Invertec STT PDF

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

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Lincoln arc welding and cutting

equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation .
. . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
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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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
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 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. 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.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar 95
ii ii
Return to Master TOC SAFETY
ELECTRIC SHOCK can kill. ARC RAYS can burn.
3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically hot when the welder is on. plates to protect your eyes from sparks and
Do not touch these hot parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
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 FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
5.a. Welding may produce fumes and gases
Semiautomatic DC Constant Voltage (Wire) Welder.

DC Manual (Stick) Welder. hazardous to health. Avoid breathing these
AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough
3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically hot. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
3.e. Ground the work or metal to be welded to a good electrical using local exhaust or mechanical ventilation. In
(earth) ground. confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.f. Maintain the electrode holder, work clamp, welding cable and also required when welding on galvanized steel.
welding machine in good, safe operating condition. Replace
5. b. The operation of welding fume control equipment is affected
damaged insulation.
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.g. Never dip the electrode in water for cooling.
welding procedure and application involved. Worker expo-
sure level should be checked upon installation and periodi-

3.h. Never simultaneously touch electrically hot parts of
cally thereafter to be certain it is within applicable OSHA PEL
electrode holders connected to two welders because voltage
and ACGIH TLV limits.
between the two can be the total of the open circuit voltage
of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
3.i. When working above floor level, use a safety belt to protect
The heat and rays of the arc can react with solvent vapors to
yourself from a fall should you get a shock.
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.j. Also see Items 6.c. and 8.
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.
5.f. Also see item 1.b.
AUG 06
iii iii
Return to Master TOC SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 7.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to Safety in Welding and Cutting (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can A safe distance from arc welding or cutting operations and
cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically hot parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been cleaned. For information, purchase Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
Precautions for Safe Handling of Compressed Gases in
Cylinders, available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturers
cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturers recommendations.
Mar 95
iv iv
SAFETY
zones o lon pique le laitier.
PRCAUTIONS DE SRET
Pour votre propre protection lire et observer toutes les instructions 6. Eloigner les matriaux inflammables ou les recouvrir afin de
et les prcautions de sret specifiques qui parraissent dans ce prvenir tout risque dincendie d aux tincelles.
manuel aussi bien que les prcautions de sret gnrales suiv-
antes: 7. Quand on ne soude pas, poser la pince une endroit isol de
la masse. Un court-circuit accidental peut provoquer un
Sret Pour Soudage A LArc chauffement et un risque dincendie.
1. Protegez-vous contre la secousse lectrique:
8. Sassurer que la masse est connecte le plus prs possible de
a. Les circuits llectrode et la pice sont sous tension la zone de travail quil est pratique de le faire. Si on place la
quand la machine souder est en marche. Eviter toujours masse sur la charpente de la construction ou dautres endroits
tout contact entre les parties sous tension et la peau nue loigns de la zone de travail, on augmente le risque de voir
ou les vtements mouills. Porter des gants secs et sans passer le courant de soudage par les chaines de levage,
trous pour isoler les mains. cbles de grue, ou autres circuits. Cela peut provoquer des
b. Faire trs attention de bien sisoler de la masse quand on risques dincendie ou dechauffement des chaines et des
soude dans des endroits humides, ou sur un plancher met- cbles jusqu ce quils se rompent.
allique ou des grilles metalliques, principalement dans
les positions assis ou couch pour lesquelles une grande 9. Assurer une ventilation suffisante dans la zone de soudage.
partie du corps peut tre en contact avec la masse. Ceci est particulirement important pour le soudage de tles
c. Maintenir le porte-lectrode, la pince de masse, le cble de galvanises plombes, ou cadmies ou tout autre mtal qui
soudage et la machine souder en bon et sr tat defonc- produit des fumes toxiques.
tionnement.
d.Ne jamais plonger le porte-lectrode dans leau pour le 10. Ne pas souder en prsence de vapeurs de chlore provenant
refroidir. doprations de dgraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanment les parties sous tension chaleur ou les rayons de larc peuvent ragir avec les vapeurs
des porte-lectrodes connects deux machines souder du solvant pour produire du phosgne (gas fortement toxique)
parce que la tension entre les deux pinces peut tre le total ou autres produits irritants.
de la tension vide des deux machines.
f. Si on utilise la machine souder comme une source de 11. Pour obtenir de plus amples renseignements sur la sret, voir
courant pour soudage semi-automatique, ces precautions le code Code for safety in welding and cutting CSA Standard
pour le porte-lectrode sapplicuent aussi au pistolet de W 117.2-1974.
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
PRCAUTIONS DE SRET POUR
corps. LES MACHINES SOUDER
3. Un coup darc peut tre plus svre quun coup de soliel, donc:
TRANSFORMATEUR ET
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant appropri ainsi
quun verre blanc afin de se protger les yeux du rayon-
nement de larc et des projections quand on soude ou 1. Relier la terre le chassis du poste conformement au code de
quand on regarde larc. llectricit et aux recommendations du fabricant. Le dispositif
b. Porter des vtements convenables afin de protger la peau de montage ou la piece souder doit tre branch une
de soudeur et des aides contre le rayonnement de larc. bonne mise la terre.
c. Protger lautre personnel travaillant proximit au
soudage laide dcrans appropris et non-inflammables. 2. Autant que possible, Iinstallation et lentretien du poste seront
effectus par un lectricien qualifi.
4. Des gouttes de laitier en fusion sont mises de larc de
soudage. Se protger avec des vtements de protection libres 3. Avant de faires des travaux linterieur de poste, la debranch-
de lhuile, tels que les gants en cuir, chemise paisse, pan- er linterrupteur la boite de fusibles.
talons sans revers, et chaussures montantes.
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
v v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
RETURN TO MAIN MENU
Page
Safety .................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Operation...............................................................................................................................Section B
Accessories ..........................................................................................................................Section C
Maintenance ..........................................................................................................................Section D
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair ................................................................................................Section F
Electrical Diagrams ..............................................................................................................Section G
STT Parts .......................................................................................................................................P257

STT II Parts ....................................................................................................................................P294
INVERTEC STT
Section A-1 Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
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 A-2
INSTALLATION
Return to Section TOC
TECHNICAL SPECIFICATIONS Invertec STT & STT II (For Codes 11092 and BELOW)
INPUT- THREE PHASE ONLY
STANDARD VOLTAGE INPUT CURRENT AT RATED OUTPUT
208/230/460/3/60 HZ 32/30/16
200/220/380/415/440/3/50/60 HZ 33/30/18/17/16
RATED OUTPUT
DUTY CYCLE AMPS VOLTS AT RATED AMPS
60% Duty Cycle 225 29

OUTPUT
CURRENT RANGE OPEN CIRCUIT VOLTAGE AUXILIARY POWER
Peak Current 1 0 - 450 Amps 85 VDC Maximum 115 2 VAC @ 4 Amps

Background 0 - 125 Amps 42 VAC @ 4 Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES

INPUT VOLTAGE FUSE(SUPER LAG) INPUT AMPERE TYPE 75 C TYPE 75 C
AND FREQUENCY OR BREAKER RATING ON COPPER COPPER
SIZE NAMEPLATE SUPPLY WIRE GROUND WIRE
IN CONDUIT IN CONDUIT
AWG (IEC) SIZES AWG (IEC) SIZES
208/60 40 32
230/60 40 30
460/60 30 16
200/50/60 40 33
220/50/60 40 30 10 (6 mm2) 10 (6 mm2)
380/50/60 30 18
415/50/60 30 17
440/50/60 30 16
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
23.2 in 13.2 in. 24.4 in. 100 lbs.
589 mm 336 mm 620 mm 46 kg

1
At low input voltages (below 208 VAC) and input voltages of 380 VAC through 415 VAC there may be a 15% reduction in Peak Current.
2
115 VAC not present on European Models.
INVERTEC STT
A-3 A-3
INSTALLATION
TECHNICAL SPECIFICATIONS Invertec STT II (For Codes 11115 AND 11116)

INPUT- THREE PHASE ONLY
STANDARD VOLTAGE INPUT CURRENT AT RATED OUTPUT
200/208/3/50/60 HZ 36/34
200/208/380/400/415/3/50/60 HZ 36/34/20/19/18
RATED OUTPUT
DUTY CYCLE AMPS VOLTS AT RATED AMPS

OUTPUT
CURRENT RANGE OPEN CIRCUIT VOLTAGE AUXILIARY POWER
Peak Current 0 - 450 Amps 88 VDC Maximum 115 1 VAC @ 4 Amps

Background 0 - 125 Amps 42 VAC @ 4 Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES

INPUT VOLTAGE FUSE(SUPER LAG) INPUT AMPERE TYPE 75 C TYPE 75 C
AND FREQUENCY OR BREAKER RATING ON COPPER COPPER
SIZE NAMEPLATE SUPPLY WIRE GROUND WIRE
IN CONDUIT IN CONDUIT
AWG (IEC) SIZES AWG (IEC) SIZES
200/50/60 40 36
208/50/60 40 34
380/50/60 30 20 10 (6 mm2) 10 (6 mm2)
400/50/60 30 19
415/50/60 30 18
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
23.2 in 13.2 in. 24.4 in. 100 lbs.
589 mm 336 mm 620 mm 46 kg
1
115 VAC not present on European Models.
INVERTEC STT
A-4 A-4
INSTALLATION
Read and understand entire Installation MACHINE GROUNDING AND HIGH
Section before starting installation.

FREQUENCY INTERFERENCE
PROTECTION
WARNING
The machine may not be suitable for use in an envi-
ELECTRIC SHOCK can kill. ronment where high frequency is present. For exam-
Only qualified personnel should
perform this installation.
ple do not place the machine in close proximity to TIG
Turn the input power OFF at the
or PLASMA operations. To minimize high frequency
disconnect switch or fuse box interference:
before installing this
equipment. Locate the STT II power source more than 15
Turn the power switch on the Invertec
feet (4.5 m) away from high frequency units
STT OFF before connecting or discon- and more than 25 feet (7.6 m) separation
necting input power lines, output cables, between ground connections or welding arcs
or control cables. of high frequency units.
Do not touch electrically hot
parts. Provide proper electrical ground to the

Always connect the ground terminal to a machine per local and national electrical
good electrical earth ground. codes.
SELECT SUITABLE LOCATION

INPUT CONNECTIONS
Locate the machine where there is free circulation of
clean air. Place the machine so that air can freely cir- FAILURE TO FOLLOW THESE INSTRUCTIONS
culate into the sides and out of the rear of the CAN CAUSE IMMEDIATE FAILURE OF COMPO-
machine. Dirt and dust that can be drawn into the NENTS WITHIN THE WELDER.
machine should be kept to a minimum. Failure to
observe these precautions can result in excessive Turn the input power off at the disconnect switch
operating temperatures and nuisance shut down of the before attempting to connect the input power lines.
Invertec STT II.
Connect the green lead of the power cord to ground
This machine carries an enclosure rating of IP21S. It per local and national electrical codes.
should not be placed in extremely damp or dirty loca-

tions. It should not be exposed to rain or snow. SUPPLY CONNECTIONS
STACKING Be sure the voltage, phase, and frequency of the input

supply is as specified on the rating plate. Input Power
The Invertec STT II cannot be stacked. supply line entry in provided on the case back of the
machine. See figure A.1 for location of the rating plate.
TILTING
The Invertec STT II should be connected only by a
Place the machine on a secure, level surface otherwise qualified electrician. Installation should be made in
the unit may topple over. 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 INSTAL-
LATION AND CONNECTION.
INVERTEC STT
A-5 A-5
INSTALLATION
CASE BACK
INPUT CABLE RATING PLATE

ENTRY ACCESS
& CABLE STRAIN RELIEF
FIGURE A.1 CASE BACK
INPUT CABLE INSTALLATION AND CON-

NECTION 5. Connect the three phase line con-
ductors to the power switch termi-
nals labeled U, V and W. Tighten
A cable strain relief is provided at the supply line entry
the connections to 3.0 Nm. (27 in.-lb.) torque.
and is designed to accommodate cable diameters of

.310 - 1.070 in. (7.9 - 27.2 mm). On European models
the strain relief is designed to accommodate cable
6. Securely tighten the cable strain relief located
diameters of .709 - 1.000 in. (18.0 - 25.4 mm). Refer to
on the case back of the machine.
Technical Specifications at the beginning of this sec-
tion for the proper input cable sizes. Refer to Figure A.1
and perform the following steps:
GROUND CONNECTION
1. Remove the wraparound cover of the
Invertec STT II. 1. Connect the ground terminal to earth
ground per National Electrical Code.
2. Feed the input cable through the input cable
entry access hole at the right rear of the 2. Replace the wraparound cover of the
machine. Invertec STT II.
3. Route the cable through the cable hangers,

located along the lower right inside edge of
the machine, up to the power switch located on

the front panel.
4. Strip away 102 mm (4 in.) of the outer jacket.

Trim fillers and strip conductor jackets to
connect to the power switch.
INVERTEC STT
A-6 INSTALLATION A-6
380-415 4A
OR
*
2. Move input voltage switch
OR * to Voltage = 380-460V
200-208 position.
3. Move lead A to 380-415
Terminal.
*(NOT PRESENT ON ALL MODELS)
380,400 or 415 VAC 1. Open reconnect panel
(Codes 11115 and access door on wrap-
FIGURE A.2 RECONNECT PANEL around.
11116) 2. Move input voltage switch
INPUT VOLTAGE RECONNECT to Voltage = 380-460V
PROCEDURE position.
As shipped from the factory, multiple voltage machines Terminal.
are internally configured for the highest input voltage
(440-460 VAC), for Codes 11092 and below and (380- 220 or 230 VAC 1. Open reconnect panel
415 VAC), for Codes 11115 and 11116. (Codes 11092 and access door on wrap-
around.
below) 2. Move input voltage switch
1. For Connections to 440 or 460 VAC verify the inter-
to Voltage = 200 -230V
nal configurations to the procedures shown below and position.
refer to Figure A.2. 3. Move lead A to 220-230
Terminal.
2. For Connections to 200,208,220,230,380,400 or 415
VAC follow the procedure shown below and refer to fig- 200 or 208 VAC 1. Open reconnect panel
ure A.2. (Codes 11092 and access door on wrap-
around.
NOTE: Turn main power to the machine OFF below) 2. Move input voltage switch

WARNING position.
before performing the reconnect procedure. Terminal.
Failure to do so will result in damage to the
machine. DO NOT switch the reconnect bar with 200 or 208 VAC 1. Open reconnect panel
machine power ON. (Codes 11115 and access door on wrap-around.
------------------------------------------------------------------------ 11116) 2. Move input voltage switch
position.
To Operate at Procedure
Terminal.
460 or 440 VAC 1. Open reconnect panel
around. OUTPUT CONNECTIONS
below) 2. Move input voltage switch
to Voltage = 380 -460V pos-
ition.
WIRE FEEDER OUTPUT CONNECTIONS

Terminal. Refer to the Accessories section of this manual for
instructions on connecting a wire feeder to the Invertec
380 or 415 VAC 1. Open reconnect panel STT II.
around. The LN-742 or STT-10 wire feeder is the recommend-
below) ed 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 B-2
OPERATION
OPERATING INSTRUCTIONS
Read and understand entire section before
operating machine.
GENERAL WARNINGS
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK
can kill.
Do not touch electrically live parts

or 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 B-3
OPERATION
GENERAL DESCRIPTION High temperature Class H insulation.
The Invertec STT II is a 225-ampere inverter based arc Protection circuits and ample safety margins prevent
welding power source specifically designed for the STT damage to the solid state components from transient
welding process. It is neither a constant current (CC) voltages and high currents.
nor a constant voltage (CV) machine. It is a power
source that delivers current of a desired wave form and Preset welding current capability.
characteristics that are superior to conventional short
circuiting GMAW. The process is optimized for short- STT II offers improvements over the previous model.
circuiting GMAW welding. Approximately 40% increase in deposition rate capa-
bility, and a significant increase in travel speed.
RECOMMENDED EQUIPMENT WELDING CAPABILITY
The LN-742 or STT-10 wire feeder is recommended for The Invertec STT II is rated at 225 amps, 29 volts, at
use with the STT II. The LN-7 GMA, LN-9 GMA, NA-5, 60% duty cycle on a ten minute basis. It is capable of
and NA-5R can all be used with the STT II. However, higher duty cycles at lower output currents. If the duty
these units can only be used to feed wire since these cycle(s) are exceeded, a thermal protector will shut off
feeders have no provision for control of the STT output. the output until the machine cools to a reasonable
operating temperature.
OPERATING CONTROLS
LIMITATIONS
The Invertec STT II has the following controls as stan-
dard: On/Off switch, Peak Current adjustment, May not be suitable for use in an environment with
Background Current adjustment, Hot Start adjustment, High Frequency present. (See Machine Grounding
Tailout, and 2 toggle switches; one for wire size selec- and High Frequency Protection in the Installation
tion and one for wire type selection. 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, light-
weight and compact design.
Twist-Mate output terminals.
Digital meters for procedure settings are standard.
Automatic Inductance or Pinch Control.
Solid state circuitry for extra long component life.
Current feedback ensures that original procedure

settings all remain constant.
Arc Sense lead assembly (Electrode and Work),

connects through a 4-pin case front connector.
Peak Current and Background Current may be


remotely controlled.
Thermostat and FET over current protector prevent

overheating from overloads, high ambient tempera-
tures, or loss of air flow.
INVERTEC STT
B-4 B-4
OPERATION
OPERATIONAL FEATURES AND CONTROLS
All operator controls are located on the case front of the Invertec STT II. Refer to Figure B.1 for locations.
4 5
6
3 2
10
1
9
11
14 13
15 12
FIGURE B.1 CASE FRONT CONTROLS
1. POWER SWITCH: Turns output 3B. PEAK CURRENT DISPLAY METER: This
power ON and OFF. This switch ON is a digital meter for displaying the preset A
V
also controls auxiliary power Peak Current. This meter displays in 1
available through the 14-pin Wire amp increments. This meter does not indi-
Feeder Receptacle. cate actual welding current only the preset

current.
OFF
2A. BACKGROUND CURRENT OUTPUT CONTROL: 4. HOT START CONTROL POTENTIOMETER:

The output current is switched to the Hot Start provides approximately 25% to
Background level at the conclusion of the 50% more current during the initial start of
preceding Peak Current pulse. This knob the weld for improved arc starting and bead
allows preset adjustment of the amplitude appearance. This control adjusts the dura-
of the background current up to 125 tion of this Hot Start current. The control range is
amperes. from 0 to 10, where 0 corresponds to the zero or no
Hot Start, and 10 is maximum for a Hot Start last-
2B. BACKGROUND CURRENT DISPLAY METER: ing for about four (4) seconds.
This is a digital meter for displaying the
preset Background Current. This meter 5. TAILOUT: Alters the current waveform to increase
displays in 1 amp increments. This meter A deposit rate and travel speed. The Minimum setting
does not indicate the actual welding cur- sets STT II to the original STT waveform. As tailout
rent, only the preset current. is increased peak and Background current may
need to be reduced to maintain optimum perfor-

3A. PEAK CURRENT OUTPUT CONTROL: The mance.
beginning portion of the welding arc is a
pulse of current referred to as Peak
Current. This knob allows preset adjust-
ment of the amplitude of the peak current
up to 450 amperes.
INVERTEC STT
B-5 B-5
OPERATION
6. WIRE SIZE SELECT SWITCH: This toggle switch 13. 115V AUXILIARY POWER CIRCUIT BREAKER
selects between electrode diameters of .035 (1 mm) (Not on European Models): The 115 VAC
and smaller or .045 (1.2 mm) and larger. The .035 supply is protected from excessive current
(1 mm) position provides improved performance of draws with a 6 amp circuit breaker. When
smaller diameter wires at higher wire feed speeds. the breaker trips its button will extend.
Depressing this button will reset the breaker.
7. WIRE TYPE SELECT SWITCH: This toggle switch
selects between mild or stainless steel. In the stain- 14. WORK TERMINAL: This twist-mate con-
less position, the pulse width of the Peak Current is nection is the negative output terminal for
changed from 1 to 2 ms for better performance for connecting a work cable and clamp to the
stainless steel welding. workpiece.
8. THERMAL SHUT-DOWN INDICATOR: This light 15. ELECTRODE TERMINAL: This twist-mate
will indicate that either the internal thermo- connection is the positive output terminal
stat(s) or the FET over current sensor has for connecting an electrode cable to the
actuated. Machine output will return after wire feeder conductor block. Refer to the
the internal components have returned to normal Accessories Section for wire feeder connection
operating temperature (if the thermostat(s) instructions.

opened) or after about 3-7 seconds (if the FET over

current sensor activated).
WELDING OPERATION
9. REMOTE RECEPTACLE: This is a 10 pin MS-type
connector for remote control of Peak Current and
Familiarize yourself with the controls on the Invertec
Background Current. Trigger switch connections
STT II before beginning to weld.
are also provided. The presence of the mating con-
nector is automatically sensed, disabling the front panel Peak
Familiarize yourself with the operating manual for the
and Background Current controls. Refer to REMOTE CON-
wire feeder and the wire feeder controls before begin-
TROL CONNECTOR in the ACCESSORIES Section of this
ning to weld.
manual for more information.
Set the Wire Size and Wire Type selection switches per
10. WIRE FEEDER RECEPTACLE: This is 14
the appropriate wire. Refer to Operational Features
pin MS-type connector for the wire feeder
and Controls in this section for the function of these
connection. 115 and 42 VAC along with
switches.
the trigger switch connections are provid-
ed. (Only 42 VAC is available on European mod-

els). There are no provisions for voltage control of
the power source by the wire feeder. Refer to the
Accessories section of this manual for wire feeder
connection instructions.
11. ARC SENSE RECEPTACLE: This is a four pin MS-

type connector for WORK and ELECTRODE sense
leads. The STT requires a WORK sense and ELEC-
TRODE sense lead for proper operation. The
ELECTRODE sense lead is bolted together with
power source electrode lead at the wire feeder gun
block. The WORK sense lead is furnished with an
alligator type clip for connection to the work piece.
Refer to the LN 742 or STT-10 wire feeder connec-
tion instructions in the Accessories section of this
manual for proper connection of these leads.

