLESHOOTING & REPAIR

HOW TO USE TROUBLESHOOTING GUIDE
F-2
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. 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
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-3

PC BOARD TROUBLESHOOTING PROCEDURES
F-3
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.
Remove the PC Board from the static-shielding bag and place it directly into the equipment. Dont set the PC Board on or near paper, plastic or cloth which could have a static charge. If the PC Board cant be installed immediately, put it back in the static-shielding bag. If the PC Board uses protective shorting jumpers, dont 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. 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. 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
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:
1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom. 2. Check for loose connections at the PC board to assure that the PC board is properly connected. 3. If the problem persists, replace the suspect 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:
PC Board can be damaged by static electricity. Remove your bodys 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 dont 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.
ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations
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.
Reusable Container Do Not Destroy
Tools which come in contact with the PC Board must be either conductive, anti-static or static-dissipative.
INVERTEC STT
F-4
F-4
Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS (SYMPTOMS)
POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS
RECOMMENDED COURSE OF ACTION
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. 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.
1. Perform the T1 Transformer Test. 2. Perform the T4 Transformer Test.
Auxiliary Auxiliary
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
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
F-5
F-5
PROBLEMS (SYMPTOMS)
Machine has no welding output (no open circuit voltage), and the wire feeder does not feed wire when the gun trigger is pulled.

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.
Return to Section TOC Return to Section TOC Return to Section TOC
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
F-6
F-6
PROBLEMS (SYMPTOMS)
Machine is dead - no output - no fan - no display.
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 setup switch and jumper "A" (the reconnect auxiliary jumper) are in the proper position for the input voltage being used. 4. With input power removed, check the continuity of the 4 amp slow blow fuse located on the reconnect panel.
1. The input power switch (S1) may be faulty. Check or replace. 2. Perform the T1 Transformer Test. Auxiliary
No output or reduced output the first time power is applied to the machine.
1. Check input voltages, fuses and input voltage reconnect procedures. See the Installation section. 2. If high input voltage (380VAC or higher) is applied, the capacitors may need conditioning. Let the "unloaded" machine idle for 30 minutes.
1. Contact the Lincoln Electric Service Department. 1-888-9353877.
CAUTION
F-7
F-7
PROBLEMS (SYMPTOMS)
No output. Main fuses are open, indicating excessive current draw.
1. With the input power removed, inspect input leads for possible shorts or grounds or misconnections. 2. Install new fuses and reapply power. If fuses open again, contact your local Lincoln Authorized Field Service Facility.
1. Check the input power switch (S1) and the reconnect switch for "shorted" or "grounded" wires or connections. 2. Perform the Input Rectifier Test. 3. Perform the Switch Board Test.
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. 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. 2. Make sure that the gun tip is not "shorted" to the work surface and that the proper welding procedures are being used.
1. The current sensor may be faulty. 2. The control PC board may be faulty.
CAUTION
F-8
F-8
PROBLEMS (SYMPTOMS)
Machine loses output while welding. The thermal indicator light is lit. Normal welding output returns after about 10 minutes.
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
F-9
F-9
PROBLEMS (SYMPTOMS)
POSSIBLE AREAS OF MISADJUSTMENT(S) 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. 2. Check the gun and nozzle for leaks or obstructions.
1. Contact the Lincoln Electric Service Department. 1-888-9353877.
3. Make certain the machine and wire feed settings are correct for the process.
CAUTION
F-10
F-10
TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S)
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. 4. The driver PC board and or control PC board may be faulty.
5. The IGBT module may be faulty. Check or replace.
CAUTION
F-11
F-11
PROBLEMS (SYMPTOMS)
Molten weld puddle appears excessively "violent."
1. The Wire Type switch may be in the wrong position for the electrode wire being used. 2. The Peak Current or Background Setting may be too high. Adjust for optimum welding performance.
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
F-12
F-12
PROBLEMS (SYMPTOMS)
Excessive weld spatter. Arc sounds and looks 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 feed settings are correct for the process and wire being used.
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.
Poor welding, weld settings drift, or output power is low.
1. Make sure the machine settings are correct for the welding process being used. 2. Check the welding cables for loose or faulty connections. 3. Make sure the reconnect switch S7 is in the correct position for the three-phase input voltage being applied.
1. The current sensor may be faulty. Check associated leads for loose or faulty connections. 2. The control PC board may be faulty.
CAUTION
Do not switch reconnect switch with input power applied to machine.
CAUTION
F-13

T1 AUXILIARY TRANSFORMER TEST
F-13
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
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
Volt/Ohmmeter (Multimeter) Invertec STT wiring diagrams 5/16" Nut driver 3/8" Wrench Slot head screw driver Return to Section TOC Return to Master TOC
Note: Component locations and disassembly procedures may vary slightly on STT II models
INVERTEC STT
F-14

T1 AUXILIARY TRANSFORMER TEST (continued)
FIGURE F.1 T1 AUXILIARY TRANSFORMER AND J30/J31 LOCATION
F-14
PLUG J30
PLUG J31
T1 AUXILIARY TRANSFORMER
TEST PROCEDURE
Return to Section TOC Return to Master TOC 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. Capacitor See the 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.
WARNING
ELECTRIC SHOCK can kill. Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock.
INVERTEC STT
F-15

FIGURE F.2 PRIMARY LEAD PLUG J21 LOCATION
F-15
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-16

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. 12. Reconnect Plugs J30 & J31. Capacitor 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.
F-16
WARNING
Return to Section TOC Return to Master TOC ELECTRIC SHOCK can kill. Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock.
TABLE F.1 T1 AUXILIARY TRANSFORMER VOLTAGES
TEST POINTS
PLUG J30 PINS 1 TO 2 (LEADS 32 TO 33) Return to Section TOC Return to Master TOC PLUG J31 PINS 1 TO 4 (LEADS 501 TO 504) PLUG J31 PINS 2 TO 3 (LEADS 212 TO 503) PLUG J31 PINS 2 TO 5 (LEADS 212 TO 43A) PLUG J21 PINS 1 TO 4 (LEADS H1 TO H2) PLUG J21 PINS 1 TO 2 (LEADS H1 TO H3) Return to Section TOC Return to Master TOC PLUG J21 PINS 1 TO 3 (LEADS H1 TO H4) PLUG J21 PINS 1 TO 6 (LEADS H1 TO H5) (H6)
NORMAL VOLTAGE
115VAC
18VAC
24VAC
42VAC
200/208VAC 220/230VAC 380/415VAC 440/460VAC
NOTE: If the main AC input supply voltage varies, the auxiliary transformer voltages will vary by the same percentages. INVERTEC STT
F-17

T1 AUXILIARY TRANSFORMER TEST (continued) 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. 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 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. 18. Install the case wraparound cover.
F-17
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
INVERTEC STT
Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC F-18
NOTES
INVERTEC STT
F-18
F-19

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. 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.
F-19
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.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter) Invertec STT Wiring Diagrams Isolated 115VAC supply 5/16" Nut driver 7/16" Wrench
INVERTEC STT
F-20

FIGURE F.3 OUTPUT CHOKE/IGBT MODULE SPLICED CONNECTION
F-20
LOWER TRAY AREA
OUTPUT CHOKE/ DARLINGTON MODULE SPLICED CONNECTION
TEST PROCEDURE
1. Turn off the Invertec STT and disconnect main AC input power to the machine. 2. Using the 5/16" nut driver, remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure. See the Maintenance section.
WARNING
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
F-21
F-21

FIGURE F.4 PLUG J1 LOCATION
J1 CURRENT SENSING PLUG
LOWER TRAY AREA

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.
OUTPUT CHOKE/ DARLINGTON MODULE SPLICED CONNECTION
PLUG J22
6. Locate and disconnect plug J22 from the wiring harness. See Figure F.5. INVERTEC STT
F-22

FIGURE F.6 STT ON ITS RIGHT SIDE
F-22
MOUNTING BOLTS (5)

7. Carefully 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. Return to Section TOC Return to Master TOC
9. Carefully slide out and support the lower tray assembly for testing purposes. 10. Locate and remove plug J13 from the IGBT drive board. See Figure F.7.
IGBT DRIVE BOARD PLUG J13
STT II
INVERTEC STT
F-23

FIGURE F.8 T4 TRANSFORMER LEAD CONNECTIONS
F-23
LEADS 32A, 32B, 33A, 33B
LEADS 32A, 32B, 33A, 33B
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
INVERTEC STT
F-24

TABLE F.2 T4 AUXILIARY TRANSFORMER VOLTAGES
F-24
TEST POINTS
PLUG J13 PINS 5 TO 6 PLUG J13 PINS 2 TO 3 PLUG J22 PINS 1 TO 2 (LEADS 240 TO 241)
NORMAL VOLTAGES
6VAC 10VAC 18VAC
PLUG J22 PINS 2 TO 9 (LEADS 241 TO 242) PLUG J22 PINS 3 TO 4 (LEADS 243 TO 244) PLUG J22 PINS 12 TO 13 (LEADS 245 TO 246)
18VAC
18VAC
18VAC
13. Check the secondary AC voltages according to Table F.2. 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.
15. After all tests are completed, reconnect the following: 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. 16. Install the case wraparound cover.
INVERTEC STT
F-25

INPUT RECTIFIER TEST
F-25
WARNING
TEST DESCRIPTION
This test will help determine if the input rectifier and associated components are functioning properly.
MATERIALS NEEDED
5/16" Nut driver Analog Voltmeter/ohmmeter (Multimeter) Inverter STT Wiring Diagrams Return to Section TOC Return to Master TOC
INVERTEC STT
F-26

INPUT RECTIFIER TEST (continued)
FIGURE F.9 - INPUT RECTIFIER LOCATION
F-26
INPUT RECTIFIER
12
TEST PROCEDURE
1. Turn off the Invertec STT and disconnect main AC input power to the machine. Return to Section TOC Return to Master 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
4. Locate the input rectifier. See Figure F.9. 5. Locate the leads needed to perform the tests. See Figure F.9. 6. Use an ANALOG ohmmeter to perform the tests shown in Table F.3.
WARNING
INVERTEC STT
F-27

INPUT RECTIFIER TEST (continued)
TABLE F.3 INPUT RECTIFIER TEST
F-27
TEST POINTS +PROBE

9 9 9 A B C
-PROBE
A B C 9 9 9 A B C 12 12 12
ACCEPTABLE METER READING

Greater than 100K ohms Greater than 100K ohms Greater than 100K ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Greater than 100K ohms Greater than 100K ohms Greater than 100K ohms 8. Test capacitors C1 and C2 and replace both capacitors if either is faulty. NOTE: Faulty capacitors could be the reason for input rectifier failure. Visually inspect the capacitors for leakage, damage, etc., and use appropriate test equipment to determine component integrity. 9. Perform the Switch Board Test. 10. After all tests are completed, install the case wraparound cover.
12 12 12 A B C
6. Replace the input rectifier when any of the tests are NOT OK. 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.
7. Inspect main power switch S1 and replace if faulty. Go to step 8.
INVERTEC STT
NOTES
INVERTEC STT
F-28
F-29

CAPACITOR BALANCE TEST
F-29
WARNING
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)
INVERTEC STT
F-30

CAPACITOR BALANCE TEST (continued)
FIGURE F.10 SWITCH BOARD TEST POINTS
F-30
12
L8441
SWITCH
TEST PROCEDURE
1. Turn off the Invertec STT and disconnect main AC input power to the machine. 2. Using the 5/16" nut driver, remove the case wraparound cover.
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.
WARNING
3. Carefully apply the correct input power to the machine.
INVERTEC STT
F-31

CAPACITOR BALANCE TEST (continued)
TABLE F.4 EXPECTED VOLTAGE READINGS
F-31
If VAC Input is:

460 440 415 380 VAC VAC VAC VAC
VDC at terminals #9 (+) and #12 (-) should be approximately:

325VDC 311VDC 293VDC 269VDC 8. After all tests are completed, remove the jumper between pins C and D on the 14-pin amphenol. 9. Install the case wraparound cover.
5. Adjust the Peak and Background controls to the minimum settings (controls on case front). 6. Jumper together pins "C" and "D" on the 14 pin amphenol. This will energize the output terminals. 7. Test for VDC across terminals #9 and #12 of one switch board and repeat the test for the other switch board. See Table F.4 in this procedure for expected voltage readings. See Figure F.10. A. 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
NOTES
INVERTEC STT
F-32
F-33

SWITCH BOARD TEST
F-33
WARNING
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
Analog Volt/ohmmeter (Multimeter) 5/16" Nut driver
INVERTEC STT
F-34

SWITCH BOARD TEST (continued)
FIGURE F.11 - SWITCH BOARD RESISTANCE TEST
F-34
TEST PROCEDURE
NOTE: There are two switch boards. One is located on each side of the machine. NOTE: The switch boards are designed to receive gate (turn-on) signals from the driver board (pulse transformer secondaries). The internal board circuitry processes the signals and outputs them to the FETs. The switch board 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. 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
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-35

F-35
TABLE F.5 SWITCH BOARD RESISTANCE TEST Apply Positive Test Probe to Terminal 1/8 Apply Negative Test Probe to Terminal Test Result Conclusion Repair Action 12 Greater than OK None 1K ohm Less than 100 ohms Shorted OK Replace both switch boards None Replace both switch boards None Replace both switch boards None Replace both switch boards None Replace both switch boards None Replace both switch boards None Replace both switch boards None Replace both switch boards
Next Procedure Notes Continue Snubber Test Continue Snubber Test Continue Snubber Test Continue Snubber Test Continue Snubber Test Continue Snubber Test Continue Snubber Test Continue Snubber Test
12
1/8
Less than 100 ohms
Greater than Open 1K ohm 9 4/5 Greater than OK 1K ohm Less than 100 ohms 4/5 9 Less than 100 ohms Shorted OK
Greater than Open 1K ohm 1/8 Return to Section TOC Return to Master TOC 9 Less than 100 ohms OK
Greater than Open 1K ohm 9 1/8 Greater than OK 1K ohm Less than 100 ohms 12 4/5 Less than 100 ohms Shorted OK
Greater than Open 1K ohm 4/5 12 Greater than OK 1K ohm Less than 100 ohms 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
F-36

F-36
TABLE F.5 SWITCH BOARD RESISTANCE TEST (continued) Apply Positive Test Probe to Terminal 12 Apply Negative Test Probe to Terminal Test Result Conclusion Repair Action 401/403 Greater than OK None 1K ohm Less than 100 ohms Shorted OK Replace both switch boards None Replace both switch boards None Replace both switch boards None Replace both switch boards
Next Procedure Notes Continue Snubber Test Continue Snubber Test Continue Snubber Test Continue Snubber Test
401/403
12
Less than 100 ohms
Greater than Open 1K ohm 9 402/404 Less than 100 ohms OK
Greater than Open 1K ohm 402/404 9 Greater than OK 1K ohm Less than 100 ohms 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
F-37
F-37
SNUBBER RESISTORS TEST WARNING
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
INVERTEC STT
F-38

SNUBBER RESISTORS TEST (continued)
FIGURE F.12 - REMOVING LEADS
F-38
TEST PROCEDURE
Return to Section TOC Return to Master TOC 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. Capacitor See the
4. Locate and gain access to the switch board. 5. Remove leads from terminals 401/403, 402/404 on the switch board. See Figure F.12.
WARNING
INVERTEC STT
F-39

SNUBBER RESISTORS TEST (continued)
FIGURE F.13 - SWITCH BOARD TEST POINTS
F-39
401/403 401
12
402/404 12
L8441
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 Return to Master TOC 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. c. If 20 ohms or less 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.
TABLE F.6 SNUBBER RESISTORS TEST Check Lead 401 to Terminal 12 Lead 402 to Terminal 9 Test Result 25 ohms >30 ohms <20 ohms 25 ohms >30 ohms <20 ohms 25 ohms >30 ohms <20 ohms 25 ohms >30 ohms <20 ohms Conclusion OK R4 open R4 faulty OK R5 open R5 faulty OK R6 open R6 faulty OK R7 open R7 faulty Next Test Step Continue Replace R4 Continue Replace R5 Continue Replace R6 Continue Replace R7 Repair Action
Lead 403 to Terminal 12 Lead 404 to Terminal 9
> = GREATER THAN
< = LESS THAN INVERTEC STT
NOTES
INVERTEC STT
F-40
F-41

POWER BOARD TEST
F-41
WARNING
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
INVERTEC STT
F-42

POWER BOARD TEST (continued)
FIGURE F.14 REMOVING THE FRONT PANEL ASSEMBLY
F-42
POWER PC BOARD
(Located on Back of Case Front)
QUICK CHECK PROCEDURE

1. Turn off the Invertec STT and disconnect main AC input power to the machine. Return to Section TOC Return to Master TOC 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.
OK. If the relays are NOT being activated, the power PC board could be faulty. Continue with the voltage tests.
VOLTAGE TEST PROCEDURE

1. Remove input power to the Invertec STT. 2. Perform the Input Filter Capacitor Discharge Procedure. See the Maintenance section.
WARNING
WARNING
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.
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
INVERTEC STT
F-43

FIGURE F.15 POWER PC BOARD TEST POINTS
F-43
309
310 POWER BOARD
212A
301 302
L8033
J7
313
J14
311 211A
J6
275 305
501 504
4. Secure and insulate the front panel assembly for POWER ON testing.
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. NOTE: If the 18VAC is NOT present, perform the T1 Auxiliary Transformer Test. Also check associated wiring. See the Wiring Diagram.
WARNING
INVERTEC STT
F-44

FIGURE F.16 SIMPLIFIED TRIGGER CIRCUIT
POWER BOARD
#301
F-44
CONTROL BOARD
7J6 FROM PROTECTION BOARD OVERVOLTAGE 2J6
11J4
#305
3J4
PWM OUTPUTS TO POWER BOARD
P W M
STT II Only T1 AUXILIARY TRANSFORMER

3J31 2 4 V A C 2J31
#212 #503A
#379
14 AMPHENOL
3.5 ohms
#210
6J22
#224
6J4
9J4
#223
8J33
13J36
#413
TO POWER BOARD
5J4 3.5 ohms 12J4 6J34 5J36

#405
#212C
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. Return to Section TOC Return to Master TOC NOTE: If the 18VAC is present but the 15VDC is NOT, the power PC board may be faulty. 8. Carefully test for 24VAC input from the T1 Auxiliary Transformer between plug J6 pin 4 (lead#211A) and plug J6 pin 9 (lead#212A). See Figure F.15. NOTE: If the 24VAC is NOT present, perform the T1 Auxiliary Transformer Test. Also check the associated wiring. See the Wiring Diagram. The control PC board or thermostats may be faulty. See Figure F.16, the Simplified Trigger Circuit diagram. 9. Carefully test for 24VDC at the power PC board at plug J7 pin 2 (lead #309)(+) to plug J14 pin2 (lead #313)(-). See Figure F.15. Return to Section TOC Return to Master TOC
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
F-45

PROTECTION BOARD TEST
F-45
WARNING
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
INVERTEC STT
F-46

PROTECTION BOARD TEST (continued)
FIGURE F.17 PROTECTION PC BOARD TEST POINTS
F-46
L7915-[ ]
PROTECTION
313
315
314
J8
317
J15 316
311
TEST PROCEDURE
1. Turn off the Invertec STT and disconnect main AC input power to the machine. 2. Using the 5/16" nut driver, remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure. See the Maintenance section.
WARNING
WARNING
ELECTRIC SHOCK can kill. Before continuing with the test procedure, perform the capacitor discharge procedure to avoid electric shock. 5. Apply the correct input power and turn the machine ON. 6. Test for approximately 1VDC from plug J8 pin 1 (lead #311)(+) to plug J8 pin 3 (lead #313) (-). See Figure F.17. A. If approximately 1VDC is present, the protection PC board is functioning properly. B. If more than 5 VDC is measured, perform the Capacitor Balance Test.
4. Locate the protection PC board just in front of the input rectifier and relay mountings.
INVERTEC STT
F-47

PROTECTION BOARD TEST (continued)
FIGURE F.18 - LEADS #309, #309A AT CR1, CR2 RELAYS
F-47
CR2 309A
CR1
309
7. If the Capacitor Balance Test is OK and more than 5VDC is present at leads #311 to #313 (Step 6), the protection PC board may be faulty. NOTE: The above voltage checks pertain only to the over voltage signal from the protection PC board to the power PC board. The 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
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.
WARNING
ELECTRIC SHOCK can kill. 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.
INVERTEC STT
NOTES
INVERTEC STT
F-48
F-49

TRIGGER CIRCUIT TEST
F-49
WARNING
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
5/16" Nut driver Volt/ohmmeter (Multimeter) Wiring Diagram and board Schematics
INVERTEC STT
F-50

TRIGGER CIRCUIT TEST (continued)
F-50
PLUG J31
TEST PROCEDURE
1. Turn off the Invertec STT and disconnect main AC input power to the machine. Return to Section TOC Return to Master TOC 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
4. Locate plug J31 at the left side of the machine. See Figure F.19.
INVERTEC STT
F-51

FIGURE F.20 14 PIN AMPHENOL AND PLUG J31 PIN ASSIGNMENTS
F-51
C B D L E M N I F G K AJ
212
PLUG J31
5. Using the ohmmeter check for approximately 3.5 ohms resistance from pin "D" of the 14 pin amphenol to plug J31 pin 2 (lead #212). See Figure F.20, and Figure F.22, Simplified Trigger Circuit Diagram. FIGURE F.21 CONTROL PC BOARD MOLEX PLUG
223
J5 J17 J27 J28 J2 J3 J1 J4
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
STT CONTROL G2782-[ ]
F-52

FIGURE F.22 SIMPLIFIED TRIGGER CIRCUIT DIAGRAM
F-52
POWER BOARD
CONTROL BOARD
7J6 FROM PROTECTION BOARD OVERVOLTAGE 2J6
#301
11J4
#305
3J4
PWM OUTPUTS TO POWER BOARD
P W M
STT II Only
3J31
#503A
14 AMPHENOL
#379
3.5 ohms
#210
6J22
#224
6J4
9J4
#223
8J33
13J36
#413
2 4 V A C 2J31
#212
TO POWER BOARD
5J4 3.5 ohms 12J4 6J34 5J36

#405
#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.
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.
WARNING
INVERTEC STT
F-53

IGBT MODULE REMOVAL AND REPLACEMENT WARNING
F-53
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)
INVERTEC STT
F-54

IGBT MODULE REMOVAL AND REPLACEMENT (continued)
FIGURE F.23 OUTPUT CHOKE LEAD DISCONNECTION
F-54
LOWER TRAY AREA

PROCEDURE
1. Turn off the Invertec STT and disconnect main AC input power to the machine.
OUTPUT CHOKE/ IGBT MODULE SPLICED CONNECTION
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
INVERTEC STT
F-55

FIGURE F.24 PLUG J1 DISCONNECTION
F-55
LOWER TRAY AREA
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. See Figure F.24.
PLUG J22
F-56

FIGURE F.26 STT PLACED ON ITS RIGHT SIDE
F-56
MOUNTING BOLTS (5)

7. Carefully lift 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. Return to Section TOC Return to Master TOC 9. Carefully slide out and support the lower tray assembly. 10. Using the needle nose pliers, remove the strain relief holding the J22 lead harness to the case bottom.
11. Using the 1/2" wrench, remove the IGBT cable from the negative output terminal. 12. Carefully remove the lower tray assembly clear from the machine. 13. Remove the rubber RTV coating from the IGBT module.
INVERTEC STT
F-57

FIGURE F.27 IGBT MODULE CONNECTIONS
F-57
IGBT MODULE
E G
STT II
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. 17. Using the 3/16" Allen type wrench, remove the four socket head cap screws that mount the 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 the socket head cap screws and torque to 35 inch pounds. Note: The torque should be rechecked after three hours. INVERTEC STT 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. 24. Apply the Silicone Rubber RTV Coating (Lincoln E2861 or Dow 3140) to the terminals and lead connections as was previously removed. 25. Replace the lower tray assembly. 26. Connect plug J22 to the wiring harness and plug J1 to the control PC board. 27. Connect the lead splice between the output choke and the IGBT module. 28. Install the case wraparound cover.
NOTES
INVERTEC STT
F-58
F-59

SWITCH BOARD REPLACEMENT WARNING
F-59
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
INVERTEC STT
F-60

SWITCH BOARD REPLACEMENT (continued)
FIGURE F.28 SWITCH BOARD REMOVAL
F-60
SOCKET HEAD SCREWS
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: 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. 3. Perform the Input Filter Capacitor Discharge Procedure. See the Maintenance section. Return to Section TOC Return to Master TOC
WARNING
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.
INVERTEC STT
F-61

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. 8. Clean the heat sink surfaces thoroughly to remove all the heat sink compound. (During machine operation, this compound helps conduct heat from the switch board to the heat sinks. 9. Apply a thin layer (.002") of Dow Corning 340 Heat Sink Compound (Lincoln E1868) to the mounting surfaces of the new switch board and to the capacitor terminals. DO NOT allow the compound to enter the mounting screw holes. It can distort the torque values. 10. Prepare to mount the new switch board on the heat sink by first lining up the mounting holes. Then press the switch board into place. 11. Insert each of the four socket head screws into the mounting holes. Thread them finger tight. The threads are soft -- be careful no to cross-thread them. 12. Insert each of the two hex head screws into the capacitor terminal holes. Thread them finger tight. Be careful not to cross-thread the screws. 13. Torque both sets of screws in 10 inch-pound increments. Use 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).
F-61
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).
INVERTEC STT
F-62

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.
F-62
TEST PROCEDURE
Return to Section TOC Return to Master TOC 1. Turn main power OFF. 2. Perform Input Filter Capacitor Discharge Procedure. See the Maintenance section.
NOTE: Repeat the Input Filter Capacitor Discharge Procedure. 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. NOTE: These fuses should be installed to protect against excessive current flow caused by a short circuit during the procedure.
WARNING
FIGURE F.29 SHORTING TERMINALS 14 AND 53 OF PROTECTION BOARD
L7915-[ ]
PROTECTION
53
14
JUMPER TERMINALS
INVERTEC STT
F-63

F-63
WARNING
ELECTRIC SHOCK can kill. With input power ON, there are high voltages in the machine. Do not reach into the machine or touch any internal part.
9. With the output free of a load, check open circuit voltages of the output. Voltage should be 85 VDC maximum. 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.
8. With the machine connected for 440/460 volt operation and the proper input voltage applied, turn on input power to the machine.
INVERTEC STT
NOTES
INVERTEC STT
F-64
F-65

CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE WARNING
F-65
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input filter capacitors C1 and C2.
MATERIALS NEEDED
5/16" Nut driver Slot head screw driver 7/16" Wrench Needle nose pliers 1/2" Wrench
INVERTEC STT
F-66
F-66
CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.30 OUTPUT CHOKE LEAD DISCONNECTION
LOWER TRAY AREA

PROCEDURE
1. Turn off Invertec STT and disconnect main AC input power to the machine.
WARNING
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
F-67
F-67

LOWER TRAY AREA

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.
PLUG J22
F-68
F-68

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. 8. Using the 7/16" wrench, remove the five bolts holding the lower tray assembly to the case bottom. Return to Section TOC Return to Master TOC 9. Carefully slide out and support the lower tray assembly. 10. Using the needle nose pliers, remove the strain relief holding the J22 lead harness to the case bottom.
11. Using the 1/2" wrench, remove the IGBT cable from the negative output terminal. 12. Carefully remove the lower tray assembly clear from the machine and set aside. 13. Carefully disconnect the leads at the top of the switch board.
INVERTEC STT
F-69
F-69
FIGURE F.34 REMOVING HEX HEAD NUTS OF THROUGH-BOLTS
HEX NUT
CAPACITOR REPLACEMENT
NOTE: Capacitors must always be replaced in matched sets (C1 and C2 as a set). When replacing Capacitors, remove the entire FET heat sink assembly, including the capacitors and switch board, as a unit.
Disassemble and reassemble only one unit at a time. Use the other unit as a model during reassembly so that all parts are reinstalled 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
F-70
F-70

FIGURE F.35 REMOVING THROUGH-BOLTS
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
F-71
F-71

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.
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
F-72
F-72

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. . . The Input Filter Capacitor Protection Circuit could have been activated and prevented output. This means the Input Filter Capacitors must be conditioned. The Input Filter Capacitor 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. 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.
CAUTION
Proper capacitor polarity must be noted when attaching the capacitor to the switch board assembly.
20. Install the switch board and capacitor assembly into the machine. Take special care that ALL insulators and sleevings are in their proper positions. See Figure F.38. 21. Install the lower tray assembly and all previously disconnected loads and plugs. 22. Perform the Test After Repair of Switch Boards and/or Capacitors. NOTE: Always make sure that the switch boards are changed in matched pairs. Never mix an old style switch board (different part number) with new style (new part number).
INVERTEC STT
F-73