12. 42V AUXILIARY POWER CIRCUIT BREAKER:

The 42 VAC supply is protected from excessive current
draws with a 6 amp circuit breaker. When the
breaker trips its button will extend.
Depressing this button will reset the breaker.
INVERTEC STT
B-6 B-6
OPERATION
WELDING PARAMETERS AND GUIDE- Adjusting this level to low will cause wire stubbing and
LINES also poor wetting of the weld metal. This is similar to a

low voltage setting on a standard CV machine
The Invertec STT II is neither a constant current (CC)
Adjust Bead Shape using Background Current
nor a constant voltage (CV) power source. In general,
wire diameter will be increased one size compared to
conventional (CV) power sources. The larger the wire
diameter the higher the deposition rate (Up to 1/16).
Wire sizes below .035 are unnecessary for most appli-
cations. The Invertec STT 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
Note: Background Current levels for applications using
electrode state, the power source will supply varying
100% CO2 is less than similar procedures involving gas
output currents to minimize spatter. The Peak and
blends with high percentages of Argon. This is a result
Background currents are two such current outputs that
of the greater heat generated in the 100% CO2 arc.

can be adjusted.
(100% CO2 is 35 volts/cm and 100% Argon is 20
volts/cm. 75% Argon, 25% CO2 is about 24 volts/cm.
Wire Feed Speed controls the deposition rate. Peak
Current controls the Arc Length. Background Current
Contact Tip to Work Distance
controls the Bead Contour. And Tailout increases
Power in the Arc.
PEAK CURRENT
The Peak Current control acts similar to an arc pinch
control. Peak current serves to establish the arc length
and promote good fusion. Higher peak current levels
will cause the arc to broaden momentarily while
increasing the arc length. If set too high, globular type
transfer will occur. Setting this level to low will cause
instability and wire stubbing. In practice, this current
level should be adjusted for minimum spatter and pud-
dle agitation.
Adjust Arc Length with Peak Current

HOT START
The Hot Start control can be set to enhance establish-
ing the arc and provide the capability of increasing the
heat at the start of the weld to compensate for a cold
work piece. Hot start adjusts the time that additional
current is applied during the starting of the arc. Refer to
Operational Features and Controls in this section
for a description of this control.
Note: In 100% CO2 shielding gas applications the peak
TAILOUT
current level should be set greater than in a corre- The tail out provides additional heat without the molten
sponding application using a gas blend with a high per- droplet becoming too large. Increase as necessary to
centage of Argon. Longer initial arc lengths with 100% add Heat to the arc without increasing arc length.
CO2 are required to reduce spatter.
(This will allow for faster travel speeds and produce

improved wetting). As tailout is increased, the peal
BACKGROUND CURRENT and/or background current is usually reduced.
The Background Current provides the control for the
overall heat input to the weld. Adjusting this level too WELDING ARC PERFORMANCE
high will cause a large droplet to form and globular type For optimum spatter reduction, the arc should be con-
transfer to occur resulting in increased spatter. centrated on the puddle.
INVERTEC STT
B-7 B-7
OPERATION
WELDING PROCEDURES FOR STT II - (Stainless Steel) Horizontal Fillet

(Steel) Horizontal Fillet (See Table B.1 and B.2) (See Table B.3 and B.4)
DIRECTION
OF
DIRECTION TRAVEL 75
OF
TRAVEL 75
TOP VIEW
TOP VIEW
DIRECTION
OF
45 TRAVEL 75
DIRECTION
OF
45 TRAVEL 75
END VIEW FRONT VIEW

Table B.3
END VIEW FRONT VIEW
90% He, 7.5% Ar, 2.5% CO2
Table B.1 Gas Shield (Set for Steel Mode)
100% CO2 Gas Shield (Set for Steel Mode) Plate Thickness (mm) 20 ga 14 ga 10 ga
Plate Thickness (mm) 20 ga 14 ga 10 ga (0.9) (2.0) (3.25)
(0.9) (2.0) (3.25) Electrode size (mm) 0.035 0.045 0.045
Electrode size (mm) 0.035 0.045 0.045 (0.9) (1.1) (1.1)
(0.9) (1.1) (1.1) WFS /min (m/min) 100 130 170
WFS /min (m/min) 100 100 170 (2.5) (3.3) (4.2)
(2.5) (2.5) (4.2) Peak Current 165 210 250
Peak Current 220 260 280 Background Current 35 60 85
Background Current 30 40 65 Tailout setting 7 7 4
Tailout setting 3 7 5 Average Amperage 40 95 120
Average Amperage 60 105 120 Travel Speed /min 12 16 16
Travel Speed /min 12 12 12 (m/min) (0.3) (0.4) (0.4)

(m/min) (0.3) (0.3) (0.3) Gas Flow cfh (L/min) 25 (12)
Gas Flow cfh (L/min) 25 (12) Electrical Stickout 1/4 - 3/8
Electrical Stickout 1/4 - 3/8 (mm) (6.4 - 10)
(mm) (6.4 - 10)
Table B.4
Table B.2 98% Ar, 2% O2
75% CO2 - 25% Ar Gas Shield (Set for Steel Mode) Gas Shield (Set for Stainless Steel Mode)
Plate Thickness (mm) 20 ga 14 ga 10 ga Plate Thickness (mm) 20 ga 14 ga 10 ga
(0.9) (2.0) (3.25) (0.9) (2.0) (3.25)
Electrode size (mm) 0.035 0.045 0.045 Electrode size (mm) 0.035 0.045 0.045
(0.9) (1.1) (1.1) (0.9) (1.1) (1.1)
WFS /min (m/min) 100 100 120 WFS /min (m/min) 100 130 170
(2.5) (2.5) (3.0) (2.5) (3.3) (4.2)
Peak Current 225 270 310 Peak Current 145 190 280
Background Current 40 65 70 Background Current 45 95 95
Tailout setting 8 4 6 Tailout setting 7 8 7

Average Amperage 70 110 130 Average Amperage 60 120 150
Travel Speed /min 12 12 12 Travel Speed /min 12 12 12
(m/min) (0.3) (0.3) (0.3) (m/min) (0.3) (0.3) (0.3)
Gas Flow cfh (L/min) 25 (12) Gas Flow cfh (L/min) 25 (12)
Electrical Stickout 1/4 - 3/8 Electrical Stickout 1/4 - 3/8
(mm) (6.4 - 10) (mm) (6.4 - 10)
INVERTEC STT
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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 C-2
ACCESSORIES
OPTIONS / ACCESSORIES STT control board to accept PEAK and BACK-
GROUND inputs on this connector rather than from

K940 SENSE LEADS: These leads are used to accu- the front panel controls. If this short is removed, the
rately sense arc voltage. One set is required for each front panel controls will be active. By adding a switch
STT II power source. A 10 ft and 25 ft set are provid- between pins J and B a LOCAL/REMOTE con-
ed as standard with the machine. Additional sets are trol switch can be created. (Switch open for local
available in 10 ft (K940-10), 25 ft (K940-25) and 50 ft and closed for remote)
(K940-50) lengths.
3. For robotic control of the PEAK CURRENT, a 0 to
K942-1 REMOTE CONTROL: Allows remote adjust- +10 volt DC signal is applied between pins A and
ment of Peak and Background Current settings. G with + applied to pin G. The BACKGROUND
CURRENT is controlled with a similar signal applied
REMOTE RECEPTACLE (For optional remote interface, between pins A and C with + applied to pin C.
Connection to the STT-10 Wire Feeder or Robotic Control) In this application pins J and B must be shorted
as described in 2 above.
1. The 10 pin MS connector labeled Remote Control
located on the front panel of the STT is used for NOTE: These analog signals should be isolated
from the robot circuitry to prevent interference.

remote control of the power source. Control for the

PEAK (PB pot) and BACKGROUND (BG pot) cur-
rent along with the trigger switch is provide through 4. The trigger switch is connected between pins D
this connector. and F. These connections are in parallel with the
trigger switch from the wire feeder.
2. Refer to figure C.1 below for details about the
remote receptacle (J38). Note that pins J and B 5. The digital meters for PEAK and BACKGROUND
are shorted together This short circuit tells the currents will show preset values in both local and
remote operation.
REMOTE
PROTECTION BOARD
+ ARC
J19
VOLTAGE
SENSE
1 290 1 (+)
CONNECTION
2 2
J37
3 291 3 (-)
- ARC 4 4
J38
3 J
2 B
BG
1 C
10K
212C 6 10 G
J38
43A 1 9 A
PB
33C 4 12 D
TRIGGER 10K
32C 8 4 F
212B 5 11 H GND
3 E
2 I OPTIONAL
7 REMOTE
223
INTERFACE
290A
8
WIRE
FEEDER
J39
N ELECTRODE SENSE LEAD
PORTION OF G3136 WIRING DIAGRAM

REFER TO ACTUAL DIAGRAM PASTED INSIDE YOUR MACHINE
INVERTEC STT
C-3 C-3
ACCESSORIES
LN-742 or STT-10 WIRE FEEDER 3. Connect the electrode lead (Twist-Mate) to (+) out-
put terminal on STT II.

CONNECTION INSTRUCTIONS
4. Connect the other end of electrode lead (Step #3)
The LN-742 or STT-10 is the recommended wire feed- and the ARC SENSE LEAD (lead with ring lug, step
er for use with the Invertec STT II. Refer to the LN- #2) together to the gun block on the LN 742.
742 or STT-10 Operator Manual for Wire Feed
Operation. Refer to Figure C.2 or C.3 and follow the 5. Connect work lead between STT (-) terminal and the
instructions below to connect the LN-742 or STT-10. work piece.
WARNING 6. Connect the ARC SENSE LEAD WORK (lead with

alligator clip) to work piece.
ELECTRIC SHOCK can kill.
Only qualified personnel should perform NOTE: For best welding performance make this
this installation. connection as close as possible to the
Turn the input power OFF at the discon- welding arc.
nect switch or fuse box before connecting
the wire feeder
7. Connect the wire feeder control cable between the

LN-742 or STT-10 and the 14-pin Wire Feeder
1. Turn the Invertec STT II power off. Receptacle on the STT II. For the STT-10 Wire
Feeder: Connect the second wire feeder control
2. Connect the ARC SENSE LEAD MS connector to cable between the STT-10 and the 10-pin Remote
the mating connector on STT II front panel. Receptacle on the STT II.
WARNING Turn off input power to the Welding

Power source using the disconnnect
switch at the fuse box before
connecting the wire feeder.
ELECTRIC Only qualified persons should install,

SHOCK use or service this machine.
CAN KILL
CONTROL, ELECTRODE, ARC SENSE "ELECT" WIRE FEEDER

LN 742
REMOTE RECEPTACLE AND ARC SENSE "WORK" CABLES SHOULD

LN7 GMA
BE TAPED TOGETHER. LN9 GMA
NA5R
NA5
WIRE FEEDER
WORK LEAD 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 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.
ELECTRIC Only qualified persons should install,
SHOCK use or service this machine.
CAN KILL
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

INVERTEC STT
Section D-1 Section D-1
TABLE OF CONTENTS
-MAINTENANCE-
Maintenance .........................................................................................................................Section D
Input Filter Capacitor Discharge Procedure................................................................................D-2
Preventive Maintenance .............................................................................................................D-3
Major Component Locations .......................................................................................................D-4
INVERTEC STT
D-2 D-2
MAINTENANCE
5. Locate the two capacitor terminals (large

WARNING
hex head cap screws) shown in Figure
Failure to follow this D.1.
capacitor discharge proce-
dure can result in electric 6. Use safety glasses, electrically insulated
shock.
gloves and insulated pliers. Hold body of
the resistor and connect resistor leads
INPUT FILTER CAPACITOR
across the two capacitor terminals. Hold
DISCHARGE PROCEDURE resistor in place for 10 seconds. DO NOT
TOUCH CAPACITOR TERMINALS WITH
1. Turn off input power or disconnect input
YOUR BARE HANDS.
power lines.
7. Repeat discharge procedure for capaci-
2. Remove hex head screws from side and
tor on other side of machine.
top of machine and remove wrap-around
machine cover.
8. Check voltage across terminals of all
capacitors with a DC voltmeter. Polarity

3. Be careful not to make contact with the
of capacitor terminals is marked on PC
capacitor terminals that are located in the
board above terminals. Voltage should be
center of the Switch Boards.
zero. If any voltage remains, repeat this
capacitor discharge procedure.
4. Obtain a high resistance and high
wattage resistor (25-1000 ohms and 25
watts minimum). This resistor is not sup-
plied with machine. NEVER USE A
SHORTING STRAP FOR THIS PROCE-
DURE.
FIGURE D.1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS.

INVERTEC STT
D-3 D-3
MAINTENANCE
PREVENTIVE MAINTENANCE Input Filter Capacitors
1. Perform the following preventive mainte- Output Terminals

nance procedures at least once every six
months. It is good practice to keep a pre- Lower base compartment
ventive maintenance record; a record tag
attached to the machine works best. 4. Examine capacitors for leakage or oozing.
Replace if needed.
2. Remove the machine wraparound cover
and perform the input filter capacitor dis- 5. Examine wraparound cover for dents or
charge procedure (detailed at the begin- breakage. Repair as needed. Cover must
ning of this chapter). be kept in good condition to assure high
voltage parts are protected and correct
3. Clean the inside of the machine with a spacings are maintained.
low pressure airstream. Be sure to clean

the following components thoroughly. 6. Check electrical ground continuity. Using
an ohmmeter, measure resistance
Power Switch, Driver, Protection, and between either output stud and an unpaint-
Control printed circuit boards ed surface of the machine case. Meter
reading should be 500,000 ohms or more.
Power Switch If meter reading is less than 500,000
ohms, check for electrical components that
Main Transformer are not properly insulated from the case.
Correct insulation if needed.
Input Rectifier
7. Replace machine cover and screws.
Heat Sink Fins
INVERTEC STT
D-4 D-4
MAINTENANCE
FIGURE D.2 MAJOR COMPONENT LOCATIONS
1. BASE ASSEMBLY
2. REAR NAMEPLATE
3. RESISTORS
4. FAN SHROUD ASSEMBLY
5. PROTECTION PC BOARD
6. DRIVER PC BOARD
7. CONTROL BOX
8. CONTROL PC BOARD
9. BLEEDER RESISTORS
10. RECONNECT PANEL
11. IGBT OR DARLINGTON MODULE
12. WRAPAROUND ASSEMBLY
12
13. CASE FRONT ASSEMBLY
14. OUTPUT TERMINALS
15. OUTPUT CHOKE ASSEMBLY
16. TRANSFORMER ASSEMBLY
17. OUTPUT RECTIFIER ASSEMBLY
18. AUXILIARY TRANSFORMER

19. FET HEAT SINK ASSEMBLY
6
9
5
8
10
17
7
15
16
18
13
19
3
14
11
INVERTEC STT
Section E-1 Section E-1
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-

Theory 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 1 OHM
T2
S B CURRENT IGBT NEGATIVE

W FET
O SENSOR MODULE OUTPUT
I A TERMINAL
T CAP
C R
H FET D
CHOKE
R VOLTAGE
PRE - SENSING
E
LINE INPUT CHARGE RECEPTACLE

M
SWITCH RECTIFIER R
P D O
E B D
CR1 R B R T
C O R O REMOTE
CURRENT I E
O T O I A TRANS V B CONTROL
E A V T3
E P O RECEPTACLE
N C R
N T R E S R A
I D I O
E D R R
O G T
C N N
E D
T A
"A" C
LEAD L
PRE -
CR2 CHARGE T WIRE
18 I FEEDER
FAN TRANS VAC P B S
FET
B O RECEPTACLE
T1 O O W O
I N
115
W A CAP A
E R T
VAC 2 C R
4 R D FET
V H D
A
TRANS C
T4 T LESS THAN 1VDC CURRENT FEEDBACK
H PULSE TRANSFORMER SIGNAL
E
R PWM SIGNAL
M
O
S 15VDC
T
A
T GUN TRIGGER
IGBT
CONTROL BOARD DRIVER
36VAC BOARD
VOLTAGE FEEDBACK
PEAK
TAILOUT CURRENT BACK- BACK- WIRE WIRE
GROUND PEAK HOT SIZE
CURRENT START GROUND TYPE
CONTROL METER
(STT II ONLY)
METER CONTROL CONTROL CONTROL SWITCH SWITCH
10VAC AND 6VAC

42VAC
FIGURE E.1 INVERTEC STT
INVERTEC STT
E-2 E-2
THEORY OF OPERATION
FIGURE E.2 INPUT VOLTAGE
POSITIVE
OUTPUT
TERMINAL
MAIN
TRANSFORMER 1 OHM
T2

W FET
I A TERMINAL
T CAP
C R
H FET D
CHOKE
R VOLTAGE
PRE - SENSING
CHARGE E
LINE INPUT RECEPTACLE
M
SWITCH RECTIFIER R
P D O
E B D
CR1 R B R T
C O R O REMOTE
CURRENT I E
E A V T3
E P O RECEPTACLE
N C R
N T R E S R A
I D I O
E D R R
O G T
C N N
E D
T A
"A" C
LEAD L
PRE -
CR2 CHARGE T WIRE
18 I FEEDER
FAN TRANS VAC P B S
FET
B O RECEPTACLE
T1 O O W O
I N
115
W A CAP A
E R T
VAC 2 C R
4 R D FET
V H D
A
TRANS C
E
R PWM SIGNAL
M
O
S 15VDC
T
A
T GUN TRIGGER
IGBT
36VAC BOARD
VOLTAGE FEEDBACK
PEAK
CONTROL METER
(STT II ONLY)
10VAC AND 6VAC
42VAC
GENERAL DESCRIPTION INPUT VOLTAGE

The Invertec STT is a 225 ampere, inverter based, arc The Invertec STT can be connected for a variety of
welding power supply specifically designed for the three-phase voltages. The initial input power is applied
Surface Tension Transfer (STT) welding process. It to the STT through a line switch located on the front of
cannot be classified as either a constant current (CC) the machine. The AC input voltage is applied to the
or a constant voltage (CV) machine. The STT pro- input rectifier and the T1 auxiliary transformer. The T1
duces current of a desired waveform to reduce spatter transformer develops the appropriate AC voltages to
and fumes. The STT process is optimized for short - operate the cooling fan, the power and control boards.
circuit GMAW welding only. The T1 transformer also supplies primary voltage to the
T4 auxiliary transformer as well as 42 VAC to an exter-
nal 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 E-3
THEORY OF OPERATION
FIGURE E.3 RECONNECT, PROTECTION BOARD, RECTIFICATION AND PRECHARGE
POSITIVE
OUTPUT
TERMINAL
MAIN
TRANSFORMER 1 OHM
T2

W FET
I A TERMINAL
T CAP
C R
H FET D
CHOKE
R VOLTAGE
PRE - SENSING
CHARGE E
M
SWITCH RECTIFIER R
P D O
E B D
CR1 R B R T
C O R O REMOTE
CURRENT I E
E
A V T3
E P O RECEPTACLE
N C R
N T R E S R A
I D I O
E D R R
O G T
C N N
E D
T A
"A" C
LEAD L
PRE -
CR2 CHARGE T WIRE
18 I FEEDER
FAN TRANS VAC P B S
FET
B O RECEPTACLE
T1 O O W O
I N
115
W A CAP A
E R T
VAC 2 C R
4 R D FET
V H D
A
TRANS C
E
R PWM SIGNAL
M
O
S 15VDC
T
A
T GUN TRIGGER
IGBT
36VAC BOARD
VOLTAGE FEEDBACK
PEAK
CONTROL METER
(STT II ONLY)
10VAC AND 6VAC
42VAC
RECONNECT, PROTECTION
BOARD, RECTIFICATION AND
PRECHARGE
The reconnect panel allows the user to switch to low or
high input voltage to match the input line voltage. The
AC input voltage is rectified and applied to the driver
board. The driver board contains precharging circuitry
for safe charging of the input filter capacitors. Once the
capacitors are precharged, the input relays are ener-
gized, connecting full input power to the input filter
capacitors. The protection board monitors the capaci-
tors for voltage balance and/or overvoltage and will de-
energize the input relays and precharge circuitry if
either occurs. The machine output will be disabled.
INVERTEC STT
E-4 E-4
THEORY OF OPERATION
FIGURE E.4 SWITCH BOARDS
POSITIVE
OUTPUT
TERMINAL
MAIN
TRANSFORMER 1 OHM
T2

W FET
I A TERMINAL
T CAP
C R
H FET D
CHOKE
R VOLTAGE
PRE - SENSING
CHARGE E
M
SWITCH RECTIFIER R
P D O
E B D
CR1 R B R T
C O R O REMOTE
CURRENT I E
E A V T3
E P O RECEPTACLE
N C R
N T R E R A
S
I D I O
E D R R
O G T
C N N
E D
T A
"A" C
LEAD L
PRE -
CR2 CHARGE T WIRE
18 I FEEDER
FAN TRANS VAC P B S
FET
B O RECEPTACLE
T1 O O W O
I N
115
W A CAP A
E R T
VAC 2 C R
4 R D FET
V H D
A
TRANS C
E
R PWM SIGNAL
M
O
S 15VDC
T
A
T GUN TRIGGER
IGBT
36VAC BOARD
VOLTAGE FEEDBACK
PEAK
CONTROL METER
(STT II ONLY)
10VAC AND 6VAC
42VAC
SWITCH BOARDS
There are two switch boards in the Invertec STT, each
containing an input filter capacitor. The capacitors are
connected in parallel when the machine is connected
for "low" input voltage. The capacitors are connected
in series when the reconnect switch is configured for
"high" input voltage. When the capacitors are fully
charged, they act as power supplies for the switch
boards. The switch boards contain the Field Effect
Transistors (FETs) which, when switched on, supply
the main transformer primary windings with DC current
flow. See Field Effect Transistor (FET) Operation
discussion and diagrams. See Figure E.4.
INVERTEC STT
E-5 E-5
THEORY OF OPERATION
FIGURE E.5 MAIN TRANSFORMER, OUTPUT RECTIFICATION AND CHOKE
POSITIVE
OUTPUT
TERMINAL
MAIN
TRANSFORMER 1 OHM
T2

W FET
I A TERMINAL
T CAP
C R
H FET D
CHOKE
R VOLTAGE
PRE - SENSING
CHARGE E
M
SWITCH RECTIFIER R
P D O
E B D
CR1 R B R T
C O R O REMOTE
CURRENT I E
E A V T3
E P O RECEPTACLE
N C R
N T R E S R A
D
E I I O
O D R G R
C T
N N D
T A E
"A" C
LEAD L
PRE -
CR2 CHARGE T WIRE
18 I FEEDER
FAN TRANS VAC P B S
FET
B O RECEPTACLE
T1 O O W O
I N
115
W A CAP A
E R T
VAC 2 C R
4 R D FET
V H D
A
TRANS C
E
R PWM SIGNAL
M
O
S 15VDC
T
A
T GUN TRIGGER
IGBT
36VAC BOARD
VOLTAGE FEEDBACK
PEAK
CONTROL METER
(STT II ONLY)
10VAC AND 6VAC
42VAC
MAIN TRANSFORMER, OUTPUT

RECTIFICATION AND CHOKE
Each switch board works as a switch pair. Each board The firing of both switch board pairs occurs during
feeds a separate, oppositely wound primary winding of halves of 50 microsecond intervals, creating a constant
the main transformer. The opposite directions of cur- 20 KHZ output.
rent flow through the main transformer primary and the The AC output from the main transformer secondary is
offset timing of the switch boards induce an AC square rectified to a DC output and is applied through a stabi-
wave output signal at the secondary of the main trans- lizer output choke, current sensor, IGBT module and
former. remote protection board to the output terminals.
The DC current flow through each primary winding,
which is monitored by the current transformer T3, is
redirected or "clamped" back to each respective input
capacitor when the FETs are turned off. This is need-
ed due to the inductance of the transformer primary
windings. The cross coupling of the primaries along
with the clamping action of the diode maintain capaci-

tor balance when they are connected in the series (high
voltage) input configuration.
INVERTEC STT
E-6 E-6
THEORY OF OPERATION
FIGURE E.6 CONTROL BOARD, IGBT DRIVE AND MODULE
POSITIVE
OUTPUT
TERMINAL
MAIN
TRANSFORMER 1 OHM
T2

W FET
I A TERMINAL
T CAP
C R
H FET D
CHOKE
R VOLTAGE
PRE - SENSING
CHARGE E
M
SWITCH RECTIFIER R
P D O
E B D
CR1 R B R T
C O R O REMOTE
CURRENT I E
E A V T3
E P O RECEPTACLE
N C R
E R A
N T R S
I D I O
E D R R
O G T
C N N
E D
T A
"A" C
LEAD L
PRE -
CR2 CHARGE T WIRE
18 I FEEDER
FAN TRANS VAC P B S
FET
B O RECEPTACLE
T1 O O W O
I N
115
W A CAP A
E R T
VAC 2 C R
4 R D FET
V H D
A
TRANS C
E
R PWM SIGNAL
M
O
S 15VDC
T
A
T GUN TRIGGER
IGBT
36VAC BOARD
VOLTAGE FEEDBACK
PEAK
CONTROL METER
(STT II ONLY)
10VAC AND 6VAC
42VAC
CONTROL BOARD, IGBT DRIVE

AND MODULE
The control board monitors the directives of the various The control board also determines when the IGBT
controls and compares these commands to the current module should be switched OFF to reduce weld spat-
and voltage feedback information received from the ter and fumes. The appropriate signal is sent to the
current sensor and voltage sensing receptacle. This IGBT drive board which then applies, or removes, the
data is processed and the suitable PWM signal is sent gate drive signal to the IGBT module. When the IGBT
to the power board. (See Pulse Width Modulation module is in the OFF state, the welding current must
discussion). pass through the one ohm resistance. This reduces
the current and, subsequently, spatter and fumes.
INVERTEC STT
E-7 E-7
THEORY OF OPERATION
FIGURE E.7 POWER BOARD AND REMOTE PROTECTION BOARD
POSITIVE
OUTPUT
TERMINAL
MAIN
TRANSFORMER 1 OHM
T2

W FET
I A TERMINAL
T CAP
C R
H FET D
CHOKE
R VOLTAGE
PRE - SENSING
CHARGE E
M
SWITCH RECTIFIER R
P D O
E B D
CR1 R B R T
C O R O REMOTE
CURRENT I E
E A V T3
E P O RECEPTACLE
N C R
N T R E S R A
D
I I O
E D R R
O G T
C N N
E D
T A
"A" C
LEAD L
PRE -
CR2 CHARGE T WIRE
18 I FEEDER
FAN TRANS VAC P B S
FET
B O RECEPTACLE
T1 O O W O
I N
115
W A CAP A
E R T
VAC 2 C R
4 R D FET
V H D
A
TRANS C
E
R PWM SIGNAL
M
O
S 15VDC
T
A
T GUN TRIGGER
IGBT
36VAC BOARD
VOLTAGE FEEDBACK
PEAK
CONTROL METER
(STT II ONLY)
10VAC AND 6VAC
42VAC
POWER BOARD REMOTE PROTECTION BOARD

The power board creates a pulse transformer drive sig- The remote protection board provides noise suppres-
nal, which is derived from the PWM signal received sion and by-pass filtering to protect the internal circuit-
from the control board. See Pulse Width Modulation ry of the STT machine.
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).
INVERTEC STT
E-8 E-8
THEORY OF OPERATIONS
FIGURE E-8 FIELD EFFECT TRANSISTOR OPERATION

GATE
SOURCE TERMINAL DRAIN
TERMINAL (0 VOLTS) TERMINAL
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 semiconduc- Drawing B above shows the FET in an active mode.
tors well suited for high-frequency switching. When the gate signal, a positive DC voltage relative to
the source, is applied to the gate terminal of the FET, it
Drawing A above shows an FET in a passive mode. is capable of conducting current. A voltage supply con-
There is no gate signal, zero volts relative to the source nected to the drain terminal will allow the FET to con-
and, therefore, no current flow. The drain terminal of duct and henceforth supply current to downstream
the FET may be connected to a voltage supply; but components. Current will flow through the conducting
since there is no conduction, the circuit will not supply FET to downstream components as long as the gate
current to downstream components connected to the signal is present. This is similar to turning on a light
source. The circuit is turned off like a light switch in the switch.
OFF position.
INVERTEC STT
E-9 E-9
THEORY OF OPERATION
FIGURE E-9 TYPICAL FET OUTPUTS
sec 48 sec sec

50 sec
MINIMUM OUTPUT
24 sec
2 sec 24 sec
50 sec
MAXIMUM OUTPUT
PULSE WIDTH MODULATION The positive portion of the signal represents one FET
group1 conducting for 1 microsecond. The negative
The term PULSE WIDTH MODULATION is used to portion is the other FET group1. The dwell time (off
describe how much time is devoted to conduction in
time) is 48 microseconds (both FET groups off). Since

the positive and negative portions of the cycle. only 2 microseconds of the 50-microsecond time peri-
Changing the pulse width is known as MODULATION. od is devoted to conducting, the output power is mini-
Pulse Width Modulation (PWM) is the varying of the mized.
pulse width over the allowed range of a cycle to affect
the output of the machine. MAXIMUM OUTPUT
MINIMUM OUTPUT By holding the gate signals on for 24 microseconds
each and allowing only 2 microseconds of dwell time
By controlling the duration of the gate signal, the FET (off time) during the 50-microsecond cycle, the output
is turned on and off for different durations during a is maximized. The darkened area under the top curve
cycle. The top drawing above shows the minimum out- can be compared to the area under the bottom curve.
put signal possible over a 50-microsecond time period. The more dark area under the curve, the more power
is present.
1
A FET group consists of the sets of FET modules grouped onto
one switch board.
INVERTEC STT
E-10 E-10
THEORY OF OPERATION
PROTECTIVE CIRCUITS THERMAL PROTECTION

Protective circuits are designed into the Invertec Thermostats protect the machine from excessive oper-
machine to sense trouble and shut down the machine ating temperatures. Excessive temperatures may be
before the trouble damages the internal machine com- caused by a lack of cooling air or operating the
ponents. Both overload and thermal protection circuits machine beyond the duty cycle and output rating. If
are included. excessive operating temperature should occur, the
thermostat will prevent output voltage or current. The
meter will remain on during this time. (In addition, the
OVERLOAD PROTECTION yellow thermo LED will light.)
The machine is electrically protected from producing Thermostats are self-resetting once the machine cools
abnormally high output currents due to short electrode sufficiently. If the thermostat shutdown was caused by
stick-out or the nozzle shorting to the work. Should excessive output or duty cycle and the fan is operating
the output current exceed 500 amps, an electronic pro- normally, the Power Switch may be left on and the
tection circuit will reduce the current to zero amps. reset should occur within a 15-minute period. If the fan
is not turning or the air intake louvers were obstructed,
Five seconds after the short is removed the Invertec

STT will produce normal output. then the power must be switched off for 15 minutes in
order to reset. The fan problem or air obstruction must
A protection circuit is included to monitor the voltage also be corrected.
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 out-
put, if any of these circumstances occur:
1. Capacitor conditioning is required
(Required if machine has been off for prolonged
periods of time.)
2. Line surges over 500 VAC
3. Internal Component damage
4. Improper connections
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 F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
This Troubleshooting Guide is provided to help Step 3. PERFORM COMPONENT TESTS. The
you locate and repair possible machine malfunc- last column, labeled Recommended Course of
tions. Simply follow the three-step procedure list- Action lists the most likely components that may
ed below. have failed in your machine. It also specifies the
appropriate test procedure to verify that the sub-

Step 1. LOCATE PROBLEM (SYMPTOM). Look
ject component is either good or bad. If there are
under the column labeled PROBLEM (SYMP-
a number of possible components, check the
TOMS). This column describes possible symp-
components in the order listed to eliminate one
toms that the machine may exhibit. Find the list-
possibility at a time until you locate the cause of
ing that best describes the symptom that the
your problem.
machine is exhibiting. Symptoms are grouped
into two main categories: Output Problems, and All of the referenced test procedures referred to in
Welding Problems. the Troubleshooting Guide are described in detail
at the end of this chapter. Refer to the
Step 2. PERFORM EXTERNAL TESTS. The
Troubleshooting and Repair Table of Contents to
second column, labeled POSSIBLE AREAS OF
locate each specific Test Procedure. All of the
MISADJUSTMENT(S), lists the obvious external
referred to test points, components, terminal
possibilities that may contribute to the machine
strips, etc., can be found on the referenced elec-
symptom. Perform these tests/checks in the order
trical wiring diagrams and schematics. Refer to
listed. In general, these tests can be conducted
the Electrical Diagrams Section Table of
without removing the case wrap-around cover.
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 pre-
sent, which are floating off case ground (floating ground). Connecting the ground lead of a test probe
(which may be connected to the case of the test equipment) to a high voltage potential presents a shock
hazard as well as the possibility of damage to the equipment in question.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call1-888-935-3877.
INVERTEC STT
F-3 F-3
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING Remove the PC Board from the static-shielding bag

and place it directly into the equipment. Dont set the
ELECTRIC SHOCK can kill. PC Board on or near paper, plastic or cloth which
could have a static charge. If the PC Board cant be
Have an electrician install and service installed immediately, put it back in the static-shielding
this equipment. Turn the machine OFF bag.
before working on equipment. Do not
touch electrically hot parts. 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
Sometimes machine failures appear to be due to PC Company for credit, it must be in the static-shielding
board failures. These problems can sometimes be bag. This will prevent further damage and allow prop-
traced to poor electrical connections. To avoid prob- er failure analysis.
lems when troubleshooting and replacing PC boards,
please use the following procedure: 4. Test the machine to determine if the failure symp-
tom has been corrected by the replacement PC
board.
1. Determine to the best of your technical ability that NOTE: Allow the machine to heat up so that all electri-
the PC board is the most likely component causing cal components can reach their operating tem-
the failure symptom. perature.
2. Check for loose connections at the PC board to 5. Remove the replacement PC board and substitute
assure that the PC board is properly connected. it with the original PC board to recreate the original
3. If the problem persists, replace the suspect PC problem.
board using standard practices to avoid static elec- a. If the original problem does not reappear
trical damage and electrical shock. Read the warn- by substituting the original board, then the
ing inside the static resistant bag and perform the PC board was not the problem. Continue
following procedures: to look for bad connections in the control
PC Board can be damaged by wiring harness, junction blocks, and termi-
static electricity. nal strips.
Remove your bodys static charge b. If the original problem is recreated by the
before opening the static-shielding substitution of the original board, then the
bag. Wear an anti-static wrist PC board was the problem. Reinstall the
strap. For safety, use a 1 Meg replacement PC board and test the
ATTENTION machine.
Static-Sensitive ohm resistive cord connected to a
Devices grounded part of the equipment 6. Always indicate that this procedure was followed
Handle only at frame. when warranty reports are to be submitted.
Static-Safe
Workstations
If you dont have a wrist strap, NOTE: Following this procedure and writing on the
touch an unpainted, grounded, warranty report, INSTALLED AND
part of the equipment frame. Keep SWITCHED PC BOARDS TO VERIFY PROB-
Reusable touching the frame to prevent sta- LEM, will help avoid denial of legitimate PC
Container tic build-up. Be sure not to touch board warranty claims.
Do Not Destroy any electrically live parts at the
same time.
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 TROUBLESHOOTING GUIDE

detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage 1. Contact your local Lincoln 1. Contact the Lincoln Electric
is evident. Authorized Field Service Service Department, 1-888-935-
Facility. 3877.
Machine has no open circuit volt- 1. Check the control cable 1. Perform the T1 Auxiliary
age. Wire feeds OK. between the feeder and the Transformer Test.
STT unit. Make sure the #2 and

2. Perform the T4 Auxiliary
#4 leads are intact.
Transformer Test.
2. Put a jumper wire between Pins
3. Perform the Power Board Test.
"C" and "D" on the 14 pin
amphenol. If normal open cir- 4. Perform the Trigger Circuit
cuit voltage (85VDC) is Test.
restored, the problem is in the
5. Perform Capacitor Balance
feeder control cable or the wire
Test.
feeder.
6. Perform the Protection Board
3. Make sure the reconnect switch
Test.
S7 is in the correct position for
the three-phase input voltage 7. Perform the Switch Board
being applied. Test.
8. Check for loose or broken con-
CAUTION nections on the heavy current
carrying conductors (i.e., main

Do not switch reconnect switch transformer, choke, output
with input power applied to diodes, IGBT module and out-
machine. put terminals).
9. The control PC board may be
faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
INVERTEC STT
F-5 F-5
TROUBLESHOOTING GUIDE Observe Safety Guidelines

OUTPUT PROBLEMS
Machine has no welding output (no 1. The 42VAC circuit breaker CB1 1. If 42VAC is NOT present at pins
open circuit voltage), and the wire may be tripped. Reset if neces- "K" and "I" on the 14 pin amphe-
feeder does not feed wire when the sary. nol, perform the T1 Auxiliary
gun trigger is pulled. Transformer Test.
2. Check the 4 amp slow blow fuse
located on the reconnect panel. 2. Check leads #43 and #212C for
Replace if faulty. loose or faulty connections
between the T1 auxiliary trans-
3. Put a jumper between pins "A"
former and the remote protec-
and "C" on the 5 pin amphenol
tion board. See the Wiring

located on the LN-742 wire
Diagram. Also check the conti-
feeder. If wire feeds, check the
nuity through the remote protec-
gun trigger. Repair or replace if
tion board to the 14 pin amphe-
necessary.
nol. See the Remote Protection
4. Check for the presence of Board Schematic.
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.
CAUTION
Call 1-888-935-3877.
INVERTEC STT
F-6 F-6


OUTPUT PROBLEMS
Machine is dead - no output - no 1. The power switch must be in the 1. The input power switch (S1)
fan - no display. "ON" position. may be faulty. Check or
replace.
2. Check the input voltage. Make
sure all three phases are 2. Perform the T1 Auxiliary
applied to the machine. Transformer Test.
3. With input power removed,
check that the input voltage set-
up switch and jumper "A" (the

reconnect auxiliary jumper) are
in the proper position for the
input voltage being used.
4. With input power removed,
check the continuity of the 4
amp slow blow fuse located on
the reconnect panel.
No output or reduced output the 1. Check input voltages, fuses and 1. Contact the Lincoln Electric
first time power is applied to the input voltage reconnect proce- Service Department. 1-888-935-
machine. dures. See the Installation 3877.
section.
2. If high input voltage (380VAC or
higher) is applied, the capaci-

tors may need conditioning. Let
the "unloaded" machine idle for
30 minutes.
CAUTION
Call 1-888-935-3877.
INVERTEC STT
F-7 F-7


OUTPUT PROBLEMS
No output. Main fuses are open, 1. With the input power removed, 1. Check the input power switch
indicating excessive current draw. inspect input leads for possible (S1) and the reconnect switch
shorts or grounds or miscon- for "shorted" or "grounded"
nections. wires or connections.
2. Install new fuses and reapply 2. Perform the Input Rectifier
power. If fuses open again, Test.
contact your local Lincoln
3. Perform the Switch Board
Authorized Field Service
Test.
Facility.
Machine loses output when gun 1. The overcurrent sensor is acti- 1. The current sensor may be
trigger is pulled or arc is struck. vated, indicating that too much faulty.
Machine output returns after a few output current is being drawn
seconds and trigger is pulled again. from the machine. Reduce
faulty.
The thermal indicator light is lit. 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 pro-
cedures are being used.
CAUTION
Call 1-888-935-3877.
INVERTEC STT
F-8 F-8


OUTPUT PROBLEMS
Machine loses output while weld- 1. Check to make sure the fan is 1. The IGBT heat sink thermostat
ing. The thermal indicator light is running and operating correctly. or fan thermostat may be defec-
lit. Normal welding output returns tive. Check or replace.
2. Welding application may
after about 10 minutes.
exceed recommended duty
cycle.
3. Dirt and dust may have clogged
the cooling channels. Blow out
the unit with clean, dry com-

pressed air.
4. Air intake and exhaust louvers
may be blocked due to inade-
quate clearance around the
machine.
CAUTION
Call 1-888-935-3877.
INVERTEC STT
F-9 F-9

WELDING PROBLEMS
Porosity in the weld. 1. Make sure the gas type and 1. Contact the Lincoln Electric
flow rate is correct for the pro- Service Department. 1-888-935-
cedure being used. Shield the 3877.
work from excessive outside air
currents.
2. Check the gun and nozzle for
leaks or obstructions.
3. Make certain the machine and
wire feed settings are correct for

the process.
CAUTION
Call 1-888-935-3877.
INVERTEC STT
F-10 F-10

WELDING PROBLEMS
Weld bead appears "cold." 1. One or more of the machine 1. Check for the correct open cir-
settings may be wrong. Check cuit voltage (approximately
the Background, Peak Current, 85VDC). If the correct open cir-
Tailout (STT II Only), and Wire cuit voltage IS present, the
Speed controls for proper set- Background control (R12) or
tings. Adjust for optimum weld- the Peak Current (R11) and
ing performance. associated wiring may be faulty.
See the Wiring Diagram. The
2. Make sure the Wire Type and
control PC board may be faulty.
Wire Size switches are in the
Also check for loose or faulty

correct position for the elec-
connections on the heavy cur-
trode wire being used.
rent carrying conductors (i.e.,
main transformer, choke, output
diodes, IGBT module and out-
put terminals).
2. If the correct open circuit volt-
age is NOT present, perform
the Switch Board Test.
3. The output diodes may be
faulty. Check or replace if nec-
essary.
4. The driver PC board and or
control PC board may be faulty.
5. The IGBT module may be
faulty. Check or replace.