OUTPUT RECTIFIER REMOVAL AND REPLACEMENT WARNING
F-73
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the output diode heat sink assembly.
MATERIALS NEEDED
5/16" Nut driver 3/8" Nut driver 7/16" Wrench Slot head screw driver Dow Corning 340 Heat Sink Compound (Lincoln E1868) Return to Section TOC Return to Master TOC
INVERTEC STT
F-74

OUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)
FIGURE F.39 CHOKE LEAD/HEAT SINK CONNECTION
F-74
HEAT SINK TAB CHOKE LEAD
PROCEDURE
1. Turn off Invertec STT and disconnect main AC input power to the machine. 2. Using the 5/16" nut driver, remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure. See the Maintenance section.
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.
WARNING
INVERTEC STT
F-75

FIGURE F.40 MAIN TRANSFORMER DIODE CONNECTIONS
F-75
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-76

FIGURE F.41 SWITCH BOARD/CAPACITOR ASSEMBLY THROUGH-BOLTS
F-76
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. 12. Using the 3/8" nut driver, loosen the front nuts from the switch board/capacitor assembly through-bolts. 13. Carefully lift the horizontal baffle away from the upper tabs of the output rectifier heat sink assembly. 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.
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. 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. 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.
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
F-77

RETEST AFTER REPAIR
F-77
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 INPUT POWER @ IDLE Return to Section TOC Return to Master TOC 3.5 AMPS 800 WATTS
MINIMUM ACCEPTABLE OUTPUT (AT MAXIMUM BACKGROUND SETTING) [STATIC GRID LOAD]
CONTROL MODE BACKGROUND AMPS 140 VOLTS 20
OPEN CIRCUIT VOLTAGE RANGE

73 TO 85 VDC
INVERTEC STT
F-78
F-78
INPUT FILTER CAPACITOR CONDITIONING

If the machine will not produce output when turned on and the following two conditions exist: The machine is connected to operate at an input voltage of 380 VAC or higher and Power has not been applied to the machine for a long period of time (many months). Then. . . The Input Filter Capacitor Protection Circuit could have been activated and prevented output. This means the Input Filter Capacitors must be conditioned.
ENVIRONMENTAL PROTECTION
High voltage connections are covered with an RTV sealant to prevent malfunction in severe environments. Sealant must be applied to connections which have been opened or otherwise lost their protection. A 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.
Return to Master TOC Return to Master TOC Return to Master TOC
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. 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
Section G-1 Return to Master TOC
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 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 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 PC Board Assembly - Remote Protection - All Codes - (L9657) . . . . . . . . . . . . . . . .G-29
INVERTEC STT
G-2
ELECTRICAL DIAGRAMS
G-2
Wiring Diagram - Entire Machine - Codes 10151 - 10153 - (G2773)

N.G. 9A 9A R7 25 25W C2+ 25 2200 F 25W450V R6 12A 12A 9 402, 404 + 4, 5 4 T2 MAIN TRANSFORMER 1 4 F TOP 10 .001/400 OUTSIDE 2 W R3 S C4 S F D11 BOTTOM BOTTOM D10 INSIDE S D9 1F D8 D7 L3 CHOKE 3 1 J18 4 2 1 J12 2 3 4 W B R B W B W C8 20/400 289B 289A CURRENT SENSE BOARD 289 E C 288B R14 2 300W 288A R13 2 300W
N.L. TOROIDAL CORE
+ ARC J19 D7 287 - ARC 1 2 J37 3 4 403 402 401 410 409 412 404 411 290 291 1 (+) 2 3 (-) 4 VOLTAGE SENSE CONNECTION
N.F. 9A 9A 9A 9A 52 14 14 53 1 53 3 J8 2 4 7500 25W R1
53
SWITCH BOARD (LEFT) 401, 403 R W R W 1, 8 12
288
C B A
INPUT RECTIFIER 9D 9D D13 9C C D+ C H1 TP1 H1 B B TP3 TP2 A A F A 12C 12D 12D
309 309A 310 CR1 310A 9D N.H. S7 RECONNECT 9B 9B 9C 12A 12C 12A 9B
309 310 311 313 307308 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
DARLINGTON MODULE E B 212C 43A 33C 32C 212B 6 1 4 8 5 3 2 7
J34
3 2 1 10 9 12 4 11
52 PROTECTION 2 BOARD 5 J15 1 4 3 H5 51 6 51 N.F.
52 52 314 315 316 317
9D 12D 12B 52
N.E. 371 374 N N O O 1 4 2 J13 3 5 6 DARLINGTON DRIVE BOARD R B W 1 4 J1 2 3 J27
223 B R W B 370 371 372 374 376
J38 J B BG C 10K G A PB D 10K TRIGGER F H GND E I OPTIONAL REMOTE INTERFACE WIRE FEEDER SPARE GND 21 82 81 4 TRIGGER 2 42 41 32 31 77 76 75 42 VAC 115 VAC N.J. CB1 42 6AMP VAC CB2 115 6AMP VAC
N.L. 12D LOAD CR2 309A 310A 12B 12B 12B 12B POWER LINE FILTER ASSEMBLY
9B N.G. 9B R5 25 25W C1+ 25 2200 F 12B 12B 25W450V 51 R4 12B 12B 9B 7500 25W
R9
W R
WR 4,5
T3 CURRENT TRANSFORMER I 5 Y Y I 5F S BOTTOM TOP OUTSIDE S F S TOP INSIDE 8F
N.E. D1 D2 D3 D4 D5 C3
402, 404 SWITCH + BOARD (RIGHT) 401, 403 1, 8 12
1 0 R2 2W .001/400 W B R B 240 241 242 307 308 309 310 501 504 7 8 2 4 5 J7 6 1 3 1 2 J14 3 4 POWER BOARD 5 3 6 8 J6 1 10 2 7 9 4 371A 374A 243 244 303 302 304 275 3 1 7 5 6 J5 8 2 4 8 1 7 14 3 11 10 6 4 2 5 9 12 13
5 6 7 2 1 4 8 3 9 10
370 371 372 374 376
8 9 10 J36 5 4 6 J33 2 3 7 1
J39 14 6 N 414 B 406 H L M 405 D 413 C 416 K 408 I 415 A 407 J E F G 43B 42 33D 31A
5 13 16 8 15 7
H1 H3 A FAN MOTOR J30 R 1 32 11 5 V R 2 33 J31 4 2 V 43A U 5 24V N 3 0V W 2 Y 4 18V Y 1 503 212 504 J22 15 32A 32C 16 32B 7 33C 8 33A 33B
J22 371 10 371A 374 11 374A R 1 18V 2 11 5 V W 18V R 9 B 3 18V B 4 10V N O 6V O U 12 245 18V U 13 246 T4 AUXILIARY TRANSFORMER 503A 212B 240 241 242 243 244 N 503A 224 J22 W 14 W 6
503B DARLINGTON HEATSINK THERMOSTAT 224A
LINE N.K. S1 POWER ON OFF W U V C C W B G R INPUT PER N.A.
4 AMP SLOW BLOW
440460V A 380415V 220230V H3 200208V
J21 H6 6
H5
FAN THERMOSTAT 224 210A 150 5W 212A 210 311 313
H4 H3 H2 H1
3 H4 H3 H2 H1
A A B B
2 4 1
303 302 304 275 212 305 301 212A 211A
1 2 3 4 5 6 J17 7 8 9 J28 10 11 12 350 351 352 353 354 355 356 357 358 359 360 361 362 363
3 6 2 J35 5 1 4
J24 353 352 1 2 3 4 5 6 J26 357 356 1 2 3 4 5 6 1 2 3 4 5 6
J23 PEAK CURRENT METER
501
N.D.
J1, J8, J3, J9, J 11 , J 1 2 , J 1 4 J 1 0 , J 1 3 , J18, J37 J15, J35
J5, J7, J34
J6, J27, J33
J24 J26
J23 J25
ELECTRICAL SYMBOLS PER E1537 COLOR CODE: B = BLACK G = GREEN N = BROWN O = ORANGE R = RED W = WHITE Y = YELLOW U = BLUE
Y Y 301 305 245 223 211A 212C 210 246 502
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
351 350 J25 1 2 3 4 5 6
BACKGROUND METER
355 354 358 359 360 361 CW (MAX) 10KR11 2W CW (MAX) 10KR12 2W
PEAK CURRENT CONTROL
J4, J17
J16, J28
J2, J36 METER PINOUT (VIEWED FROM BACK OF METER)
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) J38 J19 J39
NOTES:
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 J30 P29, P31 J29. J31 P21 J21
P22
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 )
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.
2 5 6 J3 1 4 3 CONTROL BOARD
364 365 366 367 368 369
362 363
BACKGROUND CONTROL
364 365 366 367 367A .045 368 367A
CW (MAX) 10K R13 2W
HOT START CONTROL
S2 .035
WIRE SIZE
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
G-3
ELECTRICAL DIAGRAMS
G-3

N.L. N.G. 9A 9A R7 25 25W C2+ 25 2200 F 25W450V R6 12A 12A 9 402, 404 + 4, 5 4 T2 MAIN TRANSFORMER 1 4 F TOP 10 .001/400 OUTSIDE 2 W R3 S C4 S F D11 BOTTOMBOTTOM D10 INSIDE S D9 1F D8 D7 L3 CHOKE 3 1 J18 4 2 1 J12 2 3 4 W B R B W B W 289 289A CURRENT SENSE BOARD C8 20/400 289B 288B R16 2 300W 288A R15 2 300W E C 3 2 1 10 9 12 4 11 403 402 401 410 409 412 404 411 J38 J B C G A D F H E I 288 D12 287 - ARC 1 2 J37 3 4 290 291 1 (+) 2 3 (-) 4 + ARC J19 VOLTAGE SENSE CONNECTION TOROIDAL CORE REMOTE PROTECTION BOARD
N.F. 9A 9A 9A 9A 52 14 14 53 1 53 3 J8 2 4 7500 25W R1
53
SWITCH BOARD (LEFT) 401, 403 R W R W1, 8 12
C C B A A
INPUT RECTIFIER 9D 9D D13 9C C D+ H1 TP1 H1 B TP3 TP2 A F A 12C 12D 12D
309 309A 310 CR1 310A 9D N.H. S7 RECONNECT 9B 9B 9C 12A 12C 12A 9B
309 310 311 313 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
DARLINGTON MODULE E B 212C 43A 33C 32C 212B 6 1 4 8 5 3 2 7
BG 10K TRIGGER GND OPTIONAL REMOTE INTERFACE PB 10K
J34
52 PROTECTION 2 BOARD 5 J15 1 4 3 H5 51 6 51 N.F.
52 52 314 315 316 317
9D 12D 12B 52
N.E. 371 374 N N O O 1 4 2 J13 3 5 6 DARLINGTON DRIVE BOARD R B W 1 4 J1 2 3 J27
223 B R W B 370 371 372 374 376
290A WIRE FEEDER
LOAD
N.K. POWER LINE FILTER ASSEMBLY H1 H3 TOP FAN MOTOR H1 LEFT FAN MOTOR H3 H1 H3 H1 H3
CR2 309A 310A 12B 12B 12B 12B
R9
12D
9B N.G. 9B R5 25 25W C1+ 25 2200 F 12B 12B 25W450V 51 R4 12B 12B 9B 7500 25W
W R
WR 4,5
T3 CURRENT TRANSFORMER I 5 Y Y I 5F S BOTTOM TOP OUTSIDE S F S TOP INSIDE 8F
N.E. D1 D2 D3 D4 D5 C3
402, 404 SWITCH + BOARD (RIGHT) 401, 403 1, 8 12
1 0 R2 2W .001/400 W B R B 240 241 242 307 308 309 310 501 504 7 8 2 4 5 J7 6 1 3 1 2 J14 3 4 POWER BOARD 5 3 6 8 J6 1 10 2 7 9 4 371A 374A 243 244 303 302 304 275 3 1 7 5 6 J5 8 2 4 8 1 7 14 3 11 10 6 4 2 5 9 12 13
5 6 7 2 1 4 8 3 9 10
370 371 372 374 376
8 9 10 J36 5 4 6 J33 2 3 7 1
J39 14 6 N 414 B 406 H L M 405 D 413 C 416 K 408 I 415 A 407 J E F G 43B 42 33D 31A
5 13 16 8 15 7
ELECTRODE SENSE LEAD GND 21 82 81 4 TRIGGER 2 42 41 32 31 77 76 75 42 VAC 115 VAC N.J. CB1 42 6AMPVAC CB2 115 6AMP VAC
A J30 R 1 32 11 5 V R 2 33 J31 4 2 V 43A U 5 24V 3 N 0V W 2 Y 4 18V Y 1 503 212 504 J22 15 32A 32C 16 32B 7 33C 8 33A 33B
J22 371 10 371A 374 11 374A R 1 18V 2 11 5 V W 18V R 9 B 3 18V B 4 10V N O 6V O U 12 245 18V U 13 246 T4 AUXILIARY TRANSFORMER 503A 212B 240 241 242 243 244 N 503A 224 J22 W 14 W 6
503B DARLINGTON HEATSINK THERMOSTAT 224A
N.L.
4 AMP SLOW BLOW
440460V A 380415V 220230V H3 200208V
J21 H6 6
H5
LINE
A A B C B
S1 POWER ON OFF W U V R B G
RIGHT FAN MOTOR
H4 H3 H2 H1
3 H4 H3 2 H2 4 1 H1
224
FA N T H E R M O S TAT C H O K E 379 T H E R M O S TAT 210A 150 5W 212A 210
311 313
303 302 304 275 212 305 301 212A 211A
1 2 3 4 5 6 J17 7 8 9 J28 10 11 12 350 351 352 353 354 355 356 357 358 359 360 361 362 363 377 378
3 6 2 J35 5 1 4
J24 353 352 1 2 3 4 5 6 J26 357 356 1 2 3 4 5 6
J23 1 2 3 4 5 6 J25 1 2 3 4 5 6 PEAK CURRENT METER
C W
INPUT PER N.A.
501
N.D.
J1, J8, J3, J9, J 11 , J 1 2 , J 1 4 J 1 0 , J 1 3 , J18, J37 J15, J35
J5, J7, J34
ELECTRICAL SYMBOLS PER E1537 J6, J27, J33 J24 J26 J23 J25 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 FAN SHROUD CASE BACK
Y Y 301 305 245 223 211A 212C 210 246 502
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
351 350
BACKGROUND METER
355 354 358 359 360 361 CW (MAX) 10KR11 2W CW (MAX) 10KR12 2W 377 378 364 365 CW (MAX) 10K R13 2W HOT START CONTROL
J4, J17
J16, J28
J2, J36
PEAK CURRENT CONTROL
METER PINOUT (VIEWED FROM BACK OF METER) 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) NOTES:
PLATFORM CASE BACK
J38 J19
J39
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 1 2 3 4 J30 2 1 4 3 P22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 P29, P31 1 2 3 4 5 6 J29. J31 3 2 1 6 5 4 J22 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 P21 1 2 3 4 5 6 J21 3 2 1 6 5 4
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. 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.
2 5 6 J3 1 4 3 CONTROL BOARD
364 365 366 367 368 369
362 363
BACKGROUND CONTROL CW TAILOUT CONTROL R14 500K 2W
366 367 367A .045 368 367A
S2 .035
WIRE SIZE
STAINLESS S3 MILD 369 502 Y 503 503A (+) (-)
WIRE TYPE
THERMAL OVERLOAD INDICATOR
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 )
D-RW
G3136
G-4
ELECTRICAL DIAGRAMS
G-4
G-5
ELECTRICAL DIAGRAMS
G-5