CAUTION
Call 1-888-935-3877.
INVERTEC STT
F-11 F-11


WELDING PROBLEMS
Molten weld puddle appears exces- 1. The Wire Type switch may be in 1. The IGBT module may be faulty.
sively "violent." the wrong position for the elec- Check or replace.
trode wire being used.
2. The IGBT driver PC board may
2. The Peak Current or Back- be faulty.
ground Setting may be too high.
Adjust for optimum welding per-
faulty.
formance.
3. The Tailout may not be set cor-

rectly for the process. (STT II
Only)
CAUTION
Call 1-888-935-3877.
INVERTEC STT
F-12 F-12

WELDING PROBLEMS
Excessive weld spatter. Arc 1. Check the Arc Sense leads for 1. The IGBT module may be faulty.
sounds and looks like a standard loose or faulty connections. Check or replace.
MIG process.
2. Make sure the Arc Sense 2. The IGBT driver PC board may
"WORK" lead is as close as be faulty.
possible to the welding arc.
3. Make sure the machine and faulty.
wire feed settings are correct for
the process and wire being
used.
Poor welding, weld settings drift, or 1. Make sure the machine settings 1. The current sensor may be
output power is low. are correct for the welding faulty. Check associated leads
process being used. for loose or faulty connections.
2. Check the welding cables for 2. The control PC board may be
loose or faulty connections. faulty.
3. Make sure the reconnect switch
S7 is in the correct position for
the three-phase input voltage
being applied.
CAUTION
Do not switch reconnect switch with

input power applied to machine.
CAUTION
Call 1-888-935-3877.
INVERTEC STT
F-13 F-13
T1 AUXILIARY TRANSFORMER TEST

WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting 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
Note: Component locations and disassembly procedures may

vary slightly on STT II models
INVERTEC STT
F-14 F-14
T1 AUXILIARY TRANSFORMER TEST (continued)

FIGURE F.1 T1 AUXILIARY TRANSFORMER AND J30/J31 LOCATION
PLUG
J30
PLUG
J31
T1 AUXILIARY
TRANSFORMER
TEST PROCEDURE
4. Locate the T1 auxiliary transformer and sec-

1. Turn off Invertec STT and disconnect main

AC input power to the machine. ondary lead molex plugs (J30 and J31) on
the left side, just in front of the main trans-
2. Using the 5/16" nut driver, remove the case former assembly. Check for broken or loose
wraparound cover. wires. See Figure F.1.
3. Perform the Input Filter Capacitor
Discharge Procedure. See the
Maintenance section.
WARNING
Before continuing with
the test procedure, per-
form the capacitor dis-
charge procedure to
avoid electric shock.
INVERTEC STT
F-15 F-15

FIGURE F.2 PRIMARY LEAD PLUG J21 LOCATION
PLUG J21
LOCATION BEHIND
RECONNECT PANEL
RECONNECT
PANEL
5. Locate the primary lead molex plug (J21) 7. Apply the correct input power to the machine
just behind the reconnect panel assembly on and test for the correct secondary voltages
the right side of the machine. Check for bro- at plugs J30 and J31. (Make sure the recon-
ken or loose wires. See Figure F.2. nect panel is configured properly for the
input voltage being applied.) See Table F.1.

6. Disconnect plugs J30 and J31 from the
wiring harness.
WARNING
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 F-16

8. If the correct secondary voltages are present 13. Gain access to the primary lead plug J21 by
(according to Table F.1), the T1 transformer removing the reconnect panel assembly
is functioning properly. from the upper support panel using the 3/8"
wrench and slot head screwdriver. This will
9. If the secondary voltages are missing or
allow the reconnect panel assembly to be
incorrect, the primary voltages must be
moved out of the way. Be careful NOT to
checked.
stress the leads connected to the reconnect
10. Remove input power to the STT machine. panel. See Figure F.2.
11. Perform the Input Filter Capacitor 14. Before applying input power make certain
Discharge Procedure. the reconnect panel assembly is insulated
and supported for safe operation.
12. Reconnect Plugs J30 & J31.
WARNING

charge procedure to
TABLE F.1 T1 AUXILIARY TRANSFORMER VOLTAGES
TEST POINTS NORMAL VOLTAGE
PLUG J30 PINS 1 TO 2 115VAC

(LEADS 32 TO 33)

(LEADS 501 TO 504)

(LEADS 212 TO 503)

(LEADS 212 TO 43A)
PLUG J21 PINS 1 TO 4 200/208VAC

(LEADS H1 TO H2)
PLUG J21 PINS 1 TO 2 220/230VAC

(LEADS H1 TO H3)
PLUG J21 PINS 1 TO 3

380/415VAC
(LEADS H1 TO H4)
PLUG J21 PINS 1 TO 6

(LEADS H1 TO H5) (H6) 440/460VAC
NOTE: If the main AC input supply voltage varies, the auxiliary transformer voltages will vary by
the same percentages.
INVERTEC STT
F-17 F-17

15. Apply the correct input power and carefully
WARNING test for the correct primary voltages at plug
J21. See Table F.1.
ELECTRIC SHOCK can kill. 16. If the correct AC input voltages are applied
With input power ON, to the primary windings and any or all of the
there are high voltages secondary voltages are missing or not cor-
inside the machine. Do rect, the T1 auxiliary transformer may be
not reach into the faulty.
17. After all tests are complete, reconnect plugs
internal part.
J30 and J31.
18. Install the case wraparound cover.
INVERTEC STT
F-18
NOTES
INVERTEC STT
F-18
F-19 F-19
T4 AUXILIARY TRANSFORMER TEST
WARNING
Unauthorized repairs performed on this equipment may result in danger to the technician or
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-
trical shock, please observe all safety notes and precautions detailed throughout this manual.
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the correct voltages are being:
a. applied to the primary of the T4 auxiliary transformer.
b. induced on the secondary windings of the T4 auxiliary transformer.
MATERIALS NEEDED
Volt/Ohmmeter (Multimeter)
Invertec STT Wiring Diagrams
Isolated 115VAC supply
5/16" Nut driver
7/16" Wrench

INVERTEC STT
F-20 F-20
FIGURE F.3 OUTPUT CHOKE/IGBT MODULE SPLICED CONNECTION

OUTPUT CHOKE/
LOWER DARLINGTON MODULE
TRAY SPLICED CONNECTION
AREA
TEST PROCEDURE WARNING

1. Turn off the Invertec STT and disconnect
main AC input power to the machine. ELECTRIC SHOCK can kill.
2. Using the 5/16" nut driver, remove the case Before continuing with
wraparound cover. the test procedure, per-
3. Perform the Input Filter Capacitor charge procedure to
Discharge Procedure. See the avoid electric shock.
4. Locate the lead connection splice from the

output choke to the IGBT module. Remove
the insulating sleeve. Cut any necessary

cable ties. Using the 7/16" wrench, discon-
nect the lead splice. Thread the lower lead
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
OUTPUT CHOKE/
LOWER DARLINGTON MODULE
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.
PLUG J22
6. Locate and disconnect plug J22 from the

wiring harness. See Figure F.5.
INVERTEC STT
F-22 F-22
FIGURE F.6 STT ON ITS RIGHT SIDE
MOUNTING
BOLTS (5)
7. Carefully lift and tilt the Invertec STT 9. Carefully slide out and support the lower tray
machine onto its right side. See Figure F.6. assembly for testing purposes.
8. Using the 7/16" wrench, remove the five 10. Locate and remove plug J13 from the
bolts holding the lower tray assembly to the IGBT drive board. See Figure F.7.
case bottom.
IGBT
DRIVE BOARD
PLUG J13
T4 AUXILIARY
TRANSFORMER
STT II
INVERTEC STT
F-23 F-23
FIGURE F.8 T4 TRANSFORMER LEAD CONNECTIONS
LEADS
T4 AUXILIARY 32A, 32B, 33A, 33B
TRANSFORMER
LEADS
32A, 32B, 33A, 33B T4 AUXILIARY
TRANSFORMER
STT STT II
11. Locate and remove leads #32A, #32B and 12. Carefully apply the 115VAC isolated supply
#33A, #33B from the T4 transformer tabs. to the T4 transformer at the #32 and #33
See Figure F.8. tabs.
WARNING

not reach into the
internal part.
INVERTEC STT
F-24 F-24
TABLE F.2 T4 AUXILIARY TRANSFORMER VOLTAGES
TEST POINTS NORMAL VOLTAGES

(LEADS 240 TO 241)

(LEADS 241 TO 242)

(LEADS 243 TO 244)

(LEADS 245 TO 246)
13. Check the secondary AC voltages accord- 15. After all tests are completed, reconnect the
ing to Table F.2. following:
14. With the correct 115VAC applied to the pri- Leads #32A, #32B, #33A, #33B to the
mary winding (#32 to #33), if any or all of T4 transformer tabs
the secondary voltages are missing or low,
Plug J13 to the IGBT drive board
the T4 auxiliary transformer may be faulty.
Replace the T4 auxiliary transformer. Plug J22 to the wiring harness

Reinstall lower tray assembly using

7/16 wrench and 5 bolts
Plug J1 to the control PC board
Reconnect lead splice from the output
choke to the IGBT module. Reposition
insulating sleeve.
INVERTEC STT
F-25 F-25
INPUT RECTIFIER TEST
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

INVERTEC STT
F-26 F-26
INPUT RECTIFIER TEST (continued)
FIGURE F.9 - INPUT RECTIFIER LOCATION
INPUT
RECTIFIER
A B C
9 12
TEST PROCEDURE 4. Locate the input rectifier. See Figure F.9.
1. Turn off the Invertec STT and disconnect 5. Locate the leads needed to perform the
main AC input power to the machine. tests. See Figure F.9.
2. Using the 5/16" nut driver, remove the case 6. Use an ANALOG ohmmeter to perform the
wraparound cover. tests shown in Table F.3.

Discharge procedure. See the
WARNING

charge procedure to
INVERTEC STT
F-27 F-27
INPUT RECTIFIER TEST (continued)
TABLE F.3 INPUT RECTIFIER TEST
TEST POINTS
+PROBE -PROBE ACCEPTABLE METER READING
9 A Greater than 100K ohms
9 B Greater than 100K ohms
9 C Greater than 100K ohms
A 9 Less than 100 ohms
B 9 Less than 100 ohms
C 9 Less than 100 ohms
12 A Less than 100 ohms
12 B Less than 100 ohms

12 C Less than 100 ohms
A 12 Greater than 100K ohms
B 12 Greater than 100K ohms
C 12 Greater than 100K ohms
6. Replace the input rectifier when any of the 8. Test capacitors C1 and C2 and replace both
tests are NOT OK. capacitors if either is faulty.
NOTE: When installing a new input rectifier, NOTE: Faulty capacitors could be the reason
torque the mounting nuts (in a cross-tightening for input rectifier failure.
pattern) to 6 inch-pounds (.7 Nm). Torque ter-
Visually inspect the capacitors for leakage,
minals to 26 inch-pounds (3 Nm). PROCEED
damage, etc., and use appropriate test equip-
TO STEP 7 TO CHECK RELATED COMPO-
ment to determine component integrity.
NENTS.
9. Perform the Switch Board Test.

7. Inspect main power switch S1 and replace

if faulty. Go to step 8. 10. After all tests are completed, install the
case wraparound cover.
INVERTEC STT
F-28
NOTES
INVERTEC STT
F-28
F-29 F-29
CAPACITOR BALANCE TEST
WARNING
TEST DESCRIPTION
This test will help determine if the capacitors, bleeder resistors and switch boards are func-
tioning properly.
MATERIALS NEEDED
5/16" Nut driver
Analog Volt/ohmmeter (Multimeter)

INVERTEC STT
F-30 F-30
CAPACITOR BALANCE TEST (continued)

FIGURE F.10 SWITCH BOARD TEST POINTS
9 12
L8441 SWITCH
TEST PROCEDURE NOTE: This test should only be conducted

when the machine reconnect switch and
1. Turn off the Invertec STT and disconnect jumper are set for high voltage (above
main AC input power to the machine. 380VAC) and the proper line voltage is applied.
2. Using the 5/16" nut driver, remove the 4. Test for VDC across terminals #9 and #12 of
case wraparound cover. one switch board and repeat the test for the
other switch board. See Table F.4 in this
procedure for expected voltage readings.
WARNING See Figure F.10.
ELECTRIC SHOCK can kill. A. If less than 25VDC difference is mea-

sured between each switch board, the
With input power ON, capacitive balance is OK. This indi-
there are high voltages cates that capacitors C1, C2, and resis-
inside the machine. Do tors R1 and R9 are functioning proper-
not reach into the ly. Proceed to Step #5.
internal part. B. If more than 25VDC difference is mea-

sured between each switch board, test
each of the following components:
Capacitors C1, C2 and resistors R1
3. Carefully apply the correct input power to
and R9. See the Invertec STT Wiring
the machine.
Diagram.
INVERTEC STT
F-31 F-31
CAPACITOR BALANCE TEST (continued)
TABLE F.4 EXPECTED VOLTAGE READINGS
If VAC Input is: VDC at terminals #9 (+) and #12 (-)

should be approximately:
460 VAC 325VDC
440 VAC 311VDC
415 VAC 293VDC
380 VAC 269VDC
5. Adjust the Peak and Background controls to 8. After all tests are completed, remove the
the minimum settings (controls on case jumper between pins C and D on the 14-pin
front). amphenol.
6. Jumper together pins "C" and "D" on the 14 9. Install the case wraparound cover.
pin amphenol. This will energize the output
terminals.
7. Test for VDC across terminals #9 and #12 of
one switch board and repeat the test for the
other switch board. See Table F.4 in this
procedure for expected voltage readings.
See Figure F.10.
A. If less than 15VDC difference is mea-
test is OK.
B. If more than 15VDC difference is mea-
switch board(s) and or power PC board

may be faulty. Perform the Switch
Board Test. Perform the Power Board
Test.
INVERTEC STT
F-32
NOTES
INVERTEC STT
F-32
F-33 F-33
SWITCH BOARD TEST
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
5/16" Nut driver

INVERTEC STT
F-34 F-34
SWITCH BOARD TEST (continued)
FIGURE F.11 - SWITCH BOARD RESISTANCE TEST


NOTE: There are two switch boards. One is
located on each side of the machine. ELECTRIC SHOCK can kill.
NOTE: The switch boards are designed to Before continuing with the
receive gate (turn-on) signals from the driver test procedure, perform
board (pulse transformer secondaries). The the capacitor discharge
internal board circuitry processes the signals and procedure to avoid electric
outputs them to the FETs. The switch board cir- shock.
cuitry contains snubber circuitry to protect the
FETs. This protection is supplemented by off-
board resistors. The switch board design accom- 4. Disconnect all wiring harness leads
modates the connection point(s) for the capaci- (401/403, 1/8, 9, 12, 4/5, 402/404) from the
tor(s), main transformer primary windings, input switch board.
rectifier, and reconnect switches. 5. Fold the leads up so they do not interfere with
1. Turn off Invertec STT and disconnect main the exposed terminals. See Figure F.11.
AC input power to the machine. 6. Using an analog ohmmeter, perform the resis-
2. Using the 5/16" nut driver, remove the case tance tests detailed in Table F.5 and shown in
wraparound cover. Figure F.11. If any test fails, replace both
3. Perform the Input Filter Capacitor switch boards. See the Switch Board
Discharge Procedure. See the Removal and Replacement procedure.
Maintenance section. 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 Apply Negative

Test Probe to Test Probe to
Terminal Terminal Test Result Conclusion Repair Action Next Procedure Notes
1/8 12 Greater than OK None Continue
1K ohm
Less than Shorted Replace both Snubber Test
100 ohms switch boards
12 1/8 Less than OK None Continue

100 ohms
Greater than Open Replace both Snubber Test
1K ohm switch boards
9 4/5 Greater than OK None Continue

1K ohm
4/5 9 Less than OK None Continue

100 ohms

100 ohms


1K ohm

100 ohms

1K ohm
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 Apply Negative

Test Probe to Test Probe to
Terminal Terminal Test Result Conclusion Repair Action Next Procedure Notes
1K ohm

100 ohms

100 ohms

1K ohm
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.
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
STT Wiring Diagrams
5/16 Nut driver

INVERTEC STT
F-38 F-38
SNUBBER RESISTORS TEST (continued)
FIGURE F.12 - REMOVING LEADS

TEST PROCEDURE 4. Locate and gain access to the switch board.

1. Turn off Invertec STT and disconnect main 5. Remove leads from terminals 401/403,
AC input power to the machine. 402/404 on the switch board. See Figure
2. Using the 5/16" nut driver, remove the case F.12.
wraparound cover.
Discharge Procedure. See the
WARNING
Before continuing with the
test procedure, perform
the capacitor discharge
procedure to avoid electric
shock.
INVERTEC STT
F-39 F-39
SNUBBER RESISTORS TEST (continued)
FIGURE F.13 - SWITCH BOARD TEST POINTS
401/403
401 9 12 402/404
12
L8441 SWITCH
6. Test for 25 ohms resistance from lead termi- 7. Repeat the same procedures to test R5, R6,
nal 401 to terminal 12 on the switch board. and R7 according to Table F.6.
See Figure F.13.
8. Reconnect leads 401/403 and 402/404 to the
a. If 25 ohms is measured, resistor R4 is OK. switch board.
b. If 30 ohms or more is measured, resistor 9. Install the case wraparound cover.

R4 is faulty and must be replaced.
c. If 20 ohms or less is measured, resistor
R4 is faulty and must be replaced.
TABLE F.6 SNUBBER RESISTORS TEST
Check Test Result Conclusion Next Test Step Repair Action
Lead 401 to 25 ohms OK Continue
Terminal 12 >30 ohms R4 open Replace R4
<20 ohms R4 faulty
<20 ohms R5 faulty

<20 ohms R6 faulty
<20 ohms R7 faulty
> = GREATER THAN < = LESS THAN
INVERTEC STT
F-40
NOTES
INVERTEC STT
F-40
F-41 F-41
POWER BOARD TEST
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 F-42
POWER BOARD TEST (continued)

FIGURE F.14 REMOVING THE FRONT PANEL ASSEMBLY
POWER
PC BOARD
(Located
on Back of
Case Front)
QUICK CHECK PROCEDURE OK. If the relays are NOT being activated, the
power PC board could be faulty. Continue
1. Turn off the Invertec STT and disconnect with the voltage tests.
main AC input power to the machine.
2. Using the 5/16" nut driver, remove the case
wraparound cover. VOLTAGE TEST PROCEDURE

3. Locate relays CR1 and CR2 just to the front of 1. Remove input power to the Invertec STT.
the fan motor.
2. Perform the Input Filter Capacitor Discharge
Procedure. See the Maintenance section.
WARNING
WARNING
With input power ON, ELECTRIC SHOCK can kill.
not reach into the machine
or touch any internal part.
shock.
4. Apply the correct input power and turn ON the
Invertec STT machine. 3. Using the 5/16" nut driver, loosen the front
5. After about a 5 second delay the relays control panel by removing the four sheet
should activate. This can be determined by metal screws from the top and bottom of the
an audible click which can be heard when the front panel. Carefully move the front panel
relays are activated. If the relays are being assembly to the right to gain access to the
activated, the power PC board is most likely power PC board. See Figure F.14.
INVERTEC STT
F-43 F-43

FIGURE F.15 POWER PC BOARD TEST POINTS
309 212A 301

310
302
POWER BOARD
L8033
J7 J14 311
313 J6 275
501 211A
305
504
4. Secure and insulate the front panel assembly 5. Apply the correct input power and turn ON the
for POWER ON testing. machine.
6. Carefully test for 18VAC input from the T1
Auxiliary Transformer between plug J7 pin 5
WARNING (lead#501) and plug J7 pin 6 (lead #504) at

the power PC board. See Figure F. 15.
NOTE: If the 18VAC is NOT present, perform
With input power ON, the T1 Auxiliary Transformer Test. Also check
there are high voltages associated wiring. See the Wiring Diagram.
not reach into the machine
or touch any internal part.
INVERTEC STT
F-44 F-44

FIGURE F.16 SIMPLIFIED TRIGGER CIRCUIT
POWER BOARD CONTROL BOARD
#301
7J6 11J4
FROM PROTECTION
BOARD OVERVOLTAGE
#305
2J6 3J4
PWM P
OUTPUTS W REMOTE
TO POWER
BOARD
M PROTECTION
BOARD
STT II Only
T1 AUXILIARY
14 AMPHENOL
TRANSFORMER #379
3.5 ohms
#224 #210 #223 #413
3J31 6J22 6J4 9J4 8J33 13J36 C
#503A
2
4
V TO 5J4
POWER
A BOARD
C 3.5 ohms
#212 #405
2J31 12J4 6J34 5J36 D
#212C
7. Carefully test for 15VDC output from the NOTE: If the 24VAC is present but the 24VDC is
power PC board at plug J6 pin1 (lead #275) NOT, the power PC board may be faulty.
(-) and plug J6 pin 6 (lead #302)(+). See
10. Carefully test for approximately 24VDC at
Figure F.15.
plug J7 pin 2 (lead#309)(+) to plug J7 pin 4
NOTE: If the 18VAC is present but the 15VDC is (lead#310)(-). If the 24VDC is NOT present,
NOT, the power PC board may be faulty. test for approximately 1VDC at plug J14 pin1
(lead#311)(+) to plug J14 pin 2 (lead#313)(-).
8. Carefully test for 24VAC input from the T1
See Figure F.15.
Auxiliary Transformer between plug J6 pin 4
(lead#211A) and plug J6 pin 9 (lead#212A). NOTE: If more than 1VDC is measured, perform
See Figure F.15. the Protection Board Test.
NOTE: If the 24VAC is NOT present, perform the NOTE: If approximately 1VDC IS present and
T1 Auxiliary Transformer Test. Also check the the 24VDC is NOT present at leads #309 to
associated wiring. See the Wiring Diagram. The #310, the power PC board may be faulty.
control PC board or thermostats may be faulty.
11. After all tests are completed, install the front
See Figure F.16, the Simplified Trigger Circuit
panel assembly.
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.
INVERTEC STT
F-45 F-45
PROTECTION BOARD TEST
WARNING
TEST DESCRIPTION
This test will help determine if the protection PC board is functioning properly.
MATERIALS NEEDED
5/16" Nut driver
Wiring Diagrams

INVERTEC STT
F-46 F-46
PROTECTION BOARD TEST (continued)

FIGURE F.17 PROTECTION PC BOARD TEST POINTS
L7915-[ ] PROTECTION
313 315
314
J8 J15
317
316
311

1. Turn off the Invertec STT and disconnect ELECTRIC SHOCK can kill.
main AC input power to the machine.
2. Using the 5/16" nut driver, remove the case there are high voltages
wraparound cover. inside the machine. Do
3. Perform the Input Filter Capacitor Discharge not reach into the
Procedure. See the Maintenance section. machine or touch any
internal part.
WARNING
5. Apply the correct input power and turn the
ELECTRIC SHOCK can kill. 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.