TOROIDAL CORE
N.L. N.G. 9A 9A N.F. 9A 9A 9A 9A

309 309A
C8
20/400
C2
7500 25W R1 52 53
25 2200 F 25W 450V R6 12A 12A
401, 403 R W 12
SWITCH BOARD (LEFT)

R W 1, 8 1
T2 MAIN TRANSFORMER 4
TOP OUTSIDE F S BOTTOM INSIDE S F F BOTTOM S
289A CURRENT SENSE BOARD 3 1 4 2
2 300W
288A 288
R13
D7
J37
10 2W
.001/400
R3
L3 CHOKE
289
2 300W
287 C
- ARC
E R B W B W
D11 D10 D9 D8 D7
14 14
53 53
309 310
J18
9D N.H. S7 RECONNECT 9B 9B 9C 12A 12C 12A 9B
J8
C H1 H1 B A B A A
D+ TP1 B TP3 TP2
3 2 51 J10
1 2 3 4 J11
J12
PROTECTION 2 BOARD 5
J15
H5 51 1 4 3 6
52
52 52 314 315 316 317
9D 12D 12B
8 12
52
7 3 1 2 14 13
J16
DRIVER BOARD
J9
N.E. 371 374 N N O O

D1
F BOTTOM OUTSIDE S TOP INSIDE S
12D 12D N.L. 12D LOAD N.F.
51 N.G. 9B 7500 25W R5 25 25W 9B 9B C1 + 9
W R
W R 4,5
I 5
S TOP F
5 Y Y I
D2 D3 D4 D5
CR2
309A 310A
R9
+ -
12B 12B 12B
12B 12B POWER LINE FILTER ASSEMBLY
25 2200 F 12B 25W 450V 51 R4 12B 12B
401, 403 12
10 2W
C3 R2 .001/400
W B R B 240 241 242
POWER BOARD J7
1, 8
J22 H1 FAN MOTOR H3 A

R
11 1 2
J22
32 32C
15 16 7
LINE N.K.
H6 380415V
H5
33 33C 43A 503
42V
J31
5 3
33A 33B
S1 A A B B C C W V POWER ON OFF W U R B G
H4
H4
3 B 18V B 4
24V
N
244 N N O 503A
FAN THERMOSTAT 224 210A 212B 150 5W 212A 210 311 313
10V
INPUT PER N.A.
200208V
H3
H3 H2
2 4 1
H2
0V
W Y
2 4
212 504
6V U 12 18V U
H1
O 245 246
H1
18V
Y
501
13
N.D.
J1, J8, J11, J12, J14 J18, J37

1 2
J3, J9, J10, J13, J15, J35

1 3
J5, J7, J34

1 4
J6, J27, J33

1 5
J24 J26
1
J23 J25
1
ELECTRICAL SYMBOLS PER E1537

COLOR CODE: B = BLACK G = GREEN N = BROWN O = ORANGE R = RED W = WHITE Y = YELLOW U = BLUE
Y Y 301 305 245 223 211A 212C 210 246 502
3 1
6 1
8 1
10 8
J4, J17
6
J16, J28
7
J2, J36
METER PINOUT (VIEWED FROM BACK OF METER)

7 12 8 14 9 16
P.C. BOARD CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD)
NOTES: N.A. 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.
J3
J38 J19
J39
D C 3 B A J I
E F G H
2 4
D L A E K M F J N G I H B
CONTROL BOARD
PINOUT OF FRONT PANEL CONNECTORS (REAR VIEW)
P30
1 3 2 4
J30
2 4 1 3
P29, P31
1 4 2 5 3 6
J29. J31
3 6 2 5 1 4
P21
1 4 2 5 3 6 3 6
J21
2 5 1 4
P22
1 2 3 4 5 6 7 8 8 7 6 9 10 11 12 13 14 15 16
J22
5 4 3 2 1 9 16 15 14 13 12 11 10
INLINE CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM WIRE SIDE OF CONNECTOR)
H3
1 2 3 4
J6 J14
4 AMP SLOW BLOW
115V
32A 32B
R 18V
115V
J21
W 18V R 9
241 242 243
503A
224
J22 W W
6
14
224A
307 308 309 310 501 504
7 8 2 4 5 6 1 3
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
J35
350 351 352 353 354 355 356 357 358 359 360 361 362 363
353 352
351 350 J26 357 356 1 2 3 4 5 6 1 2 3 4 5 6 J25
355 354 358 359 360 361 CW (MAX) 10K R12 2W BACKGROUND CONTROL
2 5 6 1 4 3
364 365 366 367 368 369
362 363
364 365 366 367 367A .045 368 367A STAINLESS 369 502
503 503A
J30
240
DARLINGTON HEATSINK THERMOSTAT
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
371 374
10
371A 374A
503B
3 1 7 5 6 8 2 4
5 13 16 8 15 7
I A J E F G
J5
32 31 77 76 75
3 6 2 5 1 4
43B 42 33D 31A
J24 1 2 3 4 5 6 1 2 3 4 5 6
J23
CW (MAX) 10K R11 2W
CW (MAX) 10K R13 2W
S2 .035
S3 MILD (-) Y (+)
{ { {
402, 404
IGBT DRIVE BOARD
R B W
SWITCH BOARD (RIGHT)
1 4 2 3
J1 J27
12C
T3 CURRENT TRANSFORMER
J39 14 6 414 406
N.E.
5 6 7 2 1 4 8 3 9 10
370 371 372 374 376
J33
405 413 416 408 415 407
}
N B H L M D C K SPARE GND 21 82 81 4 TRIGGER 2 42 42 41 VAC 115 VAC N.J. 42 VAC 115 VAC CB1 6AMP CB2 6AMP PEAK CURRENT METER BACKGROUND METER PEAK CURRENT CONTROL HOT START CONTROL WIRE SIZE WIRE TYPE THERMAL OVERLOAD INDICATOR
62 54
1 4 2 3 5 6
J13
INPUT RECTIFIER 9D 9D D13 9C
CR1
310 310A
1 3 2 4
311 313
1
307 308
1 2 3 4
W B
C4
IGBT MODULE E G 212C 43A 33C 32C 212B 6 1 4 8 5 3 2 7
223 B R W B 370 371 372 374 376
J34
8 9 10 5 4 6 2 3 7 1
J36
R7 25 25W
402, 404
4, 5
289B
R14
288B
+ ARC
J19 1 2 3 4 J38 J B C G A D F H E I 290 1 (+) 2 3 (-) 4 VOLTAGE SENSE CONNECTION
291
3 2 1 10 9 12 4 11
403 402 401 410 409 412 404 411
BG 10K
TRIGGER
PB 10K
GND INTERFACE REMOTE OPTIONAL
FEEDER WIRE
A G4557
G-6
ELECTRICAL DIAGRAMS
+15V
POWER PLANE 13 14 16 16 16 16 4 4 14 14 14
G-6
Schematic - Control PC Board - Codes 10151 - 11092 - (G2781 Sheet 1 of 2)

+15V
14 POWER PLANE 14 14 14 14 14 14 14 14 14
+15V
+15V
POWER PLANE 3 4 4
3.92K
+15V POWER SUPPLY FOR DIGITAL, TRIGGER & ANALOG SECTIONS
R488
R487
R486
R482
POWER PLANE
R527 +15V 10.0K
LM224
METER_1
825
OCI1 PINCH KILLER Varc ADJUST FE (SHEET 2) +5 VOLT METER POWER

2N4401
DV/DT LEVEL DETECT FROM FE (SHEET 2)
6 DV/DT 1 2
PINCH SIGNAL
Q12 Q6 Q5 Q7 Q4 Q3 Q2 VSS VDD Q11
16 15 14 13
OCI1
5
DON_MIN
Q4 Q3 Q2 VSS
DARLINGTON ON TIME
Q9 R /C Q1
12 11 10 9
825
825
825
R341
R309
s18395-23
ADJ
R528 10.0K
33.2K
1N4007
1N4007
IN
OUT
D413
R483 X34 A
1
3 4 5 13 12 6 7 8
/COUNT
10.0
2.43K R474
Q10 Q8 Q9 R
HP2231
2
15.0K
D306
D307
X8 lm350
+5.1V
REMOTE
METER_2
HP2231 HP2231
ARC PINCH /ARC
TO FE (SHEET 2) FOR ENERGY CONTROL OPTION
6 7 8
511
D310
OCI2
PINCH
150us MIN
R326
X34 B
R340
R308
1.00M
R338
2.43K
.0047
14
2.21K
R473
R313
100K
R339
BALL_OR_FUSE
3.92K
R300
D308 1N4007
1N4007
D309
500
CW
20V
100
X11
NAND
375us
4.75K R302 C300

CW
/KILLER
10
KILLER KILL_START
11
NAND
/KILLER
J28
1400V
35V 1000
R511
18 VAC
C310
12V
C313
C314
35V
1W
C463
X26 TL431
6
35V
REF
2.5V
10.0K
3
X13
NAND
1 2 12 13
11
NAND
COUNTER MC14040
/C Q1
10 9
+15V C306 330p 100V

1 2 9
12 13 NAND
13
DON_RESET
C312
C311
243
C462 1.0
DZ19
10.0
R333
C448 1.0
D305
11
/DON_MIN
NAND
511
R337
2.21K
NAND
R327
Q3
R317
R304
10K
100K
ARC/SHORT DETECT DZ9 FROM FE (SHEET 2)
/KILLER
DZ20
ARC
R540
X9
RST
3
/Q
7 12
15
14
330p
10 9 5 6 NAND 4
P_BOOST ONLY AFTER PINCH LATCH
1N4936
56.2K
R321
INTEGRATOR
CURRENT
KILL_RC
R312
/BALL
FUSE C
4
/KILLER
OCI2
10.0K
T1 A
T2 Q
X11
NAND
1ms
R318 C304 4.75K C305 D303
1N4936
H = STAINLESS L = MILD
13 1 2
R345 1.00K C309

R343 R344 2.21K 2.21K
DZ8 15V 1W
T1 A B
B T2
100V
CFB
D412
47.5K R519
10V 1W
C464
10V 1W OVERCURRENT TRIP +15V OUTPUT DISABLE D411

1
HP2231
DV/DT
9 8
X12
NAND
10 FUSE START
11
X9
RST
13
Q /Q
C308 50V 0.1
X31
A 1.3 msec PLASMA
35V
1.0
1N914
1
68.1K R513 +15V

2
.33 X35 A
1014 3
200V
OVERCURRENT
+5.1V
+15V /RESET ARC 5.62K R303 /ARC
/KILLER
1 2
13
X11
NAND
/BALL_RC
X12
NAND
BALL_DELAYED
/RESET X12
NAND
6 5
12
11 /ARC 1 2
X12
NAND
X14
/BALL PINCH
1 2
BOOST TIME LIMIT ARC_START

Q1 /Q1 CLOCK 1 RESET 1 D1 SET 1 VSS
FUSE_RESET
R563
10.0K
CURRENT SENSE BOARD
J1
R509
33.2K R518
1
2N4403
10.0K
R561
2 3 4
R467 +t
J1 J1 J1
R466 10.0 C423 1.0 35V
+15V
+15V
NAND
X36
10.0K A
3
Q7
TO TRIGGER CIRCUIT OVERCURRENT FAULT ( SHEET 2 )
100p 100V
C301
/BALL_DELAYED
/(BALL & SHORT)
332K R562
ARC
13 12
RESET
/RESET
RESET
X19
VDD Q2 /Q2 CLOCK 2 RESET 2 D2 SET 2
14 13 12 11 10 9 8
6 5
X16
NAND
/PINCH
4 2
PB_START
C307 0.1
15 14
R323 4.75K 50V
R328
CW
+15V P BOOST
10K /PB_LOCAL
1 2
X17
NAND
D416 1N4936
221K R521 33.2K R516
6
CR1
X11
NAND
11
PULSE
+15V 4.75K
/RESET /ARC 12 13 NAND
3 4 5
NAND
6 5
8 9
.25
12Vdc
2700p X35 B
1014 7
C475 50V
11
1N914 X28 D
13
D423
X13
NAND
NAND
X16
1 10
X16
3 12
T1 A B
R524
R512 75.0
10
100K R559
R331
39.2K
R560
82.5K
56.2K
68.1K
R514
R522
33.2K R517
332K
1014
D424 FUSE
R515 15.0
R307
X35
R311
1V/100A
5V
+15V
ARC KILLER PULSE
330p 100V
4.75K D302 1N4936 10K R316
1V
AMPS>100 8 13 9 NAND
H = A>100
1N914
PB_START SIGNAL TO FE (SHEET 2) /PINCH FOR ENERGY
OCI6
PB_START A
10
X17
NAND
V=ARC
START_RESET OCI3 A
7 H= OPTION ENABLED L= NO OPTION
3.92K
R329
3V
R334
10.0K
CURRENT FEEDBACK
150K
10
2901
C303 X13 A
11
9 8
X13
NAND
+5.1V B
10
+15V
R314 10K
6 7
/PWM_SYNC
KEEP IN P_BOOST UNTIL ARC STARTS
+15V
R557 4.75K R322 4.75K
11
X10
RST
13
T2 Q
10 9 5
/Q
+15V
X18
9 4 8
X18 C
10
150us FUSE ENTRY
R306
MC14013B
/PB_OPTION
L=DISABLE LOCAL PB TIME
X17 ENERGY CONTROL OPTION ENABLE (SHEET 2) HP2231 +15V
10.0K R324 +5.1V