charge procedure to
avoid electric shock. A. If approximately 1VDC is present, the
protection PC board is functioning prop-
erly.
4. Locate the protection PC board just in front
B. If more than 5 VDC is measured, per-
of the input rectifier and relay mountings.
form the Capacitor Balance Test.
INVERTEC STT
F-47 F-47
PROTECTION BOARD TEST (continued)
FIGURE F.18 - LEADS #309, #309A AT CR1, CR2 RELAYS
CR2 CR1
309A 309
7. If the Capacitor Balance Test is OK and WARNING

more than 5VDC is present at leads #311 to
#313 (Step 6), the protection PC board may ELECTRIC SHOCK can kill.
be faulty.
NOTE: The above voltage checks pertain only there are high voltages
to the over voltage signal from the protection inside the machine. Do
PC board to the power PC board. The capaci- not reach into the machine
tor precharge circuits are also incorporated or touch any internal part.
within the protection PC board. If the problem

has not been identified, carefully proceed with 11. Apply correct input power and turn ON the
the following steps. machine.
8. Remove input power to the Invertec STT 12. Check for approximately 12VDC from plug
machine. J15 pin 1 (lead #314)(+) to plug J15 pin 4
(lead#315) (-). See Figure F.17.
Procedure. See the Maintenance section. 13. Check for approximately 12VDC from plug
J15 pin 3 (lead #316)(+) to plug J15 pin 6
WARNING (lead#317) (-). See Figure F.17.
ELECTRIC SHOCK can kill. 14. If a low voltage is present in either steps 12
or 13 (approximately 1VDC), perform the
Capacitor Balance Test.
form the capacitor dis- 15. If the Capacitor Balance Test is OK, the
charge procedure to protection PC board may be faulty.
16. Be certain to replace leads #309 and #309A

onto the CR1 and CR2 relays.
10. Locate and remove leads #309 and #309A
from CR1 and CR2 relays. See Figure 17. After all tests are completed, install the
F.18. case wraparound cover.
INVERTEC STT
F-48
NOTES
INVERTEC STT
F-48
F-49 F-49
TRIGGER CIRCUIT TEST
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
Wiring Diagram and board Schematics

INVERTEC STT
F-50 F-50
TRIGGER CIRCUIT TEST (continued)
PLUG
J31
TEST PROCEDURE
WARNING
1. Turn off the Invertec STT and disconnect main
AC input power to the machine. ELECTRIC SHOCK can kill.
2. Using the 5/16" nut driver, remove the case Before continuing with the
wraparound cover. test procedure, perform
3. Perform the Input Filter Capacitor procedure to avoid electric
Discharge Procedure. See the Maintenance shock.
section.
4. Locate plug J31 at the left side of the

machine. See Figure F.19.
INVERTEC STT
F-51 F-51

FIGURE F.20 14 PIN AMPHENOL AND PLUG J31 PIN ASSIGNMENTS
B
D
L
E
AJ
M
212
I
F
PLUG J31
G
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

STT CONTROL G2782-[ ]
223
J5 J17 J27 J28 J2 J3 J1 J4
210
6. Using the ohmmeter, check for approximately (lead#223) at the control PC board. See
3.5 ohms resistance from pin "C" of the 14 pin Figure F.21 and Figure F.22, Simplified
amphenol (see Figure F.20) to plug J4 pin 9 Trigger Circuit Diagram.
INVERTEC STT
F-52 F-52

FIGURE F.22 SIMPLIFIED TRIGGER CIRCUIT DIAGRAM
POWER BOARD CONTROL BOARD
#301
7J6 11J4
FROM PROTECTION
BOARD OVERVOLTAGE
#305
2J6 3J4
PWM P
OUTPUTS W REMOTE
TO POWER
BOARD
M PROTECTION
BOARD
STT II Only
T1 AUXILIARY
14 AMPHENOL
TRANSFORMER #379
3.5 ohms
#224 #210 #223 #413
3J31 6J22 6J4 9J4 8J33 13J36 C
#503A
2
4
V TO 5J4
POWER
A BOARD
C 3.5 ohms
#212 #405
2J31 12J4 6J34 5J36 D
#212C
7. Using the ohmmeter check for continuity (zero 9. Apply the correct input power to the machine
ohms) from plug J31 pin 3 (lead#503A) to plug and turn ON.
J4 pin 6 (lead#210). See Figure F.22,
10. Locate plug J6 on the power PC board. See
Simplified Trigger Circuit Diagram.
Figure F. 15. in the Power Board Test.

8. If any of the resistance checks are abnormal-
11. Carefully check for approximately 1VDC from
ly high in steps 5, 6 or 7, check for broken or
plug J6 pin 2 (lead #305)(+) to plug J6 pin 7
loose wires, connections or "open" ther-
(lead #301) (-). If the approximately 1VDC is
mostats. Also check the small inductors on
present the power PC board and protection
the Remote Protection Board. See Figure
PC board are functioning properly for the trig-
F.22, Simplified Trigger Circuit Diagram.
ger circuit to operate. If the correct DC volt-
age is NOT present, perform the Protection
WARNING Board Test and the Power Board Test.
ELECTRIC SHOCK can kill. 12. Test to make sure the T1 auxiliary trans-
former is producing 24VAC. See Figure F.22,
Simplified Trigger Circuit Diagram.
inside the machine. Do 13. If the above tests do not reveal the problem,
not reach into the machine the control PC board or associated wiring
or touch any internal part. may be faulty. See Figure F.22, Simplified
Trigger Circuit Diagram.
INVERTEC STT
F-53 F-53
IGBT MODULE
REMOVAL AND REPLACEMENT
WARNING
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 F-54
IGBT MODULE REMOVAL

AND REPLACEMENT (continued)
FIGURE F.23 OUTPUT CHOKE LEAD DISCONNECTION
OUTPUT CHOKE/
LOWER IGBT MODULE
AREA
PROCEDURE
1. Turn off the Invertec STT and disconnect main 4. Locate the lead connection splice from the
AC input power to the machine. output choke to the IGBT module. Remove
the insulating sleeve. Using the 7/16" wrench
2. Using the 5/16" nut driver, remove the case disconnect the lead splice. Thread the lower
wraparound cover. lead down into the lower tray assembly area.
3. Perform the Input Filter Capacitor See Figure F.23.
Discharge Procedure. See the Maintenance
section.
WARNING
shock.
INVERTEC STT
F-55 F-55
IGBT MODULE REMOVAL

FIGURE F.24 PLUG J1 DISCONNECTION
J1 CURRENT
SENSING PLUG
OUTPUT CHOKE/
LOWER IGBT MODULE
AREA
5. Disconnect the current sensing plug J1 from J1 and associated leads from the control PC
the control PC board. Carefully remove plug board compartment. See Figure F.24.

PLUG J22

INVERTEC STT
F-56 F-56
IGBT MODULE REMOVAL

FIGURE F.26 STT PLACED ON ITS RIGHT SIDE
MOUNTING
BOLTS (5)
7. Carefully lift and tilt the Invertec STT 11. Using the 1/2" wrench, remove the IGBT
machine onto its right side. See Figure F.26. cable from the negative output terminal.
8. Using the 7/16" wrench, remove the five 12. Carefully remove the lower tray assembly
bolts holding the lower tray assembly to the clear from the machine.
case bottom.
13. Remove the rubber RTV coating from the
9. Carefully slide out and support the lower tray IGBT module.
assembly.
10. Using the needle nose pliers, remove the
strain relief holding the J22 lead harness to
the case bottom.
INVERTEC STT
F-57 F-57
IGBT MODULE REMOVAL


FIGURE F.27 IGBT MODULE CONNECTIONS
IGBT
MODULE
E
C
STT II
For steps 14-18, see Figure F.27.
14. Using the phillips head screw driver, remove 21. Using the 12mm wrench, assemble the large
the small leads from the small "E" and "B" lead and the smaller #289 lead to the large
terminals. Note lead placement for reassem- "E" terminal. Torque to 86 inch pounds.
bly.
22. Using the 12mm wrench, assemble the large

15. Using the 12mm wrench, remove the large lead and the smaller #287 lead to the large
lead and the #289 lead from the large "E" ter- "C" terminal. Torque to 86 inch pounds.
minal. Note lead placement for reassembly.
23. Using the phillips head screw driver,
16. Using the 12mm wrench, remove the large reassemble the small leads to the small "E"
lead and the #287 lead from the large "C" and "G" terminals. Torque to 13 inch
terminal. Note lead placement for reassem- pounds.
bly.
24. Apply the Silicone Rubber RTV Coating
17. Using the 3/16" Allen type wrench, remove (Lincoln E2861 or Dow 3140) to the termi-
the four socket head cap screws that mount nals and lead connections as was previously
the module to the heat sink. removed.
18. Carefully remove the IGBT module. 25. Replace the lower tray assembly.
19. Upon reassembly, use Dow Corning 340 26. Connect plug J22 to the wiring harness and
Heat Sink Compound (Lincoln E1868) plug J1 to the control PC board.
between the module and the heat sink.
27. Connect the lead splice between the output

20. Mount the new module using the socket choke and the IGBT module.
head cap screws and torque to 35 inch
pounds.
Note: The torque should be rechecked after
three hours.
INVERTEC STT
F-58
NOTES
INVERTEC STT
F-58
F-59 F-59
SWITCH BOARD
REPLACEMENT
WARNING
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 F-60
SWITCH BOARD REPLACEMENT (continued)
FIGURE F.28 SWITCH BOARD REMOVAL
SOCKET
HEAD
SCREWS
PROCEDURE
WARNING
NOTE: If a test indicates that a switch board is
defective, both switch boards must be replaced at ELECTRIC SHOCK can kill.
the same time. In addition to replacing the switch

boards, replace capacitors C1 and C2 if the fol- test procedure, perform the
lowing conditions exist: capacitor discharge proce-
a. The machine was operating from 380 VAC dure to avoid electric
or higher when the failure occurred. shock.
b. Burned areas are visible on the switch

boards. 4. Carefully disconnect the leads at the top of the
1. Turn off the Invertec STT and disconnect main switch board.
AC input power to the machine. 5. Using the 3/16" socket wrench, remove the
2. Using the 5/16" nut driver, remove the case four cap screws from the switch board. See
wraparound cover. Figure F.28.

INVERTEC STT
F-61 F-61

6. Using the 7/16" wrench, remove the two hex 13. Torque both sets of screws in 10 inch-pound
head capacitor screws located in the center increments. Use a diagonal tightening
of the switch board. Hold the board firmly as sequence. Torque the four socket head
you remove the screws. screws to 44 inch-pounds (5 Nm). Torque the
two hex head screws to 55 inch-pounds (6
7. Carefully remove the switch board.
Nm).
8. Clean the heat sink surfaces thoroughly to
remove all the heat sink compound. (During CAUTION
machine operation, this compound helps
conduct heat from the switch board to the
Failure to connect the switch board leads correct-
heat sinks.
ly can result in damage to the Invertec STT
9. Apply a thin layer (.002") of Dow Corning machine when power is applied.
340 Heat Sink Compound (Lincoln E1868) to
the mounting surfaces of the new switch
board and to the capacitor terminals. DO 14. Reconnect all the leads to the switch board.
NOT allow the compound to enter the Be sure each lead is connected to the correct
mounting screw holes. It can distort the terminal.
torque values.
15. Perform the Test after Repair of Switch
10. Prepare to mount the new switch board on Boards and/or Capacitors.
the heat sink by first lining up the mounting
NOTE: Always make sure that the switch boards
holes. Then press the switch board into
are changed in matched pairs. Never mix an old
place.
style switch board (different part number) with
11. Insert each of the four socket head screws new style (new part number).
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.
INVERTEC STT
F-62 F-62

TEST AFTER REPAIR OF SWITCH 3. Connect a shorting conductor across termi-
BOARDS AND/OR CAPACITORS nals 14 and 53 of the protection PC board.
See Figure F.29.
The following test must be performed after the
switch boards and/or the capacitors have been 4. Set an ANALOG ohmmeter to X1000 range
replaced. and place the probes on terminals 9 (+) and
12 () of one switch board. The meter will
NOTE: Always make sure that switch boards are show the capacitors charging up and may
changed in matched pairs. Never mix an old style take a minute or so to stabilize. The final
(different part number) switch board with a new meter reading should not exceed 8600 ohms
style (new part number). (8.6 on the scale).
5. Test the other switch board the same way.
TEST PROCEDURE NOTE: Repeat the Input Filter Capacitor
Discharge Procedure.
1. Turn main power OFF.

6. Remove the shorting conductor set up in step
2. Perform Input Filter Capacitor Discharge 3.
7. Replace 20 amp fuses with 5-amp fuses in
the input supply fuse holders.
WARNING
NOTE: These fuses should be installed to pro-
ELECTRIC SHOCK can kill. tect against excessive current flow caused by a
short circuit during the procedure.
shock.
FIGURE F.29 SHORTING TERMINALS 14 AND 53 OF PROTECTION BOARD

L7915-[ ] PROTECTION
53 14
JUMPER TERMINALS
INVERTEC STT
F-63 F-63
9. With the output free of a load, check open cir-

WARNING cuit voltages of the output. Voltage should be
85 VDC maximum.
10. Remove input power. Then remove the
With input power ON, there 5-amp fuses from the input supply fuse hold-
are high voltages in the ers.
machine. Do not reach
11. Install 20-amp fuses and test under load.
into the machine or touch
any internal part. NOTE: A resistive-type grid load bank is recom-
mended.
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
F-64
NOTES
INVERTEC STT
F-64
F-65 F-65
CAPACITOR REMOVAL AND

REPLACEMENT PROCEDURE
WARNING
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input filter capac-
itors C1 and C2.
MATERIALS NEEDED
5/16" Nut driver
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
OUTPUT CHOKE/
LOWER IGBT MODULE
AREA
PROCEDURE
WARNING
1. Turn off Invertec STT and disconnect main AC
input power to the machine. ELECTRIC SHOCK can kill.
2. Using the 5/16" nut driver, remove the case Before continuing with the
wraparound cover. test procedure, perform the

capacitor discharge proce-
3. Perform the Input Filter Capacitor dure to avoid electric
Discharge Procedure. See the Maintenance shock.
section.
4. Locate the lead connection splice from the

output choke to the IGBT module. Remove
the insulating sleeve. Using the 7/16" wrench
disconnect the lead splice. Thread the lower
lead down into the lower tray assembly area.
See Figure F.30.
INVERTEC STT
F-67 F-67

J1 CURRENT
SENSING PLUG
OUTPUT CHOKE/
LOWER IGBT MODULE
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

INVERTEC STT
F-68 F-68

FIGURE F.33 STT PLACED ON ITS RIGHT SIDE
MOUNTING
BOLTS (5)
7. Carefully lift and tilt the Invertec STT 11. Using the 1/2" wrench, remove the IGBT
machine onto its right side. See Figure F.33. cable from the negative output terminal.
8. Using the 7/16" wrench, remove the five 12. Carefully remove the lower tray assembly
bolts holding the lower tray assembly to the clear from the machine and set aside.
case bottom.
13. Carefully disconnect the leads at the top of
9. Carefully slide out and support the lower tray the switch board.
assembly.
10. Using the needle nose pliers, remove the
strain relief holding the J22 lead harness to
the case bottom.
INVERTEC STT
F-69 F-69
FIGURE F.34 REMOVING HEX HEAD NUTS OF THROUGH-BOLTS
HEX NUT
CAPACITOR REPLACEMENT Disassemble and reassemble only one unit at a

time. Use the other unit as a model during
NOTE: Capacitors must always be replaced in reassembly so that all parts are reinstalled prop-
matched sets (C1 and C2 as a set). erly.
When replacing Capacitors, remove the entire 14. Remove the two 3/8 hex head nuts from the
FET heat sink assembly, including the capacitors top of the through-bolts. The hex nuts are
and switch board, as a unit. 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 16. Remove the switch board and capacitor
Figure F.35. Slide the plastic retaining insu- assembly from the machine.
lators that go through the base of the
machine to one side. Pull the through-bolts
out of the machine, being careful to save all
the insulation and standoff material. Set
aside for reassembly.
INVERTEC STT
F-71 F-71
FIGURE F.36 REMOVING CAPACITOR NUTS

17. Remove the two 7/16 hex bolts that hold the 18. Loosen the set screw of the capacitor clamp
capacitor to the switch board. See Figure ring and remove the capacitor from the clamp
F.36. 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 18. Loosen the set screw of the capacitor clamp
capacitor to the switch board. See Figure ring and remove the capacitor from the clamp
F.36. 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 INPUT FILTER CAPACITOR CONDITIONING
7/16 hex bolts to a torque of 55 inch-pounds
(6 Nm). Tighten these bolts in increments of If the machine will not produce output when
10 inch-pounds, alternating between the two turned on and the following two conditions exist:
bolts. Capacitor installation is complete. See The machine is connected to operate at an
Figure F.38. input voltage of 380 VAC or higher and
Power has not been applied to the machine for
CAUTION a long period of time (many months). Then. . .
Proper capacitor polarity must be noted when The Input Filter Capacitor Protection Circuit could
attaching the capacitor to the switch board have been activated and prevented output. This
assembly. means the Input Filter Capacitors must be condi-
tioned.
The Input Filter Capacitor Protection Circuit mon-
20. Install the switch board and capacitor itors the voltage across input filter capacitors C1
assembly into the machine. Take special and C2. When it senses an overvoltage condi-
care that ALL insulators and sleevings are in tion, the protection circuit will prevent the
their proper positions. See Figure F.38. machine from operating.
21. Install the lower tray assembly and all previ- To condition the Input Filter Capacitors:
ously disconnected loads and plugs.
22. Perform the Test After Repair of Switch
Boards and/or Capacitors. 2. Remove any load and do not load machine
until conditioning procedure is complete.
NOTE: Always make sure that the switch boards
are changed in matched pairs. Never mix an old 3. Turn main power ON.
style switch board (different part number) with 4. Let the unloaded machine sit for 30 minutes.
new style (new part number).
6. Turn main power ON.

NOTE: The machine should be ready to operate,
and the protection circuit should have automati-
cally reset once the capacitors have been condi-
tioned and capacitor voltage has reached the
acceptable operating level.
INVERTEC STT
F-73 F-73
OUTPUT RECTIFIER
REMOVAL AND REPLACEMENT
WARNING

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
Dow Corning 340 Heat Sink Compound (Lincoln E1868)

INVERTEC STT
F-74 F-74
OUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)

FIGURE F.39 CHOKE LEAD/HEAT SINK CONNECTION
HEAT SINK TAB
CHOKE LEAD
PROCEDURE 4. Using the slot head screw driver, loosen the

input cable strain relief.
1. Turn off Invertec STT and disconnect main
AC input power to the machine. 5. Using the 5/16" nut driver, remove the four
screws securing the case back to the inter-
2. Using the 5/16" nut driver, remove the case nal horizontal baffles.
wraparound cover.
6. Carefully pull the case back away from the
3. Perform the Input Filter Capacitor output rectifier assembly.
Discharge Procedure. See the Maintenance
section. NOTE: The case back will NOT detach from
the case bottom.
WARNING 7. Using the 7/16" wrench, remove the four
bolts and washers mounting the fan motor
ELECTRIC SHOCK can kill. bracket to the top horizontal baffle.
Before continuing with Carefully set the fan and motor assembly
the test procedure, per- aside. Note insulation placement for
reassembly.

charge procedure to NOTE: The fan motor leads do NOT have to
avoid electric shock. be cut.
8. Using the 7/16" wrench, remove the choke
lead from the heat sink tab. See Figure F.39.
INVERTEC STT
F-75 F-75

FIGURE F.40 MAIN TRANSFORMER DIODE CONNECTIONS
MAIN
TRANSFORMER
SECONDARY
LEADS
9. Remove the two sleevings from the diode

connections at the main transformer. See
Figure F.40.
10. Using the 7/16" wrench, remove the diode
leads from the main transformer sec-
ondary leads. Note washer and lead
placement for reassembly.
INVERTEC STT
F-76 F-76

FIGURE F.41 SWITCH BOARD/CAPACITOR ASSEMBLY THROUGH-BOLTS
THROUGH-BOLTS
11. Using the 3/8" nut driver, remove the rear 17. Before mounting the new diode sets, clean
nuts and washers from the switch and brighten the mounting surfaces of
board/capacitor assembly through-bolts. both the diode sets and the heat sink with
See Figure F.41. fine steel wool.
12. Using the 3/8" nut driver, loosen the front 18. Apply an even coating of DOW Corning
nuts from the switch board/capacitor 340 Heat Sink Compound to the mounting
assembly through-bolts. surfaces of the diodes that contact the
heat sink. This compound layer should be
13. Carefully lift the horizontal baffle away
less than .001 inch thick. DO NOT apply
from the upper tabs of the output rectifier
the compound to the diode studs or
heat sink assembly.
mounting nut threads.
14. Slide the heat sink assembly to the right
19. Insert the diode sets into the mounting
(facing the back of the machine) to disen-
hole and tighten the diode mounting nuts
gage the bottom tabs from the lower hori-
to a torque of 25 inch-pounds (3 Nm).
zontal baffle.
20. Replace the rectifier heat sink assembly,
15. Carefully remove the output rectifier heat
leads and connections that were previous-
sink assembly and leads from the STT

ly removed. Install the fan and motor
machine.
assembly (note insulation placement).
16. Remove the nut that secures each diode Install the case back and the case wrap-
that is to be replaced. around cover.
NOTE: The output diodes must be replaced in
matched sets.
INVERTEC STT
F-77 F-77
RETEST AFTER REPAIR

Retest the INVERTEC STT:
If it fails any test and the test requires removing or replacing any mechanical part that could affect the machine's
electrical characteristics.
OR
If you repair or replace any electrical components.
MAXIMUM INPUT IDLE AMPS AND IDLE WATTS

INPUT CURRENT @ IDLE 3.5 AMPS
INPUT POWER @ IDLE 800 WATTS

MINIMUM ACCEPTABLE OUTPUT (AT MAXIMUM BACKGROUND SETTING)

[STATIC GRID LOAD]
CONTROL MODE AMPS VOLTS
BACKGROUND 140 20
OPEN CIRCUIT VOLTAGE RANGE

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

CONDITIONING High voltage connections are covered with an RTV
If the machine will not produce output when turned on sealant to prevent malfunction in severe environments.
and the following two conditions exist: Sealant must be applied to connections which have
been opened or otherwise lost their protection. A non-
The machine is connected to operate at an input corrosive, electronic grade sealant such as Dow
voltage of 380 VAC or higher and Corning 3140, 3145, or 738; Columbus Adhesives
Power has not been applied to the machine for a 0172; or GE RTV-162 is recommended. Sealant may
long period of time (many months). Then. . . also be purchased from Lincoln Electric (order E2519
Silicone Rubber RTV Coating). Apply sealant after
The Input Filter Capacitor Protection Circuit could have machine is repaired and tested. All five terminals of the
been activated and prevented output. This means the input rectifier require this type of sealant.
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 protec-
tion circuit will prevent the machine from operating.
To condition the Input Filter Capacitors:
2. Remove any load and do not load machine until
conditioning procedure is complete.
4. Let the unloaded machine sit for 30 minutes.
NOTE: The machine should be ready to operate, and
the protection circuit should have automatically reset

once the capacitors have been conditioned and capac-
itor voltage has reached the acceptable operating
level.
INVERTEC STT
Section G-1 TABLE OF CONTENTS Section G-1
- ELECTRICAL DIAGRAMS SECTION -

Electrical Diagrams ...............................................................................................Section G
Wiring Diagram - Entire Machine - Codes 10151-10153 - (G2773) . . . . . . . . . . . . . .G-2

Wiring Diagram - Entire Machine - Codes 11115-11116 - (G4557) . . . . . . . . . . . . . . .G-5
Schematic - Control PC Board - Codes 10151-11092 - (G2781 Sheet 1) . . . . . . . . .G-6
PC Board Assembly - Control - Codes 10151-11092 - (G2782) . . . . . . . . . . . . . . . . .G-8
Schematic - Control PC Board - Codes 11115-11116 - (G4649 Sheet 1) . . . . . . . . . .G-9

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)
REMOTE
PROTECTION BOARD
N.L. TOROIDAL
N.G. CORE
9A 9 C8 20/400
9A + ARC
4, 5 4 289B 288B
R7 402, 404 J19
25 + VOLTAGE
N.F. 25W C2+ T2 R14
SWITCH 2 300W SENSE
MAIN 289A 288A 1 290 1 (+)
7500 25 2200 F BOARD D7 CONNECTION
25W TRANSFORMER 2 2
9A 25W450V - (LEFT) CURRENT R13 288 J37 3
R6 401, 403 2 300W 291 3 (-)
9A R1 SENSE 287 4
53 12A R W R W 1, 8 1 4 F L3 289 - ARC 4
BOARD
9A 12A 12 TOP 10 .001/400 E C
OUTSIDE 2 W R3 CHOKE
9A 52 S C4 J38
S 3 3 403 J
F D11
BOTTOM BOTTOM 1 R DARLINGTON 2 402 B
309 309 INSIDE D10 J18 4 B 401 BG
309A 14 53 MODULE 1 C
310 1F S D9 2 W
212C 10 410 G
10K
INPUT 310 1 311 D8 6 409
RECTIFIER CR1 310A 14 B E 43A 1 9 A
9D9D 53 3 313 307308 412 PB
D13 9C J8 2 D7 1 W W B 33C 4 12 D
9D 404 TRIGGER 10K
C D+ 4 6 3 2 51 4 1 2 3 4 J12 2 B 32C 8 J34
4
411
F
C C 3 212B 5 11 H GND
H1 TP1 52 52 9D 8 J10 J11 4 3 E
H1 N.H. 12D 12
PROTECTION 52 J16 2 I OPTIONAL
B B B S7 2 12B 7 DRIVER N.E. 7 REMOTE
RECONNECT BOARD 223
5 52 3 BOARD INTERFACE
TP3 9B 371 1
A A TP2 9C 9B J15 1 314 1
J9 374 4
8
4 315 2 B 9 WIRE
A 12C 12A H5 51 3 316 14 N 2 R FEEDER
A F 12A 3 6254 1 J13 10 J36 J39
- 6 317 13 N 3 W 5
9B T3 N.E. O 5
12C CURRENT B 4 N SPARE
O 6 6 J33
TRANSFORMER 5 370 370 14 414 B GND

12D12D 51 I D1 1 371 371 2
R 6 406 H 21
W R WR B 4 7 372 372 3 6
9B 9 D2 DARLINGTON J1
N.L. N.F. N.G. 4,5 5 5F S W 2 2 374 374 7 L 82
9B D3 DRIVEBOARD
12D 9BR5 402, 404 SWITCH Y Y I BOTTOM
D4 3 J27 1 376 376 1 M 81
25 OUTSIDETOP 4 5 405 D 4
R9
7500 + S F D5
LOAD CR2 309A 25W
25W C1+ BOARD 8 13 413 C 2 TRIGGER
(RIGHT) S C3 3 416 K
25 2200 F TOP 1 0 R2 9 16 42 42
310A 12B 12B 25W450V - INSIDE 2W .001/400 408 I
10 8 41 VAC
12B 51 R4 401, 403 415 A
12B 12B 1, 8 8 8F 3 15 32 115
12B 12B 12 W 1 7 407 J 31 VAC
12B B 7
R 5 E 77
POWER LINE
FILTER J22 B 6 J5 F 76
8 75 N.J.
ASSEMBLY 371 10 371A 240 G
H1 H3 374 11 374A 503B 241 2
A 242 4 1
J30 240 DARLINGTON 2 3 43B CB1 42
FAN
J22 R 1 HEATSINK 307 7 POWER 3 6 42 6AMP VAC
18V J22 8 BOARD
MOTOR R 1 32 15 32A
2 241 W 14 THERMOSTAT 308 371A 8 4 2
503A 309 2 374A 1 J35 5
4 AMP 11 5 V 32C 16 32B 11 5 V W
18V 310 4 243 7
5
LINE SLOW 6 1 33D CB2 115
BLOW
440- J21 R 7
R 9 242 224 W 6
224A 501 5 J7 5 244 14 J17 7 4 31A 6AMP VAC
460V H5 2 33 33A 6 3 303 303 3
N.K. A H6 6 B 3 243 504 8
33C 8 33B FAN 1 6 302 302 11
J31 18V 9
4 2 V5 43A B 4 THERMOSTAT 3 8 304 304 10
U 244 J6 1 275 6 J28 10
275
S1 380- H4 3 H4 N 224 311 1 10 212 4 11
415V 2 4 V3 10V 210A 313 2 J14 12 J24 J23
POWER 503 2 305 2
N N 503A 212B 3 5
A ON OFF H3 7 301 9 350 353 1 1
220- 4 9 9
A W 230V H3 2 O 150 5W 212A 6 351 352 2 2
U H3 H2 0V 6V 4 211A 12 PEAK
200- H2 4 W 2 212
O 13 12 352 3 3
CURRENT
B 208V 212A 210 8 353 4 4
504 METER
B V
R INPUT H1 1 Y 4 U 12 245 2 354 5 5
PER H1 18V 18V 1 355 6 6
C N.A. U 13 246 13 356 351
C B Y 1 501 4 357 350
W J2 15
T4 358 J26 J25
G N.D.
AUXILIARY 16 359
T1 TRANSFORMER Y 2 357 1 1
AUXILIARY Y 8 10 360 356
TRANSFORMER 7 361 2 2
301 11 3 3
14 362 4 4 BACKGROUND
305 3 3 363
245 1 5 5 METER
5 6 6
J1, J8, J3, J9, 223 9 J4 11
J 11 , J 1 2 , J 1 4 J 1 0 , J 1 3 , J5, J7, J24 J23 ELECTRICAL SYMBOLS PER E1537 211A 5 355
J18, J37 J15, J35 J6, J27, J33 212C 12 354
J34 J26 J25
COLOR CODE: 210 6
246 7 358
B = BLACK 4 CW (MAX)
G = GREEN 502 10 10KR11 PEAK
359 CURRENT
N = BROWN 2W CONTROL
O = ORANGE 360
J4, J17 J16, J28 J2, J36 R = RED
W = WHITE 361
CW (MAX)
METER PINOUT (VIEWED FROM BACK OF METER) Y = YELLOW 10KR12 BACKGROUND
362 CONTROL
U = BLUE 2 364 2W
5 365 363
6 366
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 NOTES: J3
1 367
(VIEWED FROM COMPONENT SIDE OF BOARD) N.A. 4 368
1. FOR MACHINES SUPPLIED WITH INPUT CABLE 3 369 364
CW (MAX)
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. 10K R13 HOT START
J38 CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT. 365 CONTROL
J39 2W
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. CONTROL
BOARD 366
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
J19 CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
367
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE 367A
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. S2 WIRE SIZE
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT. .045
368 .035
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT. 367A
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 STAINLESS S3 WIRE TYPE
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. 369 MILD
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 )
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. (-)
CONNECTION SHOWN IS FOR 440-460V OPERATION. 502
THERMAL
P30 J30 P29, P31 J29. J31 P21 J21 N.E. D1 THRU D5 OUTPUT DIODES ARE A MATCHED SET. OVERLOAD
Y INDICATOR
D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET.
N.F. R1, R9 BLEEDER RESISTORS ARE A MATCHED SET. 503 (+)
N.G. C1, C2 CAPACITORS ARE A MATCHED SET. 503A
P22 N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
J22
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.
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 N.L. PRESENT ON EUROPEAN VERSIONS, CODE 10309 AND HIGHER.
( 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 )
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
N.L. REMOTE
PROTECTION BOARD
TOROIDAL
N.G. CORE
9A 9 C8 20/400
9A + ARC
4, 5 4 289B 288B
R7 402, 404 J19
25 + VOLTAGE
N.F. 25W C2+ T2 289 R16 288
SWITCH 2 300W SENSE
MAIN 289A 288A 1 290 1 (+)
7500 25 2200 F BOARD D12 2 CONNECTION
9A 25W 25W450V TRANSFORMER R15 2
- (LEFT) CURRENT J37 3 291 3 (-)
9A R1 R6 401, 403 SENSE 2 300W
1 4 F L3 - ARC 4 4
53 12A R W R W1, 8 BOARD 287
9A 12A 12 TOP 10 .001/400 E C
OUTSIDE 2 W R3 CHOKE
9A 52 S C4 J38
S 3 3 403 J
F D11 1 R 402
BOTTOMBOTTOM DARLINGTON 2 B
309 309 INSIDE D10 J18 4 B 401 BG
309A 14 53 MODULE 1 C
310 1F S D9 2 W
212C 6 10 410 G
10K
INPUT 310
CR1 310A 1 311 D8 B E 409
RECTIFIER9D9D 14 53 307308 43A 1 9 A PB
3 313 D7 1 W W B 412 D
C D13 9C J8 2 33C 4 12 10K
9D 404 TRIGGER
C C D+ 4 6 3 2 51 4 1 2 3 4 J12 2 B 32C 8 J34
4
411
F
3 212B 5 11 H GND
H1 TP1 52 52 9D 8 J10 J11 4 3 E
H1 N.H. 12D 1 2 J16
PROTECTION 52 2 I OPTIONAL
B S7 2 12B 7 7 REMOTE
B B BOARD DRIVER N.E. 223
RECONNECT 5 52 3 290A INTERFACE
TP3 9B BOARD 1
371
A TP2 9C 9B J15 1 314 1
J9 374 4
8
4 315 2 B 9 WIRE
A A F 12C 12A H5 51 3 316 14 N 2 R 10 FEEDER
A 12A 3 6254 1 J13 J36 J39
- 6 317 13 N 3 W 5
9B T3 N.E. O 5
12C CURRENT B 4 N ELECTRODE SENSE LEAD
O 6 370 370 6 J33

TRANSFORMER 5 14 414 B GND

LOAD 12D12D 51 I D1 1 6 371 371 2
R 406 H
W R WR B 4 J1 7 372 372 3 6 21
9B 9 D2 DARLINGTON
N.F. N.G. 4,5 5 5F S W 2 2 374 374 7 L 82
9B D3 DRIVEBOARD
9BR5 402, 404 SWITCH Y Y I BOTTOM 3 J27 1 376 376 1 M 81
12D OUTSIDETOP D4 4 405 D
25 5 4
R9
7500 + S F D5 8
CR2 309A 25W
25W C1+ BOARD 13 413 C 2 TRIGGER
N.K. (RIGHT) S C3 3 416 K
25 2200 F TOP 1 0 R2 9 16 42 42
310A 12B 12B 25W450V - INSIDE 2W .001/400 408 I
10 8 41 VAC
12B 51 R4 401, 403 415 A
POWER 12B 12B 1, 8 8 8F 3 15 32 115
LINE 12B 12B 12B 12 W 1 7 407 J 31 VAC
FILTER B 7
R 5 E 77
ASSEMBLY 6 J5 F 76
J22 B
8 75 N.J.
371 10 371A 240 G
H1 H3 374 11 374A 503B 241 2
H1 H3 A 1
DARLINGTON 242 4 43B
TOP J30 240 2 3 CB1 42
FAN
J22 R 1 HEATSINK 307 7 POWER 3 6 42 6AMPVAC
18V J22 308 8 BOARD
N.L. MOTOR R 1 32 15 32A
2 241 W 14 THERMOSTAT 371A 8 4 2
32C 16 32B 503A 309 2 374A 1 J35 5
4 AMP 11 5 V 11 5 V W
18V 310 4 243 7
5
SLOW 6 1 33D CB2 115
H1 H3 H1 H3
BLOW
440- J21 R 7
R 9 242 224 W 6
224A 501 5 J7 5 244 14 J17 7 4 31A 6AMP VAC
460V H5 2 33 33A 243 504 6 3 303 303 3
LEFT A H6 6 33C 8 33B B 3 8
FAN 18V FA N 1 6 302 302 11 9
MOTOR J31 T H E R M O S TAT C H O K E 3 8 304 10
LINE RIGHT 4 2 V5 43A B 4 304 J28 10
U 244 379 T H E R M O S TAT J6 1 275 275 6
S1 FAN 380- H4 3 H4 N 224 311 1 10 212 4 11
MOTOR 415V 2 4 V3 313 2 J14 12 J24 J23
POWER 503 10V 2 305 2
N N 503A 212B 210A 3 5
A ON OFF H3 7 301 9 350 353 1 1
220- 4 9 9
A W 230V H3 2 O 150 5W 212A 6 351 352 2 2
U H3 0V 6V 4 211A 12 PEAK
200- H2 4
H2 W 2 212
O 13 12 352 3 3
CURRENT
B 208V 212A 210 8 353 4 4
504 METER
B V
R INPUT H1 1 Y 4 U 12 245 2 354 5 5
PER H1 18V 18V 1 355 6 6
C N.A. U 13 246 13 356 351
C B Y 1 501 4 357 350
W J2 15 J25
T4 358 J26
G N.D. AUXILIARY
16 359
T1 TRANSFORMER Y 2 357 1 1
AUXILIARY Y 8 10 360
7 361 356 2 2
TRANSFORMER 3 3
301 11 14 362
J1, J8, J3, J9, 3 363 5 5 METER
ELECTRICAL SYMBOLS PER E1537 245 1 5
J 11 , J 1 2 , J 1 4 J 1 0 , J 1 3 , J5, J7, 377 6 6
223 9 J4 11 378
J18, J37 J15, J35 J34 J6, J27, J33 J24 COLOR CODE: 211A 5 355
J23 354
J26 212C 12
J25 B = BLACK CASE CASE TR AY FAN CASE 210 6
G = GREEN FRONT BOTTOM SHROUD BACK 246 7 358
N = BROWN 4 CW (MAX)
O = ORANGE 502 10 10KR11 PEAK
359 CURRENT
J4, J17 J16, J28 J2, J36 R = RED 2W CONTROL
W = WHITE 360
Y = YE LLOW 361
U = BLUE CW (MAX)
METER PINOUT (VIEWED FROM BACK OF METER) PLATFORM CASE 10KR12 BACKGROUND
362 CONTROL
BACK 2 364 2W
NOTES: 5 365 363
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 CW TAILOUT
N.A. N.M. 6 366
(VIEWED FROM COMPONENT SIDE OF BOARD) J3 377 CONTROL
1. FOR MACHINES SUPPLIED WITH INPUT CABLE 1 367 R14
4 368 378 500K
FOR SINGLE PHASE INPU T: CONNEC T GREEN LEAD TO GROUND PER NATIONA L E LECTRIC CODE. 2W
3 369 364
CONNEC T BLACK & WHI T E LEADS TO SUPP LY CIRCUI T. CW (MAX)
WRA P RED LEAD WITH TAP E TO PROVIDE 600V. INSUL ATION. 10K R13 HOT START
J38 365 CONTROL
J39 FOR THREE PHASE INPU T: CONNEC T GREEN LEAD TO GROUND P ER NATIONA L EL ECTRIC CODE. 2W
CONNEC T BLACK, RED & WHI T E LEADS TO SUPPLY CIRCUI T. CONTROL
BOARD 366
J19 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. 367
CONNEC T TERMINALS U & W TO SUPPLY CIRCUI T. 367A
FOR THREE PHASE INPU T: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRIC A L CODES. S2 WIRE SIZE
.045
CONNEC T TERMINALS U, V & W TO SUPP LY CIRCUI T. 368 .035
N.B. SINCE COMPONENTS OR CIRCUITRY O F A PRINTED CIRCUIT BOARD MAY C HANGE WITHOUT AF FECTING
367A
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. STAINLESS S3 WIRE TYPE
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VO LTAGE. MILD
369
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 )
CONNECTION SHOWN IS FOR 440-460V O PERATION.

N.E. D1 THRU D5 OUTPUT DIODES ARE A M ATCHED SET. 502 (-)
D7 THRU D 11 OUTPUT DIODES ARE A M ATCHED SET. THERMAL
P30 J30 P29, P31 J29. J31 P21 J21 OVERLOAD
N.F. R1, R9 BLEEDER RESISTORS ARE A M ATCHED SET. Y INDICATOR
1 2 2 1 1 2 3 3 2 1 1 2 3 3 2 1 N.G. C1, C2 CA PACITORS ARE A M ATCHED SET. 503 (+)
3 4 4 3 4 5 6 6 5 4 4 5 6 6 5 4 N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VO LTAGE.
CONNECTION SHOWN IS FOR 380-460V O PERATION. 503A
P22 J22 N.I. DENOTES A T WISTED WIRE PAIR OR GROU P.
1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 N.J. NO T PRESENT ON EUROPEAN VERSION.
9 10 11 12 13 14 15 16 16 15 14 13 12 11 10 9 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.
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
N.M. PRESEN T ON EUROPEAN VERSIONS, CODE 10383 AN D HIGHER.
( 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
REMOTE
PROTECTION BOARD
N.L. TOROIDAL
N.G. CORE
9A 9 C8 20/400
9A
4, 5 4 + ARC
R7 402, 404 289B 288B J19
N.F.
25 + R14
} VOLTAGE
25W C2 + SWITCH T2
2 300W 1
SENSE
288A 290 1 (+)
7500 25 2200 F BOARD MAIN 289A
D7 2 2
CONNECTION
TRANSFORMER
9A 25W 25W 450V - (LEFT) CURRENT R13 288 J37
3 291 3 (-)
9A R1 R6 401, 403 SENSE 2 300W
53 12A R W R W 1, 8 1 4
F 10 .001/400
L3
BOARD 289 287 - ARC 4 4
9A TOP
12A 12 2W E C
OUTSIDE R3 CHOKE
9A 52 S J38
C4 3 403
BOTTOM
S F
BOTTOM
D11 } 1 R IGBT
3
2 402
J
B
}
309 INSIDE D10 J18 4 BG
14 53 309 B 1 401 C
309A 310 F S D9 2 W MODULE 10K
1 10 410 G
INPUT 1 212C 6
CR1 310 311 D8 B E 9 409
RECTIFIER 9D 9D 310A 14 53 43A 1 A PB
}
3 313 307 308 412
D13 9C J8 D7 } 1 W W G 33C 4 12 D
9D 2 404 TRIGGER 10K
J12 2 B 32C 8 4 F
C C C D+ 4 6 3 2 51 4 1 2 3 4 3 J34 411
212B 5 11 H GND
H1 TP1 52 52 9D 8 J10 4 3 E
H1 N.H. J11
PROTECTION 52 12D 12
J16
2 I INTERFACE
B S7 2 DRIVER REMOTE
B B BOARD 12B 7 N.E. 7
} }
RECONNECT 5 223 OPTIONAL
TP3 9B
52 3 BOARD 371 1
1 314 1 8
A A TP2 9C 9B J15 FEEDER
4 315 2 J9 374 4
B 9
A A F
- 12C
12A H5 51 3 316 14
62 54
N 2
J13 R 10 J36
WIRE
}
12A 3 1 J39
6 317 13 N 3 W 5
9B T3 N.E. O 5
12C CURRENT B 4 N SPARE
O 6 370 370 J33 414
}
6
12D 12D 51 TRANSFORMER
} } 5 14 B GND
I D1 2
R 1 6 371 371 406