4 5
R523
150K
R335
+15V R525
6
TRIP TIMING
HP2231
6 9 8 2
15.0K
OVERCURRENT
CONTROL OPTION
( SHEET 2 )
CFB
1V=100A
R310 10.0K
1014 12
ARC_START
DISABLE OPTION TO START
2901
J3
R551
FAST RAMP
10.0K
WIRE SIZE SELECT < .035 DIA WIRE

-
35V
10.0K
R564
56
Q8
20V
47.5K
15.0K
X21
3.92K
R332
+t
C412 1.0
X36
NAND
10.0K B
4
100
R510
2N4401
C465 39
R409
R410
Q10
2N4401
/HOT_START +5.1V 15.0K C419 1.8

5 6 3 H= OPTION PB TIME L= LOCAL PB TIME
D422 1N4936
H= .045 L= .035 J3 R405 100 SS_WIRE C409 1.0 35V DZ12 15V 1W
8
X22
B
9 6
1000A/ms
R411 6.81K
PINCH RAMP
PINCH
ENERGY CONTROL OPTION P_BOOST TIME (SHEET 2)

3.1V
OCI3
L=DISABLE OPTION PB TIME
13 12
H= OPTION PB TIME
X18
11
2N4401
( SHEET 2 )
Q4
R554
HP2231
24.3K R553
V+ VISYNC I+ CT COMP RT Vref
22.1K
R555
> .045 DIA WIRE

-
50V R412 10K R413 200

.294V
R453
13
PINCH COMMAND
100p 100V
PINCH FAST RAMP ENABLE
2.21K
2.21K
R418
R417
R552
1014 10
PINCH
R422 150K
R423 267K
100K
WIRE TYPE SELECT MILD
+15V
X24
X25
CLIM Vin Vc
1 15 13 12 11 14 16
C474
C407
.0047
PWM_EN
15.0K
C472
20V
HP2231
10 4 8
+15V OUTA OUTB 10K R455 +15V

7
J28 /PWM_SYNC +15V

0.01 W1
PHB OUTPUT
3
B
3
OCI6
X21
C473
+15V_REM J28 +15V

11
J3
+15V +15V
B.PT
8 14
PWM
GND OUTA OUTB SHUT
12 11 10
3.92K
R461
STAINLESS
R454
3.01K
R456
PINCH BREAKPOINT
R458
REMOTE_POTS
(PINCH KNEE)
75.0 R504 C460 1.0 35V DZ18 12V 1W C461

R402 75.0
CONTROL POTS POWER

13
R505
1.30K
R506
1.30K
R400
2901
1.30K
1.30K
R401
47p CFB R421 47.5K R419

COMMAND
100V D401 R424 100K 1N4936 +15V X24

1014
3us MAX DEADTIME
R550 15.0K
10
500A MAX PINCH LIMIT
1.00K R425
CW
2901
R457 START_RESET
3.01K
10 VDC
+15V
3.92K
10K
X23
GENERATOR
.018
R463
R414
SAWTOOTH
C410
WAVEFORM
C418 50V
WIRE TYPE POSITION TO FE (SHEET 2) J28 W4 0.01

0.01 0.01 W2 W3
X21
SG3846
3.92K X23
1
PHA OUTPUT
10
FOR ENERGY CONTROL OPTION
2.67K
4.75K
R502
11
PINCH COMMAND
LOCAL_POTS
R415 47.5K
10 12
R416 X31 D
11
R420 47.5K
R459
100K
C401
X23
2901
8.25K
100K
3.32K R426
R452
26.7K
R451
R530
R471
475K
2
10K
1.00K R428
Verror
PWM_EN
(SHEET 2)
475
R427
+5.1V
J28
COMM
6
R529 10.0K R539 10.0K D405
HP2231
OCI4
A
7
REM
+15V_REM
A C422 50V
4 2
OCI4
HP2231
Vcc
TL431
6
REF
R503
R500
1.50K
10.0
35V
CURRENT
R429
C400 1.0
X33
2.5V
"ANALOG LOGIC"
100K
CW
1us MIN PULSEWIDTH
OCI4 OCI4 B
6
C430 50V 0.1
CW
ERROR AMP
500
RAMP
+15V
.0047
HP2231
HP2231 GND 5
POWER BOARD
TO
R501
R532 +15V PB_SCALED X31

3 5 12
R441
10.0
10K
COMMAND
/ARC
+15V
B
3
OCI4
HP2231
ISOLATED CIRCUIT
REM
J27
REMOTE PB POT
9 15
J2
LOCAL PB POT
1.00K
6
P_BOOST COMMAND
C471
330p
9 8
26.7K
R538
ARC & /RAMP CTRL
COMMAND
R533
R408
R446
17.8K
100K
100
R507 100
35V
C403
1 5
TAIL OUT
LOCAL
C406
500K
J2
R443 82.5K
2700p 50V
INCREASE TAILOUT DURING HOT START
BACKGROUND COMMAND
13 12
X30 R490
X36
NAND
11 5 4
.0047 50V
RAMP
/RAMP
OCI5
TO FRONT END ( SHEET 2 )
100 R437 15.0K C413 0.1

R436 1.00K
+15V
CW
SHORT OR 500K POT
11
J2
267K +15V
10.0K R445 C450 0.1 50V
13
X24
1014
D403 D
14
ARC
12 3 10 11
R433
J2
13
+VIN
D404
+1.42V 4
T1 A B
1.00M
R449
R448
13.7K
R447
12
B 1.00M
X21
R450
X22 100K
P BOOST
X10
RST
3
T2 Q /Q
6 7
HP2231
3
50V
J2
4
-VIN
D409 2.67K R546 2.67K R545 2.67K R544 2.67K R406 C404 1.0 DZ11 12V 1W C405
8 6
X31
C
LOCAL BG POT
9
J2
C415 "KEEP ALIVE"
+15V OUTA OUTB
J2
-PWR
R434 10.0
LOCAL_POTS
D414
R468 4.75K
10K
14
J2
CURRENT LEVEL
METER_1
J2
9
+PWR
1.00M
R469
35V
100
R491 100
1.00M
R534
C454
X30
8 6
C
9
R440
REMOTE
J2
12V 1W
35V
C416 50V
PB_SCALED
332 R430
10.0K R431 C411 0.1 50V
100 R470
820p
J2
12
+VIN
5.62K
R472
3SEC
2
C446 1.0 35V
+15V
R498 20.0K
2 9
ARC_START
100
HOT START TIME
HOT_START J27
R475 10.0K REMOTE BG POT
5
CW
5
J3
R489
R492 10.0 R549 2.67K R493 100
X29 REMOTE_POTS D415 R547 2.67K R495 2.67K

1.00M R520
LOCAL X30 D
11 12
LM224
R497 150K
10 4
SCALED_BGND
3 5
1.00K
LM224
R432
D407
+15V
X30
X29
J2
8
-VIN
R494
1.00M
R476
10K
6
J3 J3
10.0K
C447 1.0 35V +15V
DZ15 12V 1W
C449
12
X29
LM224
R548 2.67K
14
13
D408
CW J27
7
C451 1.0 35V
DZ17
10
DURING HOT START
12V
1W
C455
HOT_START
6.81K
R478
10K
J27
11% BACKGROUND INCREASE
C453
J2
6
-PWR
R496 100K
1 3
2 4
Input- Current
Feedback
R477
OFF
100
/HOT_START HOT START TIMING GENERATOR

6
REMOTE
1 6 5 10
J1 Remote Control
1 9 8 16
GENERAL INFORMATION
Analog Logic I/O to Control Panel
ELECTRICAL SYMBOLS PER E1537 CAPACITORS = DIODES =
3 6
FILE: G2781_1D1
UNLESS OTHERWISE SPECIFIED)
LAST NO. USED RC165, 242, 345, 564 129, 211, 314, 475 117, 211, 310, 424
PLASMA BOOST METER

DZ20 OCI7 X36 Q10 W4
+15V
R435 10.0K C452 1.0
CW
DZ16
PINCH RAIL
P_BOOST
MFD ( .022/50V 1/4W
R480
100K
D406
X29
5 LM224
PINCH SLOW RAMP
RESISTORS = Ohms ( 1A, 400V
LABELS
D-
Unused Devices +5.1V

13 12 9
J27
5 4 2
J2
7 14
(UNLESS OTHERWISE SPECIFIED)
SUPPLY
VOLTAGE NET
ARC_START
1 2
2N4401
Q6
R481 100 C469 39 20V R536 10.0K
J28 J28 J28
J28 J28 J28
PINCH KNEE
1 8
PINCH FAST RAMP
X18
NAND
Drive- Output Vac In
Darlington
1 4
Analog Logic I/O to Control Panel
REFERENCE DESIGNATOR SERIES DEFINITIONS 100 SERIES- ARC SENSE CIRCUIT 200 SERIES- TRIGGER CIRCUIT 300 SERIES- DIGITAL LOGIC CIRCUIT 400 SERIES- ANALOG LOGIC CIRCUIT (SHEET 2) (SHEET 2) (SHEET 1) (SHEET 1)
POWER SUPPLY SOURCE POINT COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION
R485 33.2K
J28
TAILOUT BACKGND
J3
8 4
J27 J27 J27

4
X22
3 5
BACKGND
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER.
UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E-2056 ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS ON 2 PLACE DECIMALS IS + .O2 Ch'ge.Sht.No.
RAMP BALL KEEP_ALIVE LEVEL FUSE KEEP_ALIVE LEVEL
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

SCALE DR.
EQUIP. TYPE
STT CONTROL SCHEMATIC (Sheet 1 of 2)

SUP'S'D'G. SHT. NO.
R479
562
5-19-95 5-24-96E
COMMAND SIGNAL
NONE
CHK.
SUBJECT
MLD
DATE
04/12/94
2781-A
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.
BACKGROUND METER
10
10
R404
C402 1.0
1W
LM224
13
P BOOST
56.2K
R442
J2
1.00M
J27
R407
22.1K
R499
10K
10K
10.0K
DZ10 12V
13
X34
15.0K D
14 10
LM224
/HOT_START
1 13
R444
D402
/ARC OR RAMP CTRL
16
R403
X34 C
X22
10.0K
1014
R439
15.0K
CW
J27
CW
D400 J2
X24
X36
NAND
10
D418
D419
D417
100V R537 /RAMP 4.75K
C470 330p 100V
P BOOST RAMP IN
120us
OCI5 METER_2 J2
2
C417
C414
HP2231
PWM OUTPUT
+PWR
4.75K
R526
SLOW RAMP
100A/ms
R556
10.0K
1N4936
R330
PRI_FB
ARC
D421
L= OPTION PB TIME
D410
X35
14
X23
100
1N4936
R342
G
X25
PWM
2781-A
C439 50V C440 4.7 35V 0.1
Vcc C458 50V 0.1
Vcc C429 50V 0.1
X19
DUAL FF
C441 50V 0.1
COUNTER
X20
C442 50V 0.1
COUNTER
X32
C456 50V 0.1
X9 MC14538B
8 TIMER
C443 50V 0.1
C445 X10 MC14538B

8 TIMER
50V
0.1
X34
OP AMP
C466 50V 0.1
X35
OP AMP
C467 50V 0.1
X11
NAND
C432 50V 0.1
X12
NAND
C433 50V 0.1
X13
NAND
C434 50V 0.1
X14
NAND
C435 50V 0.1
X15
NAND
C436 50V 0.1
X16
NAND
C437 50V 0.1
X17
NAND
C444 50V 0.1
X18
NAND
C438 50V 0.1
X36
NAND
C468 50V 0.1
C425 X21
SWITCH
SG3846
12
MC14013B
7
MC14040
8
MC14040
8 GROUND PLANE
LM224
11
LT1014
11
4093B
4093B
4093B
4093B
4093B
4093B
4093B
4093B
4093B
50V
0.1
X22 4066B
7 SWITCH
C426 50V 0.1
X31
SWITCH
C457 50V 0.1
X30
SWITCH
C459 50V 0.1
X23
COMPARATOR
C427 50V 0.1
X24 LT1014
11 OP AMP
C428 50V 0.1
X29
OP AMP
OCI2 HP2231 GND 5
OCI3 HP2231 GND 5
C424 50V 0.1
4066B
7
4066B
7
4066B
7
LM2901
12
LM224
11
7 GROUND PLANE
GROUND PLANE
J27
2.67K R543
2.67K R542
2.67K R541 +15V
2.67K R508
6
LOCAL
+15V
+15V 4.75K
DV/DT KILLER
B
+15V 4.75K PINCH LIMITER REPETITIOUS

FORCES THIRD CONSECUTIVE PINCH TO BREAK INTO ARC
+15V
1 2 3 4
Q12 Q6 Q5 Q7
VDD Q11
16 15 14 13
+15V
"DIGITAL LOGIC"
R319
X20
Q10 Q8
COUNTER MC14040
4 8
J28 D304 J28
X32
J28
LM224
R484
PINCH X17 D
12
/PINCH
2N4401
Q9
1 OPTO ISOLATOR ON DARL. DRIVE BOARD
X15
X15
10
X15
NAND
+15V
+15V
BALL
R301
BALL_OR_FUSE
X16
X14
11
/PWM_SYNC
12
D
11
PWM_SYNC
750us
C302 R305
CW
X14
NAND
X14
NAND
10K C
10
50K
CW
R320
BALL_OR_FUSE
2 1
NAND
Q2 A
3
X15
R325 10.0K
2N4401
SS_WIRE
GROUND PLANE
D300
4.75K
FUSE GEN.
D301 /PB_LOCAL
D420 /PB_OPTION
G-7
ELECTRICAL DIAGRAMS
G
2781-B
G-7

FRONT END
13.7K 13.7K 13.7K 13.7K R100 R102 R103 R101
Varc FILTERED
R105
13.7K
13.7K
13.7K
13.7K
R104
R106
R107
TO ENERGY CONTROL OPTION
J17
10
+12VFE
- STUD
J5 FE
+12VFE
R138
J5
100V 47.5K R109 DZ1 C102 R110 47.5K