W R W R 3 6 H 21
9B 9 D2 B 4 7 372 372
N.G. 4,5 5 5 IGBT J1 L 82
N.L. N.F. 9B F
S W 2 2 374 374 7
D3 DRIVE BOARD
9B R5 Y Y I BOTTOM 3 1 376 376 1 M 81
402, 404 J27
12D SWITCH OUTSIDE TOP D4 4 405 {
7500 25 + BOARD
5 D 4
R9
S F D5 8
LOAD CR2 309A 25W 25W C1 + 13 413 C 2 TRIGGER
25 2200 F (RIGHT) S
10
C3 3
16 416 K {
42 42
TOP R2 9
12B 12B 25W 450V - 408 41 VAC
}
310A INSIDE 2W .001/400 10 8 I
51 R4 401, 403 415
12B F 3 15 A 32{
12B 12B 1, 8 8 8 115
W 1 7 407 J 31 VAC
12B 12B 12B 12
B 7
R E 77
POWER LINE 5
J22 B 6 J5 F 76
FILTER N.J.
ASSEMBLY 371 10 371A 240 8 G 75
H1 H3 503B 241 2
374 374A
11
}
}
1
}
A 242 4
J30 DARLINGTON 2 3 43B CB1 42
240
FAN
MOTOR
4 AMP
R
115V
1 32
32C
J22
15
16
32A
32B 115V
R
18V
W
18V
1
2 241 503A
W
J22
14
HEATSINK
THERMOSTAT
307
308
309
7
8
2
POWER
BOARD 371A
374A
8
1
3
4
5
J35
} 6
2
5
42 6AMP VAC
LINE 310 4 243 7 6 1 33D CB2 115

SLOW R W J7
J21 R 9 242 224 501 5 5 244 14 J17 31A
BLOW 6 224A 4
N.K.
380-
H6 6
H5
42V
U
J31
2
5
33
43A
33C
7
8
33A
33B B
18V
B
3
4
243
244
FAN
THERMOSTAT
504 6
1
3
}
6
3
8
1
303
302
304
275
303
302
304
3
11
10
6 J28
7
8
10
9
6AMP VAC
}
415V H4 275 11
S1 A H4 3 N 224 311 1 J6 10 212 4
24V 210A 313 2 12 J24 J23
POWER 3 503 10V J14 2 305 2
ON OFF
N
N 503A 212B 3 301 5
A 7 350 353 1 1
H3 4 9
B
A
C
U
W
B
R
}
INPUT
PER
N.A.
200-
208V
H3
H3
H2
H1
2
1
H2
H1
W
18V
0V
Y
2
4
212
504
501
U 12
18V
U
6V
13
O
O
245
246
212A
150 5W
210
9
4
212A
211A
9
12
13
2
6
12
8
1
13
4
} 351
352
353
354
355
356
357
352
351
350
2
3
4
5
6
2
3
4
5
6
PEAK
CURRENT
METER
}
C W 1
T4 J2 J26 J25
15 358
G N.D. AUXILIARY
T1 16 359
Y 2
TRANSFORMER 357 1 1
AUXILIARY 10 360
Y 8 356 2 2
TRANSFORMER 7 361
301 11 3 3
305 3 3 363
1 5 5 METER
245 5
J1, J8, 9 6 6
J3, J9, 223 J4 11
J11, J12, J14 J10, J13, J5, J7, J24 J23 ELECTRICAL SYMBOLS PER E1537 211A 5 355
J18, J37 212C 12 354
J15, J35 J34 J6, J27, J33 J26 J25
1 2 1 3 1 4 1 5 COLOR CODE: 210 6
1 1 246 7 358
B = BLACK 4 CW (MAX)
G = GREEN 502 10 PEAK
359 10K R11
CURRENT
3 4 4 6 5 8 6 10 N = BROWN 2W
CONTROL
O = ORANGE 360
J4, J17 J16, J28 J2, J36 6 6 R = RED
1 6 1 7 1 8 361
W = WHITE CW (MAX)
METER PINOUT (VIEWED FROM BACK OF METER) Y = YELLOW BACKGROUND
362 10K
R12 CONTROL
U = BLUE 2 2W
7 12 8
P.C. BOARD CONNECTOR CAVITY NUMBERING SEQUENCE

14 9 16
NOTES: J3
} 5
6
1
364
365
366
367
363
(VIEWED FROM COMPONENT SIDE OF BOARD) N.A. 4 368

1. FOR MACHINES SUPPLIED WITH INPUT CABLE 3 369 364
CW (MAX)
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. 10K R13
HOT START
365
J38 J39 CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT. 2W CONTROL
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. CONTROL
BOARD 366
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
J19 C CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
D E D B 2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE
367
C J F L 367A
A E FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. S2 WIRE SIZE
1 K M CONNECT TERMINALS U & W TO SUPPLY CIRCUIT. .045
2 3 B I G J N F FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. 368 .035
A H I G CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.

4 367A
H N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING S3 WIRE TYPE
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT STAINLESS
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. 369 MILD
PINOUT OF FRONT PANEL CONNECTORS (REAR VIEW)
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. (-)
CONNECTION SHOWN IS FOR 380-415V OPERATION. 502
THERMAL
P30 J30 P29, P31 J29. J31 P21 J21 N.E. D1 THRU D5 OUTPUT DIODES ARE A MATCHED SET. OVERLOAD
Y INDICATOR
1 2 1 2 3 3 2 1 1 2 3 3 2 1
D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET.
2 1
4 5 6 6 5 4
N.F. R1, R9 BLEEDER RESISTORS ARE A MATCHED SET. 503 (+)
3 4 4 3 4 5 6 6 5 4
N.G. C1, C2 CAPACITORS ARE A MATCHED SET. 503A
P22 N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
J22
CONNECTION SHOWN IS FOR 380-415V OPERATION.
1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 N.I. DENOTES A TWISTED WIRE PAIR OR GROUP.
9 10 11 12 13 14 15 16 16 15 14 13 12 11 10 9 N.J. NOT PRESENT ON EUROPEAN VERSIONS.
N.K. NOT PRESENT ON EUROPEAN VERSIONS.
INLINE CONNECTOR CAVITY NUMBERING SEQUENCE N.L. PRESENT ON EUROPEAN VERSIONS.
(VIEWED FROM WIRE SIDE OF CONNECTOR)
A
G4557
Schematic - Control PC Board - Codes 10151 - 11092 - (G2781 Sheet 1 of 2)
G +15V +15V
+15V +15V
2781-A
POWER PLANE POWER PLANE POWER PLANE
13 14 16 16 16 16 4 4 14 14 14 14 14 14 14 14 14 14 14 14 14 3 4 4 8 8
Vcc Vcc
C439
X25 C442 C445 C432 C444 C425
OCI2
C429
OCI3
0.1 X19 C441 X20 0.1 X32 C456 C443
0.1
C466 C467 X11 0.1 X12 C433 X13 C434 X14 C435 X15 C436 X16 C437 X17 0.1 X18 C438 X36 C468
0.1
C426
C457
C459 C427 C428 C458
0.1
C424
50V 0.1 0.1 X9 0.1 X10 X34 0.1 X35 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 X21 X22 0.1 X31 X30 0.1 X23 0.1 X24 0.1 X29 0.1 0.1
PWM DUAL FF COUNTER COUNTER NAND NAND NAND NAND NAND NAND NAND NAND NAND
50V TIMER TIMER 50V OP AMP OP AMP 50V 50V SWITCH 50V SWITCH SWITCH 0.1 SWITCH COMPARATOR OP AMP OP AMP 50V
C440 50V 50V 50V 50V 50V 4093B 4093B 50V 4093B 50V 4093B 50V 4093B 50V 4093B 50V 4093B 4093B 50V 4093B 50V 50V 50V 50V 50V 50V 50V
MC14013B MC14040 MC14040 MC14538B MC14538B LM224 LT1014 4066B 4066B 4066B 50V 4066B LM2901 LT1014 LM224 HP2231 HP2231
SG3846 4.7
35V
12 7 8 8 8 8 11 11 7 7 7 7 7 7 7 7 7 7 7 7 7 12 11 11 GND 5 GND 5
GROUND PLANE GROUND PLANE GROUND PLANE
2.67K 2.67K 2.67K 2.67K +15V +15V +15V 1 Q12 VDD

16
J27 LOCAL +15V
DV/DT KILLER
R543 R542 R541 R508 +15V 4.75K 2 15
1 Q6 Q11
6 4.75K FORCES THIRD CONSECUTIVE
REPETITIOUS X20
"DIGITAL LOGIC" R319 3 Q10 14
+15V PINCH TO BREAK INTO ARC Q5
PINCH LIMITER
R308
X34 B 7 R340
3.92K
4 13
B Q7 Q8
R326
150us MIN
+15V POWER SUPPLY FOR D310 4 OCI2 1 PINCH
511
5 LM224
DARLINGTON
R527 METER_1 B DV/DT LEVEL DETECT OCI1 A 5
Q4 Q9 12
DIGITAL, TRIGGER & ANALOG SECTIONS POWER PLANE OCI1 6 PINCH SIGNAL ON TIME
+15V FROM FE (SHEET 2)
R488
R487
R482
R486
10.0K DON_MIN
6 11
825
PINCH KILLER Varc TO FE (SHEET 2) Q3 R
825
825
825
1 16 8
DV/DT Q12 VDD ARC
X8 +5.1V REMOTE ADJUST FE (SHEET 2) FOR ENERGY 7 10 J28
METER_2 HP2231 Q2 COUNTER /C
2 Q6 Q11 15 CONTROL OPTION
D306 D307 lm350 HP2231 PINCH /ARC 8 9 D304
X32 VSS Q1
R341
15.0K
1N4007 1N4007 IN OUT R483 3 Q10 14 HP2231
+5 VOLT Q5
R309
D413 2 MC14040
33.2K
s18395-23 R528 3 2 1
10.0 METER 4 13
X34 A 1 Q7 Q8 Q9 6 J28
POWER
/COUNT
10.0K 8 OPTO
J28 R484 5 12
2N4401 X15 4
ADJ B
2.43K
Q4 Q9
R474
LM224 ISOLATOR
3 PINCH /PINCH
R317
Q3
R327
7 NAND
2.21K
R337 5
511
NAND ON
1 10.0 2N4401 R333 6
Q3 R 11 /DON_MIN
9 C
C312 DZ19
13
X15
10 DARL. DRIVE
C311 243 C462 C448 D305 X17 D
DON_RESET
C310 X26 8 10.0K 11 7
Q2 COUNTER /C 10 13
18 VAC
1.0 12V C463 1.0
2.5V
1 +15V 12 X15
BOARD
1.00M
R511
35V
2.43K
R338
NAND
.0047 1W REF X13 D 12 D
1000 35V 35V TL431 3 8
VSS Q1 9 NAND NAND
1400V NAND C306 D /PWM_SYNC 12 PWM_SYNC
C314 6 2 12 MC14040 13 11 11
BALL
J28 C313 +15V +15V BALL_OR_FUSE
9 X16 330p X14
D
R473
2.21K
/KILLER
14 X11 11
100 10 KILLER NAND
100V
13 Q2
20V 375us /KILLER
8 NAND D KILL_START
9 10K 2
500 SS_WIRE
R313
NAND
4.75K
100K
1 X14 BALL_OR_FUSE A R325 2N4401
D308 D309 C302 C 10 3
R339
X15
BALL_OR_FUSE
750us CW X14 NAND R320
1N4007 1N4007 R301 R302 A 3 8 1 10.0K
2
R300
3.92K
CW NAND
CW D301 D420
50K R305
GROUND PLANE
C300
D300 4.75K FUSE GEN. /PB_LOCAL /PB_OPTION
CW
R342
1N4936
100
FUSE 1N4936
/BALL
R312
KILL_RC H = STAINLESS
R304
10K
1 2 6 1ms R318 L = MILD
CURRENT X11
100K
/KILLER
T1 T2 C 4 C304 4.75K
INTEGRATOR OCI2 4 A 6 5
NAND C305 D303 R345
A 10.0K A Q
56.2K
R321
ARC/SHORT DETECT 1N4936 13
7 ARC
5 X9 7 15 14 330p 1.00K C309 DZ8
DZ9 FROM FE (SHEET 2) R540 B /Q
DZ20
/KILLER
T1 B T2 100V 1 2 1.0 15V
RST
DV/DT 12 A Q 10 C308 35V
R343
R344
1W
2.21K
2.21K
CFB 9 A
HP2231 X31
3 X12 X9 0.1
47.5K 10V 10V 10 11 9 5

D412 D B /Q 4 P_BOOST ONLY AFTER

50V
1W C464 1W 8
NAND
NAND PINCH LATCH
R519 /RESET FUSE RST B 1.3 msec PLASMA
6
+15V BALL_DELAYED X14
OVERCURRENT TRIP +15V 13 6 START BOOST TIME LIMIT
1N914 +5.1V
/KILLER
1 X12 X12 13
68.1K OVERCURRENT /RESET X11 A 11
C 4
/BALL
.33 200V 5.62K 3
B 12
NAND
1 X12 3 5
NAND ARC_START
R513 OUTPUT DISABLE /BALL_RC NAND B FUSE_RESET
R323
1 2 /ARC NAND PINCH R328 +15V
J1
2 ARC R303 6 PB_START
CURRENT
X35 A D411 14 C307
C301
/BALL_DELAYED
2
/(BALL & SHORT)
1 Q1 X19 VDD X16 4 4.75K
CW 10K
1 R509 2N4403 B
1014 /ARC /RESET RESET NAND 0.1
+15V Q7 100p /PINCH 2 /Q1 Q2 13 5 P BOOST
R563
10.0K
1
SENSE RESET
TO TRIGGER CIRCUIT
10.0K 50V
10.0K
R561
3 1 X17 2 15 14 /PB_LOCAL
100V 3 3 12
NAND
X36 A /Q2 A
33.2K
OVERCURRENT FAULT CLOCK 1

R518
3 3 T1 T2
R467 ARC
13 2
NAND X16
+15V +15V A 332K
PULSE
NAND ( SHEET 2 )
1 2 2 4 CLOCK 2 11 8 1 12 10
X11 RESET 1 A B Q
BOARD
NAND
2 R466 A 11 6 C
D416 CR1 R562 NAND X13 X16
10 X10 5 9
J1 +t C423 12
C 4 5
D1 10 11
B /Q 9 B
10.0 D423 RESET 2 9 R557 X18 4 10
1N4936 12Vdc C475 NAND +15V +15V X18 C
3 .25 1.0 5
11 1N914 6 SET 1 D2 9 /PWM_SYNC RST 6 8
J1 +15V 4.75K
221K
35V 2700p +5.1V R314

R521
9
4 6 33.2K 50V X28 13 +15V /RESET X13 7
VSS SET 2 8 13 /PB_OPTION
R516
X35 B 100K D C303 B 10 10K KEEP IN P_BOOST
J1 R524 MC14013B R322
7 10
2901 4.75K 12 8
NAND UNTIL ARC STARTS
1014 NAND
R559 /ARC A R306
CURRENT FEEDBACK 150K 150us FUSE ENTRY
11 4.75K
X13
R512
R331
10.0K
3V 5 10 R334
3.92K
R329
75.0
ARC KILLER PULSE
13 4.75K H = A>100
330p 6 START_RESET
1V/100A 5V +15V
39.2K
V=ARC
R311
X35 8
D302 X17
R307
D424 1 AMPS>100 L=DISABLE LOCAL PB TIME
R522 C 100V 1V 4
56.2K
R560
R514
68.1K
82.5K
1014 10 NAND B A H= OPTION ENABLED
9 PB_START 10K 8 C 5 OCI3
33.2K
1N4936 NAND
R517
332K 1N914 PB_START SIGNAL OCI6 L= NO OPTION

10.0K
FUSE A R316 X17 7
TO FE (SHEET 2) 13 9 R324
R515
15.0
D410 FOR ENERGY X35 ENERGY CONTROL OPTION 4
/PINCH D +5.1V X23
14
L= OPTION PB TIME
CONTROL OPTION ENABLE (SHEET 2)
R523
1014
150K
OVERCURRENT 2
CFB R310 HP2231 5 2901
ARC_START
R335
15.0K
+15V TRIP TIMING HP2231 ( SHEET 2 )
12
PRI_FB 1V=100A 10.0K ARC +15V

2 D421
DISABLE OPTION TO START
R525
R330
6 1N4936
R556
10.0K
R526 SLOW RAMP 100A/ms
4.75K
6 10.0K 100 /HOT_START
1 C465 9 8
J3 X36 4 R409 R410 Q10
+t C412 NAND B R510 39 2N4401 D422
5 B +5.1V
3.92K
R332
1.0 20V 47.5K 15.0K X21 L=DISABLE OPTION PB TIME
13
56 Q8 OCI3 H= OPTION PB TIME 1N4936
B
R564
10.0K
35V 2N4401 ENERGY CONTROL OPTION L= LOCAL PB TIME X18 11
WIRE SIZE SELECT D
PINCH
H= OPTION PB TIME 12
15.0K P_BOOST TIME (SHEET 2)
10.0K
FAST RAMP
R551
6
1000A/ms Q4 R554
H= .045 X22 B
RAMP
3.1V
< .035 DIA WIRE 2N4401 C419 4
- L= .035 R411 HP2231
( SHEET 2 ) 1.8 HP2231
8 9
J3 C407 .0047 PINCH PWM_EN 15.0K 20V
6.81K C472
R405 5 2
C474
4
V+ Vref
R553
6
24.3K
50V R453 100p
R555
22.1K
100 C409 6 1
> .045 DIA WIRE DZ12 100V V- CLIM
- 1.0 13 PHB OUTPUT
R412 X25 J28 B OCI6
PINCH FAST RAMP ENABLE

15V
2.21K
2.21K
15
R418
R417
35V 9 3
I- Vin 3
SS_WIRE +15V X24 +15V
WIRE TYPE SELECT 1W 10K C 2 1
PINCH COMMAND
R552
13
100K
1014 8 R422 10
SYNC Vc OUTA +15V_REM 3
R413 PINCH C473 OUTB /PWM_SYNC

10 A X21 150K 4 12
I+ GND
MILD 200 .294V PWM 10K +15V
+15V J28
R423
B.PT
267K
8 11
CT OUTA 11
+15V
W1
0.01
J3 12 14
R455
7
3 SAWTOOTH COMP OUTB WIRE TYPE POSITION
+15V C418 +15V
R414 16 TO FE (SHEET 2)
C410 WAVEFORM
.018
R463
8 11 10 9
R461
3.92K
3.92K
RT SHUT 7
STAINLESS +15V 10K GENERATOR 3.92K FOR ENERGY CONTROL
50V SG3846
14 X23
10 VDC
B X21 X23 1 PHA OUTPUT OPTION
C J28
R454
R456
3.01K
3.01K
2901 47p 100V 3us MAX DEADTIME B R457 10
9 2901 W4
CONTROL
6
R400
PINCH BREAKPOINT
R505
R506
1.30K
1.30K
1.30K
1.30K
1.00K
R401
CFB D401 COMM

REMOTE_POTS R550 +5.1V START_RESET 0.01 J28

500A MAX
POTS
R458
6
R421 R424 R425 R427
475
15.0K PINCH LIMIT
(PINCH KNEE)
Verror PWM_EN 1
POWER 475K 100K 1N4936 10K 1.00K
0.01
0.01
W3
W2
CW (SHEET 2)
75.0 47.5K
R530 R471 R529 HP2231 REM
10 2
+15V R428 OCI4 A +15V_REM
2.67K
26.7K
R451
R452
R504 X23 R419
D 8.25K 100K 3.32K 10.0K
13 X24 1 D405 7
DZ18 C461 C401
2901
A
C460 COMMAND 1014 R426 R539
12V
R459
100K
11 3 8
4.75K
R402
75.0
PINCH COMMAND
R502
1.0 R420 Vcc

1W R415 R416 10.0K A OCI4 HP2231
35V
TO
LOCAL_POTS 1
47.5K
47.5K X31 D 100K OCI4 C430
"ANALOG LOGIC"
C400 X33 8 CW C422 4 2
POWER
2.5V 1us MIN PULSEWIDTH
0.1
R429
1.0
TL431 REF 10 11 CURRENT 500
RAMP +15V .0047
50V
HP2231 OCI4 B HP2231
50V
35V
BOARD
6
ERROR AMP
6
R500
12
R503
1.50K
10.0
GND 5
CW
COMMAND /ARC
ISOLATED
R501
+15V B OCI4 HP2231
R441
10K
10.0
R532 REM
CIRCUIT
+15V 3
J27 J2 1.00K P_BOOST COMMAND
PB_SCALED C471
9 15 330p 9
REMOTE PB POT
6
X36 D418
LOCAL PB POT
D400 10 1
CW CW X31 B 7 NAND C D419 D417
J27 J2 9 X24 8 A
26.7K
R538
R439
15.0K
X22 A 10.0K B
2 16 R403 1014 100V 120us OCI5
3 4 X34 C
/ARC OR RAMP CTRL

13 8 5
DZ10 15.0K R444 D402
ARC & /RAMP CTRL

10.0K P BOOST
10K 10K 12V LM224
1 2 C470
X34 D 14 10 /HOT_START R537 RAMP IN METER_2
R499
COMMAND
5
22.1K
J27 R407 330p
1.00M
J2 J2
PWM OUTPUT
56.2K
R442
R533
1W 13
R404 C402 LM224 P BOOST 13 4.75K 100V +PWR
10 10 12 /RAMP C414 2
1.0 C417 4 HP2231
BACKGROUND METER
BACKGROUND COMMAND
1 2 13 .0047 RAMP /RAMP
TO FRONT END
100 35V C403 2700p X36 100
R408
R446
17.8K
100K
LOCAL D 11 50V B 2 J2
C406 5 R443 X30 A 50V NAND OCI5 +VIN
J2 12 R437 R433 13
( SHEET 2 )
R507
100
500K 82.5K 5 12
D404
1 2 C413
INCREASE TAILOUT
ARC 15.0K
TAIL OUT R490 13 D403 +1.42V
0.1
DURING HOT START T1 T2
X24 4 3 10 11
10.0K D 4 A A Q 6 50V
+15V CW J2 267K 1014
HP2231 J2
14 B X21 X22 D P BOOST X10 -VIN
R436
1.00K
11 R445 5 B /Q 7 4
12 3
SHORT OR 500K POT
+15V
1.00M
R447
R448
R449
13.7K
RST +15V
C450 100K J2
R450
D409 1.00M C415 -PWR
0.1 1
2.67K 2.67K 2.67K 2.67K J2 3
X31 C 50V OUTA OUTB
7 R434 R468
R546 R545 R544 R406 LOCAL_POTS D414 "KEEP ALIVE"
METER_1
LOCAL BG POT
8 9 10.0 4.75K J2
CURRENT LEVEL
10K +PWR
J2 9
C404 DZ11 6
14 R435
+15V
1.00M
R469
1.0 12V CW C452 DZ16