2
2.67K
100p
TRIGGER
1V REF
CW
CIRCUIT
1.00K D200 R200
.400V
8.25K
R141
J5
ARC VOLT FILTER

243
SAMPLE
R140
R202
R204
R205
4.75K
R111
1W
DERIVATIVE_TRIP
INPUT FROM VOLTAGE SENSE PANEL
10.0
10.0
10.0
10.0
.0047
4.75K
R137
R113
3000V
400V
R112
OP470 3
R209
R206
50V
10K
100K
20.0K
20.0K
R108
R162
47.5K
R114
J5
DZ2
FE +12VFE FE
+12VFE C109
5 7
12V 1W
100V
R142 10K
X5 B X4 B
7
dv/dt
13
DV/DT 2
10
2901
26.7 R207
26.7 R208
1N4936
R232
C103 100p
26.7
26.7
X3
11
HP2231
D203 1N4936
D204
R241
267
.0047
C104
D101 1N914
NEW DV/DT Varc SAMPLE
SMP04
FE
TO DIGITAL LOGIC ( SHEET 1 )
J4
8
10.0
C100
C101 .001
47.5K
FE
X4 A
4.75K R159
VARC_SCALED
X3
20V
TURN
10
0.1
50V
J4
2
OCI2
DV/DT LEVEL DETECT

CURRENT TRANS.
R203
R201
DV/DT
C107
D202 1N4936
1.30K
10K
D201 1N4936 C200
R242
12V
C108 1.8
R139
DV/DT Varc
FEEDBACK 125:1 RATIO
PRIMARY CURRENT
1N4936 PRI_FB +15V

( SHEET 1 )
C201
.33 200V
1.7V = 150A PRIMARY
+15V
R143
825
R233
SMP_STROBE
4.75K
R125
1N4007
R144 X3
11
R237
10K
R119 J5 13.7K R121 13.7K
R120 13.7K
1N914
9
15
R145 10K +12VFE
AMPLIFIER
15.0K
R212
R126
51.1K
+ STUD
R122 13.7K +12VFE
2901
R164
D116
X5
1N914
14
3.92K
+12VFE
J4
3
3.6V
R213
13.7K
13.7K
68.1K
R123
R124
D117
DV/DT 10X
10K
R117
R118
1.00M
NEG_CLAMP
FE
+15V
10K
13.7K
13.7K
D100
FE
FE
L=HIGH DV/DT
C206
R236
10K
R115
R116
R165
+12VFE
50V
100K
820p
SMP04
OP470
100K
H=LOW DV/DT
+15V
R234 332K
+15V
( SHEET 1 )
PWM_EN
TO ANALOG LOGIC ( SHEET 1 )
PWM ENABLE
X28
8 2901
R210 22.1K
R211 47.5K C202
SMP04
OLD DV/DT Varc SAMPLE
X28 B
2901
D205
1
X28
4 2901
14
H=PWM OFF L=PWM ON
H=PWM ON L=PWM OFF
DV/DT SAMPLE PULSE
R235
100K
8.25K
R146
R127
D102 1N914 4.75K R128 C105
FE
SHORT DETECT
68.1K
R147
10K
Varc SAMPLE
DETECTOR
ARC
1N4936
C205 330p 100V
TRIGGER OPTOCOUPLER ON POWER
8.95V
26.7K
R129
+12VFE
47.5K
22.1K
R132
R135 47.5K 267K

DT_DELAYED OUT
SMP04 D115 1N914
10K
820p
ARC_TRIP
+12VFE
100V
12 10
14
R148
C110
X5 A
2901
4 2
J17
R215
FE
100p
X3
BOARD
C203
R214 10K
C204 0.1 50V
OCI2
50V FE
TO DIGITAL LOGIC
ARC 2
ARC/SHORT DETECT
OVERVOLTAGE OPTOCOUPLERS ON PROTECTION BOARD 11
TRIGGER INTERFACE
R130
3.92K
R131
3.92K
HP2231
2
( SHEET 1 )
FROM PWM PHASE B FROM PWM
OCI5
B
6 1 2
FE X6 A
3
R133
DT_RC
X5
6 2901
1.89V NORMAL 2.3V PINCH START
R149
PHASE A
4.75K
R136
332
NEG_CLAMP
J4
DZ3 D104 +12VFE 15V 1W
H=SHORT L=ARC
R134 D103 1N914 1.00K
OVERCURRENT FAULT
3.92K C106 100V FE

DT_DELAYED
CW
R150
DT
330p
OVERHEAT INDICATOR
10
R216 D206 2.21K
.13
60V
13 11
R225 1.50K DZ4 43V 1W R217 1.30K R219 R218 1.30K R220 1.30K R222 1.30K R224 1.30K R226
D207
D208 DZ6 1W 3.3V
R229 CNY17-3
OCI7
5K
3.92K
R152
OCI5
A
7
13 12
R240
X6 B
DT
11
TRUNCATES DT_DELAYED
J4
6
CHOKE TSTAT FAN TSTAT
1.50K R227 1.50K R228 1.50K D209
5 ON=TRIGGER ON OFF=TRIGGER OFF
FAN R
ARC DETECTOR
5W
2N4401
Q1
10K
681
R151
HP2231
ADJUSTMENT FOR INITIAL PINCH PULSE
3.92K R153
B OCI1
6
PINCH KILLER ( SHEET 1 ) Varc ADJUST

T1 AUX XFMR 24 VAC
D211 C207 20 50V

2 6 4
1.30K R221 1.30K J4

12
43V J4 1W
R238 +t TO POWER BOARD 5
R223 1.30K
DT
D210
FE J17
8
C
1
TRIGGER
D
9
J4
R154 1.50K A
DIODE ON = OPTION ENABLED
ENERGY CONTROL OPTION ENABLE
OCI3
ENERGY CONTROL OPTION ENABLE ( SHEET 1 )
TO POWER BOARD
56
ISOLATED CIRCUIT
D105 1N4936
DIODE OFF = OPTION DISABLED
HP2231
9
J17
R155 1.50K
+15V
J17
R160 1.50K
DIODE ON = OPTION P_BOOST TIME
UNUSED
ENERGY CONTROL OPTION P BOOST TIME

2
B D106 1N4936
DIODE OFF = LOCAL P_BOOST TIME OR NOT OPTION P_BOOST TIME
OCI3
ENERGY CONTROL OPTION P BOOST TIME ( SHEET 1 )
J4 X28 J4
COMPARATOR
C211 0.1 50V
X28 "D" COMPARITOR ON SHEET 1
LM2901
12
HP2231 J17 R161 1.50K

3
J4
H = PINCH
A
7
J17
L = NOT PINCH
OCI1
PINCH SIGNAL FOR ( SHEET 1 ) ENERGY CONTROL OPTION
HP2231
H = START PLASMA BOOST TIMING
J17
L = NOT PLASMA BOOST
A
7
OCI6
PB_START SIGNAL FOR ( SHEET 1 ) ENERGY CONTROL OPTION
HP2231
H = STAINLESS
12
J17
L = MILD STEEL
B
6
OCI6
WIRE TYPE POSITION ( SHEET 1 ) ENERGY CONTROL OPTION
ISOLATED CIRCUIT
+12VFE +12VFE
POS FE POWER PLANE
HP2231
+12VFE
14
16 Vdd
J17 +12V OUT

3
Vcc C122
Vcc C123 0.1
Vcc C128
D107
C121 0.1 50V
X6
NAND
X3 SMP04
Dgnd 8 Vss 13
0.1
OCI5 HP2231 GND 5
OCI1 HP2231 GND 5
4093B
50V
50V
50V
0.1
OCI6 HP2231 GND 5
C129
50V
0.1
X1
7
D108 1N4007
36 VAC XFMR 18 VAC 8
D109 1N4007 C111 C112
IN
LM350 s15128-15k1
OUT FE GROUND PLANE
1.82K R156 500

CW
ADJ
FE R157 243 C117 27 35V
FE
J5 C113 J5
35V 1000
C118
D113 +12VFE
R158
.0047
CT
1400V C114 C115 47 35V D111 1N4007 C116

IN
UNUSED GATES
POS FE POWER PLANE
.0047
18 VAC 4
GND
C119 27 35V
OUT
C120
D114
C124 0.1 50V
V+
C126 0.1 50V
+12VFE
6 5
J5
1400V
X2 7915
X4
OP AMP
X5
COMPARATOR
X6 C
NAND
D110 1N4007 ENERGY OPTION -15V OUT J17 J17
s15128-12 -15VFE D112 FE FE
C125 0.1 50V
OP470
11
LM2901
12
C127
V-
50V FE -15VFE
0.1
10
FILE: G2781_1D1
X4 C
8
CONTROL COMMON OUT
11
NEG FE POWER NET
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537 CAPACITORS = MFD ( .022/50V 1/4W UNLESS OTHERWISE SPECIFIED) RESISTORS = Ohms ( UNLESS OTHERWISE SPECIFIED)
47.5K
DZ5
R231
HP2231
150
10.0
HP2231
1N914
R230
R163
FROM SHEET 1
CR 1
4
CR1
6
R239
CR1
+t 9
( UNUSED CONTACT )
X6
10
J4
267
OP470
LAST NO. USED RC165, 242, 345, 564 129, 211, 314, 475 117, 211, 310, 424
DZ20 OCI7 X36 Q10 W4
-15VFE
12
LABELS
D-
POWER SUPPLY FOR "FRONT END"
13
OP470
X4 D
14
DIODES =
1A, 400V
SUPPLY
VOLTAGE NET
REFERENCE DESIGNATOR SERIES DEFINITIONS 100 SERIES- ARC SENSE CIRCUIT 200 SERIES- TRIGGER CIRCUIT (SHEET 2) (SHEET 2)
FE
300 SERIES- DIGITAL LOGIC CIRCUIT (SHEET 1)
NOTES :
1 5 4 8
400 SERIES- ANALOG LOGIC CIRCUIT (SHEET 1)
Vac and Varc
Front End
1 7
6 12
Energy Option
Control
1 7
6 12
Trigger Circuit I/O and Vac
N.A.
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER.
UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E-2056 ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS ON 2 PLACE DECIMALS IS + .O2
Ch'ge.Sht.No. 5-19-95 5-24-96E

SCALE DR.
EQUIP. TYPE
STT CONTROL SCHEMATIC (Sheet 2 of 2)

SUP'S'D'G. SHT. NO.
J5
J17
J4
NONE
CHK.
SUBJECT
MLD
DATE
04/04/94
FV
2781-B
NOTE:
G-8
ELECTRICAL DIAGRAMS
ITEM REQ'D PART NO IDENTIFICATION ITEM REQ'D PART NO IDENTIFICATION
G-8
PC Board Assembly - Control - Codes 10151 - 11092 - (G2782)

G 2782-1
C443
C119
R140
X13
C418
R328
D303
C434
R320
R151
X10
C302
X16
C117
X12
X9
R318
R301
C305
Q1
D104
R126
R129
R132
R147
R123
R149
R153
C127
R471
R550
R530
R555
Q4
D300
R308
R309
R529
R330
C440
C439
X19
X17
R124
R135
R146
DZ3
C438
X25
X18
C126
X36
X32
C456 D202 D201 D203 D204
X23
R457
R553
OCI2
R339
C474
R125
R128
C313
R164
D102
X21
R456
R454
D403
R130
R113
X3
R137
C115
C123
C430
R145
OCI5
D101
OCI4
R142
R522
R521
D117
R143
R165
D116
D115
D423
R563
R562
X28
R234
DZ6
D208
R516
R524
R311
C207
X35
R534
DZ16
X34
D414
C454
R332
R329
R324
R341
R333
C406
R407
C424
C124
R152
C103
R114
D105
R155
R154
R518
OCI3
DZ1
DZ2
C467
X30
X29
R316
R229
R517
R240
X4
D210
C458
D207
R112
D106
C111
OCI1
C128
DZ11
D409
R511
R495
R319
C405
R406
R469
DZ9
R223
R221
R219
R227
R228
R226
R225
R217
X31
C413
C411
DZ4
C464
R431
R515
R160
R161
R509
R512
OCI6
C129
C448
DZ20
X26
C116
C112
R417
R418
DZ12
R218
R220
R222
R224
D416
DZ5
R493
R546
R542
Q7
C400
D412
C310
R526
D304
R326
R435
R443
R470
R491
R404
R476
R500
R505
R402
R327
R501
R434
R433
R342
R477
R478
R405
D206
R238
R467
R216
C200
CR1
R489
R507
R492
R504
R484
C401
R483
R519
R506
R400
R401
R502
C412
R549
C423
R543
R466
R513
R206
R207
Q2
STT CONTROL
C202 C206 C203 R232 R215 R214 R233 R212 R210 R211 C204 C201 R200 R205 R204 R203 R202 R201 R213 R241 R242 R209 R208
C429
R429
C314
R141
R338
R337
R413
Q10
R335
R131
C109
R450
C425
C428
X24
X6
X22
R559
G2782-[ ]
X5
C468
X2
X1
R300
R540
D405
C311
R459
C422
R537
NOTE:
R236
D424
C475
D205
D200
C205
R235
C211
R560
J4
C471
D420
D301
X15
C442
X11
X14
X20
C436 R237 R561 D209
Q8
R439
R325
R525
R523
R468
D410
C414
R441
R510 D411 R239
OCI7
R230
R231
C465
R514
D211
C445
C444
R557 C441
J1
R426
R453
R322
R323
R310
R314
C307
R425
R428
R427
R419
C437 D401 R451 R452 R564 C409 D402 R412 R449 DZ15 C419 R424 C449 R420 R423 D407 R554 C472 C473 R458 R552 C447 C450 R455 C446
R488
R486
R487
R482
R472
J3
D406
R444
R445
R440
C416
R536
R421
R422
C410
R481
R480
D408
R307 R539 R551 R411
C469
C407
R474
R473
C427
D421
R414
R409
R410
D422
R498
R497
R496
R494
R485
R490
R479
R475
C303
C426
R306 R321
Q6
C417
D302
J2
C415
R437
R436
R432
R442
R447
R538
R446
D417
D404
D418
D419
C453
C459
C452
C435 C470 R448 R499 C306 R520 DZ17 D415 C455 C451 R403 R430 R331 R343 C309 DZ8
R344
C432
X8
C402
R305
R317
C308
D310
DZ19
D400
C403
DZ10
R533
R415
R416
C463
R527
R528
D413
J28
R304
C457
R556
R503
R532
R345
X33
D308
C466
D309
R303 C433 C312 R461 D307 D306
C301
W4
W1
C404
C462
D305
R547
R548
R508
R541
R463
R408
Q3
R302
W3
W2
C300
Q9
R340
R544
R545
R334
C304
R312
R313 J27
DZ18 C461 C460
R150
C108 R134 R127 R136 R133 D103 R163 C106
J17
C121
R110
R109
C102
R121
R119
R117
R115
R122
R120
R118
R116
R111
R162
R108
C107
D100
R139 R138 C105 C101 C125 C104 R159 R144 C100 R103 R102 R101 R100 R107 R106 R105 R104 C110 R148 D107 C122
J5
C113
C114
C120
R158
D113 D114 C118 R156 D110 D111 D109 D108 R157 D112
CAPACITORS = MFD/VOLTS RESISTORS = OHMS
OWNED BY
NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF
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.
THE LINCOLN ELECTRIC CO. TYPE

CLEVELAND, OHIO U.S.A.
SCALE DR
F.V. FULL 6-8-94
EQUIP.
STT INVERTER WELDER CONTROL P.C. BOARD ASSEMBLY

L8441-3
SUBJECT REF.
DATE
CHK
FV
SHT. SUP'S'D'G NO.
G 2782-1
G-9
ELECTRICAL DIAGRAMS
G-9
NOTE:
G-10
ELECTRICAL DIAGRAMS
G-10
NOTE:
G-11
ELECTRICAL DIAGRAMS
G-11
PC Board Assembly - Control - Codes 11115 - 11116 - (G4648)
NOTE:
G-12
ELECTRICAL DIAGRAMS
M 16018
+15V 1.0 R1
100K 100K
+t D1 D3 IN OUT +
G-12
Schematic - Power PC Board - All Codes - (M16018)
5W
R44
.25
D5
R69
R5
R6
.24
Vin + Vc OUT
1.50K
P7
J7
R4
X1 LM350
D15 C8 0.1 50V
267 R7 267
X67
GND INV IN N.I. IN
1.0A
D16
30V F
1.0A
30V
TO PULSE TRANSFORMER
18Vac
FROM AUXILIARY TRANSFORMER
TP1 15J
50V
3300
C1
ADJ
P7
2.67K
J7
50V
C2
R3 243
R2
J7 J7
8 7
P7 P7
C3
150
R8
Vin + Vc
50V DZ5 12V 1W DZ4 12V 1W
D2
D4
OUT
X68
GND INV IN N.I. IN
C9 0.1 50V
D7
1.0A
D6
30V
1.0A
30V
J7
3 6
J6
8
J6
3
J6
1
J6
1
J7
P7
TO PILOT
LIGHT
P6
TO CONTROL BOARD (+15V)
P6
PWM SIGNAL
P6
PWM SIGNAL
P6
TO CONTROL BOARD (COM)
P7
TO PILOT
LIGHT
+24V
(+)
(-)
+24V
150K
J7 475K 10K R12

5
R9
P7
RELAY COILS
10K
R41
D14 1N4936
D
D 267K R20
J7 Q5 IRF513
S
P7
DZ6 6.2V
1
1W
J14
100 R43
R42 Q40 40V 600mA

100K R10
R11
33.2K X4
7
100 C5 39 20V
6
R15 DZ1
R16
33.2K R17
D13
10K R19 C6 1.8

10
2.21K X4
8
J6
1 5
P6
R18
15V 1W
33.2K
R21
FROM PROTECTION BD. J14
C14
26.7K
20V
2 6 4
OCI1 CNY17-3
CONTROL TRIGGER
COM J14 J14

D12
COM
+24V A
+24V
33.2K R13 COM 15.0K +24V COM

3 4 2
R22
COM
100K J6 P6
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER.
P6 P6
5 4
J6 J6
D8
D10 IN
X5 LM350
OUT
R14
24Vac P6 P6 J6 J6
50V 15J
9 10
C10
500
C11
5.11K
R25
TP2
X4
ADJ
50V
4.75K R23
R24 267 C
C7
GENERAL INFORMATION
UNUSED
LAST NO. USED
X4 LM224
11 12
ELECTRICAL SYMBOLS PER E1537 CAPACITORS = MFD ( .022/50V 1/4W UNLESS OTHERWISE SPECIFIED) UNLESS OTHERWISE SPECIFIED) RESISTORS = Ohms ( DIODES = 1A, 400V
RC-
69 14 16 DZ- 6
D9
D11
X4
13
14
LABELS
SUPPLY
D-
VOLTAGE NET
COM J14 J7 J6
COM
COM
POWER SUPPLY SOURCE POINT COMMON CONNECTION
FILENAME: M16018_6JA
4-13-95C 3-29-96L 9-27-96F 10-25-96
DR.
FRAME CONNECTION EARTH GROUND CONNECTION
UNLESS OTHERWISE SPECIFIED TOLERANCE

3 4 5 8 6 10
ON HOLES SIZES PER E-2056 ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS ON 2 PLACE DECIMALS IS + .O2
Ch'ge.Sht.No.
3-22-91 9-11-92B 6-25-93A 9-24-93D

SCALE MJH DATE
EQUIP. TYPE
INVERTEC POWER BD SCHEMATIC

SUP'S'D'G. SHT. NO.
NONE
CHK.
SUBJECT
11/10/92
M 16018
NOTE:
G-13
ELECTRICAL DIAGRAMS
G-13
PC Board Assembly - Power - All Codes - (L8033)
ITEM
REQ'D
PART NO.
IDENTIFICATION
D14 R5 R6 D1 D3
X5
D12
R41
C10
C14 C11 DZ6
D15
F E
R8 DZ4 D7 D6 C8
TP2
D11 D9 D8 D10
D16 C9
R2
R4
DZ5
R7
R14
C6
Q40 Q5
DZ1
R16
R42
R21
R18
C1
X68 X67
D13 R19 R20
R17
R10
R15
X1
C
C3
R25
D
R13 R12 R11 C7 R9
D5
C2
R69
R1
R44
R24 R23
X4
R3
POWER BOARD
TP1
R43
C5
L8033-[ ]
J7
J14
J6
R22
OCI1
D2
D4
CAPACITORS = MFD/VOLTS
INDUCTANCE = HENRYS
NOTE:
G-14
ELECTRICAL DIAGRAMS
+V
G-14
Schematic - Darlington Drive Board - Codes 10151 - 10383 - (M17581)

M 17581
.5 AUXILLARY WINDING R1 D4 8A J13
2
+V
5W
TRANSFORMER
D1 400V C12 C15 8A
DZ1 18V POWER 3300 C16 SUPPLY 10.0 R6 1W
C17
500p
400V
1000V
1 3
10VAC
J13
3
3300
Q1 6A 100V
50V
50V
10W
2.7
R11
R9
400V
R
8A
400V
8A
J13 GND J13
2.7
10W
D3
D2
10W
10W
6VAC
2 AMP BASE DRIVE
R10
2.7
R12
NEGATIVE BIAS DARLINGTON HOLD - OFF 2.7 10W J12

1
for
2.7
DARLINGTON MODULE
R13 2.7 D6 1N5402 D10 1N5402 D12 1N5402 D7 1N5402 D8 C9 3300 50V J12 J12 C10 .33 200V 1N5402
2
10W R14
1.00K 1.00K 1.00K 1.00K R15 R17 R16 R18
BLUE
TWISTED PAIR E
J12
3 4
BLACK
Symmetric Gate Drive Layout
D11 1N5402
D13 1N5402
STT CONTROL BOARD +15V
+V
1N5402 R8 20 10.0 R7 DZ3 5W
D9
1K
J13
R2
3.92K R4
D G S
Q2 4A 100V
1.50K OCI1
2
267 R5 DZ2 12V 1W C5 0.1 50V
1 2 3 4
VS IN NC GND X2
VS OUT OUT GND
8 7 6 5
D5
3
C8
18V 1W
500p
1000V
HP2201
ON
OFF = Darlington OFF
= Darlington ON
J13
4429
C6 0.1 50V GND
R3 1.50K
GND
GENERAL INFORMATION
LAST NO. USED R18 17 13 DZ3
+V
CAPACITORS = RESISTORS = Ohms ( DIODES =
MFD ( .022/50V 1/4W
UNLESS OTHERWISE SPECIFIED) UNLESS OTHERWISE SPECIFIED)
C-
LABELS
D-
1A, 400V
SUPPLY
VOLTAGE NET
NOTES :
Vcc C14 0.1 50V
8
POWER SUPPLY SOURCE POINT COMMON CONNECTION FRAME CONNECTION
J13 1 3 1
J12 2
N.A.
OCI1 HP2201 GND

5
FILE: M17581_1AB
Ch'ge.Sht.No.
EARTH GROUND CONNECTION
UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E-2056 ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE ON 2 PLACE DECIMALS IS + .O2
5-19-95 3-29-96L
DR.

SCALE
EQUIP. TYPE
INVERTER WELDERS SCHEMATIC, DARLINGTON DRIVE

SUP'S'D'G. SHT. NO.
GND
MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS
NONE
CHK.
SUBJECT
MLD
DATE
03/23/94
BS
M17581
NOTE:
G-15
ELECTRICAL DIAGRAMS
G-15
PC Board Assembly - Darlington Drive - Codes 10151 - 10383 - (G2778)
ITEM
REQ'D
PART NO.
IDENTIFICATION
J13
STT DARLINGTON DRIVE G2778-[ ]

D10 D6 D7 D8 R18 R17
J12
R15 R16
XXX
XXX
XXX
R8
R14
D11
R2 R3
C10
XXX
R13
D4
D3
D5
XX X X X
XXX
XX
XXX
DZ2
R1
R4
R5
X
C12
C5
XXX
C16
XXX
Q2
R11
XXX
DZ3
XXX
C8
X X X
Q1
R7
R9
XXX
C6
C15
X2
R6
C17
DZ1
R12
XXX
NOTE:
XX
XXX
OCI1
C9
R10
C14
XXX
XXX
D13
XXX
D1
D2
D12
D9
XXXX X
CAPACITORS = MFD/VOLTS RESISTORS = OHMS
G-16
ELECTRICAL DIAGRAMS
G-16
Schematic - IGBT Drive Board - Codes 11090 - 11116 - (L12144)
NOTE:
G-17
ELECTRICAL DIAGRAMS
G-17
PC Board Assembly - IGBT Drive - Codes 11090 - 11116 - (L12145)
NOTE:
G-18
ELECTRICAL DIAGRAMS
G-18
Schematic - Switch Board - All Codes - (L8440)

L 8440
SCALE
MATERIAL TOLERANCE ("t") TO AGREE
POWER SUPPLY SOURCE POINT
SWITCH BOARD SCHEMATIC

SUBJECT
VOLTAGE NET
COMMON CONNECTION
FRAME CONNECTION
LAST NO. USED
1N4936 W 221
D4
R3
1N4936
100V IRFD110 22.1K R16 1
1A
D3
1N4936
R35
47.5
1.00K
R14
1.00K
1N4936
B
600mA Q6
R12
1W
R11
R42
R18
R13
1N4936
C2
2700p 50V
10.0 R33 10.0 C3
R7
1.50K
.047
R5
C7
1200V
R
C2
4 5
A2
TRANSFORMER PRIMARY
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
A2
1N4936 W 221
D1
R38 39.2K R41 39.2K
R39 39.2K R40 39.2K
INPUT CAPACITOR FILTER
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
BYT30P600
R1
1N4936
R2
D6
100
Q1
R36
100V IRFD110 22.1K R23 1
1A
D7
1N4936 47.5
C2
A1
BYT30P600
R22
ON ALL ANGLES IS + .5 OF A DEGREE
40V
1.00K
2N4403 6.2V 1.00K 1W D10 Q9
R21
1 8
A
600mA R19 DZ7 15V 1W 10.0 R26 10.0 R25
G1 G2 G3 G4 G5 S1 S2 S3 S4 S5 D1 D2 D3 D4 D5
TRANSFORMER PRIMARY
R20
1N4936
C5 DZ8 3.3V 1W
Q10
100V IRFD110 1 DZ12 1A
DZ2 10V 1W 600mA Q8
C4
40V 2N4403
.047
1200V A1
40V 20
R28
Q12
600mA 2N4401 D8
1/2W 15.0K
40V 2N4403
10V
1W
R32
10.0
R31
1N4936
C8
R29
R37
475
475
R27 10.0 R34 10.0
A1
SNUBBER
BYT12P600
2700p 50V
A1
RESISTOR
R30
1.50K
100
C1
R24
C6
12
NEGATIVE INPUT
NOTE:
N.A.
IRFP460
401 --403
NOTES :
ON 3 PLACE DECIMALS IS + .OO2
ON HOLES SIZES PER E-2056
ON 2 PLACE DECIMALS IS + .O2
600mA
DZ9
NUMBER.
WITH PUBLISHED STANDARDS
Q11
1/2W
A2
UNLESS OTHERWISE SPECIFIED TOLERANCE
Ch'ge.Sht.No.
10-8-93A
9-11-92
DR.
100
M. A. P.
R9
DIODES =
D5
20
475
475
402 --404
CAPACITORS =
40V 2N4401
10V
1W
15.0K
R6
R10
10.0
RESISTORS = Ohms (
DZ3
S1 S2
S3
S4
S5
1A, 400V
600mA
1/2W
G5
DATE
Q4
40V 2N4403
600mA
Q5
DZ4 15V 1W
R17 10.0
G3 G4
IRFP460 C1
BYT12P600
GENERAL INFORMATION
A2
A2
RESISTOR
1/4W
IRFD110
G2
3.3V
10.0
MFD ( .022/50V
DZ5
1W
A1
SNUBBER
CLEVELAND, OHIO U.S.A.
100V
NONE
10V
R8
G1
D1
D2
D3
D4
D5
FILE NO. L8440-1AA
11-25-91
C1
1A
DZ1
40V 2N4403
THE LINCOLN ELECTRIC CO.
Q3
CHK.
6.2V
1W
D9
POSITIVE INPUT
40V 2N4403
DZ6
BS
600mA
R15
1/2W
TYPE
Q7
EQUIP.
SUP'S'D'G.
100
R4
D2
Q2
LABELS
INVERTEC V300
42
C-
D-
R-
10
SUPPLY
SHT. NO.
AUSTRALIA
CANADA
FRANCE
L 8440
G-19
ELECTRICAL DIAGRAMS
G-19
PC Board Assembly - Switch - All Codes - (L8441)
21B
11B
9B
01B
3B
7B
5B
6B
2B
1B
ITEM C1, C5, C6, C7 C2, C8 C3, C4 D7, D8, D9, D10 D1, D2, D3, D4, D5, D6, DZ1, DZ2, DZ3, DZ12 DZ4, DZ7
Q11
REQ'D 4 2 2 10 4 2 2 2 4 2 6 4 2 10 2 2 4 4 2 2 4 2 4
PART NO. S16668-5 S16668-4 S13490-112 T12705-34 T12702-27 T12702-29 T12702-40 T12702-53 T12704-73 T12704-68 T12704-69 S19400-1000 S19400-2210 S19400-10R0 S19400-1501 S19400-1502 T14231-20 S19400-1001 S19400-20R0 S19400-2212 S19400-4750 S19400-47R5 S19400-3922
IDENTIFICATION .022/50 2700pF/50 .047/1200 1N4936 1N4740 1N4744A 1N4735 3.3V 1W IC PKG MOSFET 2N4401 2N4403 100 1/4W 221 1/4W 10 1/4W
C3
C4
D2
D4
C1
C5
D1
R1
R3
D6
Q7
D8
B8
B4
DZ6, DZ9 DZ5, DZ8 Q1, Q2, Q3, Q10 Q4, Q12 Q5, Q6, Q7, Q8, Q9, Q11 R1, R3, R5, R24 R2, R4 R6, R8, R9, R17, R19, R25
R16
R14
R12
R30
R21
R20
R23
D5
DZ5
DZ8
R13
Q3
Q2
Q1
Q10
R11
R15
R22
DZ12
R28
R24
R5
R4
R2
R31
Q12
Q4
R7
R26, R27, R33, R34 R7, R30 R10, R32
DZ3
R38
R39
R40
R41
1.5K 1/4W 15K 1/4W 1 1K 20 475 1/2W 1/4W 1/4W 1/4W
R35
R33
R27
R25
R34
R36
D3
R6
R9
DZ9
DZ6
D7
R11, R15, R22, R28 R12, R14, R20, R21 R13, R31 R16, R23 R18, R29, R37, R42 R35, R36 R38, R39, R40, R41
R18
R42
R17
R19
R26
R29
R37
C7
DZ4
C6
DZ7
R8
22.1K 1/4W 47.5 1/4W 39.2K 1/4W
Q5
R10
DZ1
R32
C2
Q8
D10
D9
C8
Q6
NOTE:
Q9
L8441-[ ]
SWITCH
DZ2
G-20
ELECTRICAL DIAGRAMS
S
20799
G-20
Schematic - Driver Board - All Codes - (S20799)
R3
3
R4 150K
R5
J16
J9
G1
250
R1
150K
150K
GATE
10 4
J9 J9
1 3
S1 G2
20W R2 250
J11
DRIVE
12
9 5
J9 J10
6 1
S2 S3
SWITCH
BOARD
GATE
8 6
TO POWER BOARD
J10 J10
4 6
G3 S4
900V
4A
Q1 R7 100 12V DZ1 J16

1
R6
J11
T1
GATE
TO
20W
150K
FROM PROTECTION BD.

2
GATE
7
J10
G4
1W
Power Switch Drive Transformer
Capacitor Pre-charging Circuits
J16 J16
R8 250 150K
R9 150K
R10
J16
R13
20W R14
150K
Q2 3 4 8
14
900V
4A
R12 100 DZ2 J16
R11
250
20W
150K
14
FROM PROTECTION
13
J11
NOTES :
N.A.
J9,J10
J16
1W
12V
BD.
J16
12
J16
FILE: S20799-1AA
Ch'ge.Sht.No.
6-25-93C

SCALE DR.
LC
EQUIP. TYPE
INVERTER WELDERS SCHEMATIC, DRIVER BOARD

SHT. NO.
NONE
11-4-92
SUBJECT CHK.
BS
DATE
SUP'S'D'G.
S 20799
NOTE:
G-21
ELECTRICAL DIAGRAMS
G-21
PC Board Assembly - Driver - All Codes - (L9134)
XXXX
XXXX
XXXX
XXXX
DRIVER
L9134-[ ]
ITEM
REQ'D
PART NO.
IDENTIFICATION
R8
R7
Q1
DZ1
R13
R14
R2
R1
XXXX XXXXX XXXXXXX
R9
R6 R5
R10
T1
Q2
R11
R4
XXXX
XXXX
R12
DZ2
XXXX
XXXX
J10 J9
XXXXXXX XXXXX XXXX

J11
INDUCTANCE = HENRYS
RESISTORS = OHMS/WATTS
J16
NOTE:
R3
G-22
ELECTRICAL DIAGRAMS
M 16097
G-22
Schematic - Protection PC Board - Codes 10151 - 11092 - (M16097)
+5V
+5V
R18
FROM (+) UPPER CAPACITOR

B52
10K
10
R5
R6
56.2K
150K
X1 15.0K
D1 9
R15 475
J8
1 5
OCI2
R21
3.32K
CNY17-3V
2 6 4
TO POWER BD. (Over Voltage)

J8
R27
56.2K
R4
150K
5
R14 100K
7
R19
C6
56.2K
X1
6
D7
R8
D5
R20
+5V
IN
R10
FROM BLEEDER RESISTOR

X2
B14
OUT
56.2K
CW
R32
5K
R37 332
R2
10K
681K
1.82K DZ1
GND
C2 27 35V 56.2K 1.82K

2 6 4
OCI3
J15
CNY17-3V
TO DRIVER BD. (Over Voltage)

4
R16
1W
R26
R9
R3
10V
10K
C3
50V
B53
FROM (-) UPPER CAPACITOR
+5V R35 R28 10K R22 332K

CW 3 1 5 3
R34
.022
267K
J15
332 D6
OCI4
J15
CNY17-3V
2 6 4 6
TO DRIVER BD. (Over Voltage)
1.82K
R13
FROM (-) LOWER CAPACITOR

R12
B51
R7
5K
2
X1
150K
150K
D4
50V 15.0K
R33
J8 D8
1 5
FROM CENTER LEG OF INPUT H5 R30 15.0K

R31 15.0K R29 15.0K R25 15.0K R24 15.0K R23 15.0K
1N4007
D3
R36
R11
C4
.022
267K
J15
OCI1
CNY17-3V
2 6 4
F I L E : M 16097-2F1
TO CONTROL BD. (Single Phase)
J8
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537 CAPACITORS = RESISTORS = Ohms ( DIODES = 1A, 400V MFD ( .022/50V 1/4W UNLESS OTHERWISE SPECIFIED) UNLESS OTHERWISE SPECIFIED)
LAST NO. USED RC_ _ _
C5
681K
LABELS
R1
D-
SUPPLY
VOLTAGE NET
+5V
NOTES :
N.A.
12
C1
X1 LM224
11
X1
13
14
Ch'ge.Sht.No.
1-25-91 12-10-93A
DR.
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. BS/DB

SCALE DATE
EQUIP. TYPE
INVERTEC V300 PROTECTION

SUP'S'D'G. SHT. NO.
9-11-92B
NONE
CHK.
SUBJECT
9-7-89
TJP
M 16097
NOTE:
G-23
ELECTRICAL DIAGRAMS
G-23
PC Board Assembly - Protection - Codes 10151 - 11092 - (L7915)
R1 C5
R2 C6
J8
L7915-[ ]
OCI1
OCI2
R12 D3
51 H5
B51
D8 R23 R24
PROTECTION
R25 R29 R31 R30

R3 D1
R26 R21
R11
B5
R20
R13
D4
R33
R4
B52
R5
R15
R14
R7
R8 R27 R6
R10
X1
C1
D5
52
D6 R35 R37 R32 R19 R18

R9
R22 R28
53
B53 B14
C2
DZ1
R16 D7
14
OCI3
X2
J15
R34 C3
OCI4
R36 C4
NOTE:
G-24
ELECTRICAL DIAGRAMS
G-24
Schematic - Protection PC Board - Codes 11115 - 11116 - (M20352)
NOTE:
G-25
ELECTRICAL DIAGRAMS
G-25
PC Board Assembly - Protection - Codes 11115 - 11116 - (L12235)
NOTE:
G-26
ELECTRICAL DIAGRAMS
S 21410
+15V
G-26
Schematic - Current Sense PC Board - All Codes - (S21410)
681K
EXCITATION CURRENT SOURCE MIN OFF SET ADJUSTMENT
R11
100A/V CURRENT OUT
1.00K
CURRENT CAL
3.8V = 38 mA
R10 13.7K
R3
X1 1014
7
J18
1
R5
100
R9 13.7K
CW
R16
VREF
R2
2K
X1
1.6V = 16 mA
R8
1.50K
R1
C1 C2 150p 50V +IC -VH 4
CW
R7
R6
1014
R4 1.00K
Q1 3A 100V 20K
681K
3 2 1
2
6.81K
10
HALL EFFECT SENSOR
+VH -IC
+15V
9
10.0K
X1 1014
X2
J18
10.0 R15
4 12
R14
1.50K
R12
TL431
6
REF
C4 0.1 50V
100
X3
C3 J18
3
50V
50
C5
X1 X1 LT1014
11
J18
14
13
1014
R13
2.94K
J18
4
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY
AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON CIRCUIT BOARD MAY CHANGE A PRINTED
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537 CAPACITORS = MFD ( .022/50V 1/4W UNLESS OTHERWISE SPECIFIED)
LABELS
FILE: S21410_1BA
VOLTAGE NET FRAME CONNECTION
WITHOUT AFFECTING BOARD.
SUPPLY
THE INTERCHANGEABILITY
OF A COMPLETE
THIS DIAGRAM MAY NOT OR CIRCUITRY OF
SHOW THE EXACT COMPONENTS CODE NUMBER.
RESISTORS = Ohms ( DIODES = 1A, 400V
POWER SUPPLY SOURCE POINT COMMON CONNECTION
CONTROLS HAVING A COMMON
Ch'ge.Sht.No. 5-19-95 9-27-96F 11-15-96E

SCALE DR.
EQUIP. TYPE
STT-CURRENT SENSE SCHEMATIC

SHT. NO.
NONE
CHK.
SUBJECT
MLD
DATE
03/21/94
FV
SUP'S'D'G.
S 21410
NOTE:
G-27
ELECTRICAL DIAGRAMS
G-27
PC Board Assembly - Current Sense - All Codes - (M17591)
C3
R14
XXXXXXXX XX XXX X XX XX
X2
R15 R3 R13 R1 R16
C4
X3
Q1
R2
C2 R4 R12 C1 R8 R9
C5
J18
X1
NOTE:
XXX
R6
R10 R11 R5
X XX
R7
M17591-[ ]
XX XX XX
XXX XXXX
STT CURRENT SENSE
ITEM
REQ'D
PART NO.
DESCRIPTION
XX XX
X X
XXX XX XX
G-28
ELECTRICAL DIAGRAMS
10 PIN REMOTE AMPHENOL E I
3
G-28
Schematic - Remote Protection PC Board - All Codes - (M17609)

M 17609
L1 J33
1
OPTIONAL
INTERFACE
REMOTE
.39mH L2 J33
J36
.39mH L3 J33
J36
.39mH L4 J33
J36
10K
BG
POT
.39mH L5 J33 .39mH L6 J33
10
10K
J36
PB
POT
J36
C1
.0047 3KV C2 .0047 3KV
C3
.0047 3KV C4 .0047 3KV
C5
.39mH C6
12
J36 J36 J36

4
D F H
.0047 3KV
TRIGGER
.0047 3KV
11
GND
C7
.0047 J34
J36 L7 .39mH J36 J36
14 13
B C D
GND 2 4 TRIGGER
3000V
6
J34 C8 J34 J36 J35 J36 J35 J36 J35 J36
41 42 VAC
.0047
3000V J35
3
16
42
J34 C9 J34 J35
31 115 VAC
.0047
8
3000V C10 C11 C12 J35

2
15
A E F G L M N
32
J33
5
.0047 TP1 TP2 R1 160J 320V C16 .05 600V VOLTAGE SENSE 160J 320V 1200 5W R2 1200 5W
3000V TP3 80J

B1 B2
.0047
.0047
3000V
3000V
(+) STUD (-) STUD

6
150V
J33 C15 .05 600V
J36
H 14 PIN WIRE
21
FEEDER AMPHENOL
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537 CAPACITORS = RESISTORS = Ohms ( DIODES = MFD ( .022/50V 1/4W UNLESS OTHERWISE SPECIFIED) UNLESS OTHERWISE SPECIFIED)
J33
10
LAST NO. USED RC8 16 0 LTP7 3
R3 332
R4 332 R7 332
R5 332 R8
J37
J33 C13 C14
LABELS
D-
R6 332
.0047
3000V J34 J34 J34 J37 J37 CHASSIS
.0047
3000V
NOTES :
N.A.
332
J37
1A, 400V
SUPPLY
VOLTAGE NET
POWER SUPPLY SOURCE POINT COMMON CONNECTION FRAME CONNECTION
7 3 2 2 4
FILE: M17609_1BA
EQUIP. TYPE
UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E-2056 ON 2 PLACE DECIMALS IS + .O2
Ch'ge.Sht.No. 5-19-95

SCALE DR.
STT REMOTE PROTECTION BOARD SCHEMATIC

SUP'S'D'G. SHT. NO.
CHASSIS
CHASSIS
ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS
NONE
CHK.
SUBJECT
MLD
DATE
04/20/94
F.V.
17609
NOTE:
G-29
ELECTRICAL DIAGRAMS
G-29
PC Board Assembly - Remote Protection - All Codes - (L9657)
NOTE:

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View Safety Info

For use with machine code numbers:10151,10152,10153,10309,10381,10382,10383,11090,11091,11092,

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Safety Depends on You

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View Safety Info

Copyright 2006 Lincoln Global Inc.

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FOR ENGINE powered equipment.

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ELECTRIC AND MAGNETIC FIELDS may be dangerous

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ARC RAYS can burn.

FUMES AND GASES can be dangerous.

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5.f. Also see item 1.b.

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FOR ELECTRICALLY powered equipment.

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PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR

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MASTER TABLE OF CONTENTS FOR ALL SECTIONS

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TABLE OF CONTENTS - INSTALLATION SECTION -

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RECOMMENDED INPUT WIRE AND FUSE SIZES

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208/60 230/60 460/60 200/50/60 220/50/60 380/50/60 415/50/60 440/50/60

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TECHNICAL SPECIFICATIONS Invertec STT II (For Codes 11115 AND 11116)

RECOMMENDED INPUT WIRE AND FUSE SIZES

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200/50/60 208/50/60 380/50/60 400/50/60 415/50/60

115 VAC not present on European Models.

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Read and understand entire Installation Section before starting installation.

MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION

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