10.0K
PLASMA BOOST METER

35V 1W 1.0 12V PB_SCALED 332 10.0K 100
C405 REMOTE J2 1W C416 J2 +VIN
35V
R440
X30 C
1.00M
R534
R491 R430 R431 R470
100
3 820p 12
C454
50V C411
100 8 9 R498
5.62K
R472
+15V 0.1
ARC_START 9
C446 20.0K 50V
3SEC 6
100 1.0 HOT_START J2
35V +15V 2 X29 8 -VIN
X30 B C 8
D407
R432
LM224
1.00K
SCALED_BGND
2 R489 J27 X29 1 10
A R497
J3 R492 3 4
HOT START TIME
5 LOCAL 3
LM224
CW REMOTE_POTS
R475
10.0K
150K
REMOTE BG POT
D415 J2
10.0 5
10K X30 D C453 -PWR
R494
11% BACKGROUND INCREASE 6
5 R478 J27
6.81K
J3 12 DURING HOT START

X29 R549 R548 R547 R495
DZ15 C449 D 6
10K 10.0K 10 11
C447 LM224 14 CW DZ17
J3 12V D408 2.67K 2.67K 2.67K 2.67K C451 HOT_START Input- Current
1.00M
R476
1 2
1.0 12V C455 12 R496
6 1W 13 J27 1.0 Feedback
35V 1W 3 4
1.00M
R520
+15V 7 R493 35V 100K

OFF
/HOT_START 100 GENERAL INFORMATION
REMOTE J1 FILE: G2781_1D1
LAST NO. USED
R477
100
DZ20
HOT START R- 165, 242, 345, 564 OCI7
PINCH RAIL P_BOOST ELECTRICAL SYMBOLS PER E1537
TIMING 6
1 5 1 8 Analog Logic I/O C- 129, 211, 314, 475 X36
Remote CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
GENERATOR 6 10 9 16
LABELS
Q10
X29 PINCH SLOW RAMP Control to Control Panel RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
D- 117, 211, 310, 424
D406 B 7
R480
100K
W4
DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
5 LM224 J27 J2 SUPPLY VOLTAGE NET
Unused Devices
PINCH KNEE
Q6 J28 J28 1 3 Analog Logic I/O POWER SUPPLY SOURCE POINT
R481 13 5 1 7 Darlington REFERENCE DESIGNATOR SERIES DEFINITIONS
2N4401 +5.1V 4 6
1 100 J28 J28 8 Drive- Output to Control Panel 100 SERIES- ARC SENSE CIRCUIT (SHEET 2)
COMMON CONNECTION
ARC_START R536 12 4 14
X18 C469 Vac In
A 3
J28 J28 J3 200 SERIES- TRIGGER CIRCUIT (SHEET 2)
R485 39
PINCH FAST RAMP FRAME CONNECTION
2 NAND 10.0K 9 2 J28 300 SERIES- DIGITAL LOGIC CIRCUIT (SHEET 1)
20V EARTH GROUND CONNECTION
33.2K BACKGND TAILOUT BACKGND 400 SERIES- ANALOG LOGIC CIRCUIT (SHEET 1)
J27 X22 NOTES :
8
RAMP EQUIP.
J27
STT CONTROL
Ch'ge.Sht.No.
4 4 3
BALL FUSE
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE UNLESS OTHERWISE SPECIFIED TOLERANCE THE LINCOLN ELECTRIC CO. TYPE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY ON HOLES SIZES PER E-2056
J27
R479
5-19-95
SCHEMATIC (Sheet 1 of 2)
562
KEEP_ALIVE LEVEL KEEP_ALIVE LEVEL

3 5 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE ON 2 PLACE DECIMALS IS + .O2
ON 3 PLACE DECIMALS IS + .OO2
CLEVELAND, OHIO U.S.A. SUBJECT
NUMBER. 5-24-96E
ON ALL ANGLES IS + .5 OF A DEGREE SCALE NONE
SHT.
G
COMMAND SIGNAL
MATERIAL TOLERANCE ("t") TO AGREE
DR. MLD DATE 04/12/94 CHK. SUP'S'D'G. NO. 2781-A
WITH PUBLISHED STANDARDS
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided
for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. INVERTEC STT & STT II
2781-B G
FRONT END
Varc FILTERED J17 +12VFE
13.7K
13.7K
13.7K
13.7K
R100
R102
R103
R101
R105
TO ENERGY
13.7K
13.7K
13.7K
13.7K
R107
R104
R106
10
CONTROL OPTION
J5
7
- STUD +12VFE
100p
R138
TRIGGER CIRCUIT
FE
2.67K
J5
3 100V
1V REF
ARC VOLT FILTER
47.5K
J5 1.00K
C102 D200
6 R109
R141
8.25K
.400V
PRIMARY CURRENT R200
R110 DV/DT Varc CW
DZ1
FEEDBACK 125:1 RATIO
R140
243
1N4936
R139
12V 47.5K SAMPLE C108
R242
10K D201
1.30K
1.8 C107 D202
DV/DT
R202
R204
R205
PRI_FB
R203
4.75K
R201
1W 4
J4
R111
20V 0.1
Y 1N4936 1N4936
X3 A 10
4.75K B
DERIVATIVE_TRIP
DV/DT LEVEL DETECT
INPUT FROM OCI2 2
C101 2 VARC_SCALED TURN 50V
X4 A C201 +15V
VOLTAGE C100 .001 47.5K FE R159 C200
10.0
10.0
10.0
10.0
10.0
1 3 2 J4
TO DIGITAL LOGIC
OP470 Y
.0047 400V NEW DV/DT
SENSE PANEL R112 C104 D101 6 8 ( SHEET 1 )
3000V 3 Varc SAMPLE FE CURRENT
.0047 1N914
4.75K
SMP04
( SHEET 1 )
.33
R137
R113
TRANS.
R241
267
HP2231
10K
50V 200V
11 D204
R209
B +15V
R206
C103 X3 D203
1.7V = 150A PRIMARY
26.7
26.7
3
100K
R232
FE +12VFE
20.0K
20.0K
1N4936 1N4936
R108
DZ2
R162
100p 5 X5 B 13
R114
47.5K
J5 R142 26.7 26.7
12V FE 5 1
5 100V C109 X4 B 7 dv/dt
10 2901 2
1W +12VFE 7 10K
DV/DT
R207 R208 ( SHEET 1 )
820p OP470 +15V
6 R234
R143
SMP04 +15V PWM_EN
100K
50V
PWM ENABLE
+12VFE H=LOW DV/DT
825
100K 332K
R165
R115 R116
R236
10K
D100 FE FE L=HIGH DV/DT C206
R233
TO ANALOG LOGIC
13.7K 13.7K
10K
1N4007 R144
SMP_STROBE
+15V
4.75K
R125
R117 R118 1.00M NEG_CLAMP 9
FE
R237
( SHEET 1 )
10K
D117 C DV/DT 10X
R123
68.1K
X3
13.7K 13.7K R124 5 X28 14
R213
1N914 AMPLIFIER 3.6V
10K
R145 C
J4 2901
R119 R120 11 15 X28 A
2 8
9 +12VFE 3 R210 R211 D205 H=PWM OFF
9 10K 6
13.7K 13.7K 3.92K X28 B 4 2901
L=PWM ON
22.1K 47.5K
1N914
J5 X5 D 14
SMP04 C202 H=PWM ON
D116
2901 R164 2901 1
+ STUD 1 R121 R122 +12VFE L=PWM OFF
15.0K
R212
8 1N4936
R126
DV/DT SAMPLE PULSE
51.1K
+12VFE OLD DV/DT 7 C205
13.7K 13.7K
ARC
R235
100K
FE Varc SAMPLE 330p
R146
8.25K
D102 8.95V 100V
DETECTOR TRIGGER
R127
SHORT DETECT
68.1K
1N914 OPTOCOUPLER
C105 Varc SAMPLE
R147
4.75K ON POWER
10K
R214
26.7K
R129
1 BOARD C203
+12VFE R128 C204
X3 D 10K
A 0.1
ARC/SHORT DETECT
FE 100p OCI2
47.5K
R215
R148 J17 50V
12 14 4
100V 4
C110 X5 A
TRIGGER
+12VFE 10
TO DIGITAL LOGIC
ARC_TRIP
10K 820p 2901 2
SMP04
INTERFACE
OVERVOLTAGE
R135 50V
( SHEET 1 )
R132
22.1K
5 OPTOCOUPLERS
HP2231
DT_DELAYED OUT
267K
R130
D115 J4
R131
3.92K
3.92K
2 ON PROTECTION
47.5K 7 FE ARC 2
NEG_CLAMP
4.75K
BOARD 11
PHASE A
1N914
R136
R149
332
DT_RC
OCI5 B FE R133 X5 1
1.89V NORMAL DZ3
C H=SHORT
FROM 6 1
R134
6 2901 2.3V PINCH START
D104 L=ARC
OVERCURRENT FAULT
CR 1
CR1 R239 CR1
3 3.92K FROM SHEET 1
6
X6 A Y
PWM D103 9
( UNUSED
267
2 1.00K R163 +12VFE J4 9 CONTACT )
C106 X6 D 10 4 +t
R230
HP2231 1N914 1N914
10.0
DT_DELAYED
10 R216 R225 R229
330p 8
15V .13 60V 13 D207 D208
CW
OVERHEAT INDICATOR
8
DT
100V D206 2.21K 1.50K
R150
1W 11 DZ6
FE J4 CNY17-3
PHASE B
13 TRUNCATES DT_DELAYED
DZ4 R217 R218 R226 3.3V
5K
1 OCI7 5
OCI5 A 11 6 43V
X6 B
3.92K
1W
R152
1.30K 1.30K 1.50K
FROM
12 CHOKE FAN 1W
R240
TSTAT TSTAT ON=TRIGGER ON
10K
7
DT Q1 R219 R220 R227 D211 OFF=TRIGGER OFF
PWM
2N4401 B OCI1
PINCH KILLER
5W
ARC DETECTOR
1.30K 1.30K 1.50K
3.92K C207
FAN R
HP2231 ADJUSTMENT 2 6 4
Varc ADJUST
681
6
R151
FOR INITIAL R153 R221 R222 R228 20
150
50V
( SHEET 1 )
PINCH PULSE 1.30K 1.30K 1.50K
HP2231 T1 AUX XFMR
R231
J4 DZ5
47.5K
R223 R224
24 VAC 12 43V D209
1.30K 1.30K D210
DT
J4 1W
FE
TO POWER BOARD 5 R238
J17 C D J4
9
8 R154
1 TRIGGER +t
ISOLATED CIRCUIT
1.50K 56
A TO POWER
ENERGY CONTROL DIODE ON = OPTION ENABLED OCI3 ENERGY CONTROL BOARD
OPTION ENABLE
D105 DIODE OFF = OPTION DISABLED
OPTION ENABLE 1N4936

HP2231 ( SHEET 1 )
+15V
2
J17
9 R155
1.50K
J17
7 R160 UNUSED 3
4
1.50K J4 X28 "D" COMPARITOR
B
ENERGY CONTROL DIODE ON = OPTION P_BOOST TIME OCI3 ENERGY CONTROL 4
X28
C211
0.1
ON SHEET 1
COMPARATOR
OPTION P BOOST
DIODE OFF = LOCAL P_BOOST TIME
D106 50V
OPTION P BOOST J4 LM2901
OR NOT OPTION
1N4936 P_BOOST TIME
TIME ( SHEET 1 )
1
TIME
HP2231
12
3
J17
2 R161
J4
1.50K 7
H = PINCH A
OCI1 PINCH SIGNAL FOR
L = NOT PINCH
ENERGY CONTROL OPTION

J17 7
1
HP2231 ( SHEET 1 )
H = START PLASMA BOOST TIMING
L = NOT PLASMA BOOST

A OCI6 PB_START SIGNAL FOR
J17 7
5
HP2231 ( SHEET 1 )
H = STAINLESS
B
WIRE TYPE POSITION
OCI6
L = MILD STEEL
J17 6
12
HP2231 ( SHEET 1 )
ISOLATED CIRCUIT
+12VFE +12VFE +12VFE
POS FE POWER PLANE
14 16 8 8 8
Vcc Vcc Vcc
J17 Vdd
C123
+12V OUT 3 C121 X6 C122 OCI5 OCI1 C128 OCI6 C129
D107 X3 0.1
0.1 NAND 0.1 0.1 0.1
50V
50V 4093B SMP04 50V 50V 50V
HP2231 HP2231 HP2231
Dgnd Vss
X1
7 8 13 GND 5 GND 5 GND 5
IN LM350 OUT
D108 D109
1N4007 s15128-15k1 FE GROUND PLANE
1N4007
1.82K ADJ FE FE
C111 C112
36 VAC
35V R156 R157
XFMR J5
1000 C117
8 243 C118 D113
18 VAC 500 27
+12VFE
R158
C113 35V
.0047 CW UNUSED GATES
CT J5 1400V
2 POS FE POWER PLANE
C114 C115 C120 D114

GND C119 C124 4 3 C126 +12VFE
.0047 V+
47 27 0.1 0.1
1400V
18 VAC J5 35V C116 X2 35V 50V 50V 6
4 X6 C 4
X4 X5
5 NAND
IN 7915 OUT OP AMP COMPARATOR
D111
D110 s15128-12 OP470 LM2901

C125 C127
1N4007
1N4007 -15VFE 0.1 0.1
V-
FILE: G2781_1D1
50V 11 12 50V
D112 10
-15V OUT J17
ENERGY 11
FE FE NEG FE POWER NET
X4 C
8 GENERAL INFORMATION LAST NO. USED
CONTROL FE DZ20
J17 9 OP470
OPTION R- 165, 242, 345, 564 OCI7
COMMON OUT 6 ELECTRICAL SYMBOLS PER E1537
C- 129, 211, 314, 475 X36
-15VFE -15VFE CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
Q10
12 RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- 117, 211, 310, 424
W4
POWER SUPPLY FOR "FRONT END"

14 SUPPLY VOLTAGE NET
X4 D
13 OP470
POWER SUPPLY SOURCE POINT
REFERENCE DESIGNATOR SERIES DEFINITIONS
COMMON CONNECTION
100 SERIES- ARC SENSE CIRCUIT (SHEET 2)
FE 200 SERIES- TRIGGER CIRCUIT (SHEET 2)
FRAME CONNECTION
300 SERIES- DIGITAL LOGIC CIRCUIT (SHEET 1)
400 SERIES- ANALOG LOGIC CIRCUIT (SHEET 1) EARTH GROUND CONNECTION
NOTES :
EQUIP.
STT CONTROL
Ch'ge.Sht.No.
Energy Trigger Circuit
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE UNLESS OTHERWISE SPECIFIED TOLERANCE THE LINCOLN ELECTRIC CO. TYPE
1 4 Front End 1 6 1 6 WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY ON HOLES SIZES PER E-2056
Control
SCHEMATIC (Sheet 2 of 2)
5-19-95
Vac and Varc I/O and Vac
5 8 7 12
Option
7 12 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE ON 2 PLACE DECIMALS IS + .O2
CLEVELAND, OHIO U.S.A. SUBJECT
NUMBER. 5-24-96E
J5 J17 J4 SHT.
DR. MLD DATE 04/04/94 CHK.
FV
SUP'S'D'G. NO. G 2781-B
PC Board Assembly - Control - Codes 10151 - 11092 - (G2782)
ITEM REQ'D PART NO IDENTIFICATION ITEM REQ'D PART NO IDENTIFICATION

G 2782-1
C301 R307
R139 C432 C435 D302 C437 R557
R303 C436
R138 R306
C443
C108 R313 R441
R321
R328
D303
C434
R320
C418
C119
C303
R140
X13
X10
R151
C442
X20
X11
X14
R150
R312 R439
C302
X15
X16
R322
X12
C117
X9
C304 R323 R468
C107 C414
C307
R318
C305
R301 R455 R325
R317 C306
Q1
C120 C473 R314 C445

R305 C427 D301
D104
R123
R126
R129
R132
R147
R149
R153
R302 C433
C127
D113 R552
R453 C444 D420
Q4
R539
R555
C300 R331 C472
D114 D305
C118 R304
R471
R550
R530
R510
D300
R529
R308
R309
R330
C440
C439
R451 Q8
C456
X23
X19
X17
X32
R452
X25
R124
R146
R135
DZ3
C438
X36
X18
R538
C126
G2782-[ ]
R564 R525
X5
C468
R447
R537
R446 D410
X1
X2
R540
R300
D421
D405
R523
C311
R459
C422
C415 D422 C441
R442 R554 C471
R457
R553
OCI2
R127 D411
C474
R414
R339
R136 R458 R426
D417 R409
C313
R164
R125
R128
C106 C419
D102
D112 R410
D404
STT CONTROL
D107 R134 R412
C429
R429
R157 R411
R133
C314
D418 R551 R449 C465

R156 D103 C312 D310
R141
D402
R338
R337
R413
C110 C105 D419 C407
R163 D309
R148 R428
Q10
R158 C122 D307 R427
R335
R559
R131
R450
C109
D306 X8 R448 R560
C425
C428
X24
C470 D424
X6
X22
D308 R425
X21
D403
R499
R456
R454
C475
R113
R130
C204
R463 W4
X3
C211
R215
W3 W1
R137
R514 R214
R444 R420 R237
C121 R461 C426 D401 R212
C115
R421 R424 R561

C123
C459 R419 R211

W2 C466
C430
C417 C410 R423 C202

R145
OCI5
OCI4
D101
R144 C452 R422
R521
R142
R522
R494 R232
D117
R143
X28
R165
D116
D115
C104
D423
R563
R562
R234
R408 DZ19 C453 C450 R233
R159
DZ6
R311
D208
R516
R524
R498 C206
C463 R497 R536
C207
X35
R210
DZ16
X34
R527
R534
C454
D414
R485 R445
R332
R324
R329
R341
R333
C203
C406
R407
R236
C424
D413
C124
R518
R152
OCI3
R440
DZ1
DZ2
C103
D105
R155
R154
R114
Q6 C205
C467
R528 R241
X30
X29
C416
R316
R229
R240
R517
R242
X4
D210
Q9 R235
C458
D207
Q3 D400 D415 R479 R481 R213
C462
D205
R110 R490 D406 R310 R200

C404 C403 C455
C102 R340 D200 C201
R496 R480
D106
R112
OCI1
C111
R109 DZ10 DZ17 D211 D209 R205

C128
R475 D408 C449

C125 C402 R520 R204
DZ11
D409
R511
R495
C405
R319
R406
R469
D407 R203
DZ9
R533 C451 C469
C101 R202
R227
R228
R226
R225
R223
R221
R219
R217
R415 DZ15 OCI7
DZ4
X31
C413
C411
R403 R201
C464
R431
R515
R512
R509
R111
R161
R160
R547 R416 R430 C447 R209

OCI6
R162 R544
D108 R103 R545 R548 R208
C129
C448
R108 C308 R488 R231

R102 R334 R508
D110 R486
DZ20
X26
D100 R230
DZ12
R101 R541 C309

C116
C112
R417
R418
R487
R218
R220
R222
R224
C457
DZ5
D202
D109 R100 R122 DZ8
D204
D416
R207
C461 R437 R482
R107 R120 R345
Q2
R542
R493
R546
D111 R344 R436 R472

Q7
R106 R118 DZ18 R556 R474
C200
R343 R432 R473 C446 C409
CR1
R105 R116 C460 R532
C113
R104 R503
R238
R216
R121
R467
C400
D203
D412
D206
C310
R526
D304
D201
C114
R500
R505
R402
R326
R327
R501
R434
R435
R433
R443
R470
R491
R404
R342
R477
R478
R476
R405
R206
R489
R507
R492
R504
R519
R484
R483
C100 R119
C401
R513
R506
R400
R401
R502
C412
C423
R543
R549
X33
R466
R117
R239
R115
J5 J17 J27 J28 J2 J3 J1 J4
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
THIS SHEET CONTAINS PROPRIETARY INFORMATION UNLESS OTHERWISE SPECIFIED TOLERANCE EQUIP.
OWNED BY THE LINCOLN ELECTRIC CO. AND IS ON HOLE SIZES PER E2056 5-19-95 THE LINCOLN ELECTRIC CO. TYPE STT INVERTER WELDER
ON 2 PLACE DECIMALS IS .02
NOT TO BE REPRODUCED, DISCLOSED OR USED 7-28-95C CLEVELAND, OHIO U.S.A.
WITHOUT THE EXPRESS PERMISSION OF
ON 3 PLACE DECIMALS IS .002
5-24-96E
SUBJECT CONTROL P.C. BOARD ASSEMBLY
ON ALL ANGLES IS .5 OF A DEGREE
G 2782-1
SCALE FULL
MATERIAL TOLERANCE t(" ") TO AGREE SHT.
THE LINCOLN ELECTRIC CO. WITH PUBLISHED STANDARDS. DR F.V. DATE 6-8-94 CHK FV REF. L8441-3
SUP'S'D'G NO.
PC Board Assembly - Control - Codes 11115 - 11116 - (G4648)
Schematic - Power PC Board - All Codes - (M16018)
M 16018
+15V
1.0 5W .25 D5
R44 R69
R1
+t + t
Vin + Vc
100K
100K
.24
R5
R6
D1 D3
IN OUT
X1 OUT D15
D16
C8 1.0A
R4
P7 J7 267 X67 1.0A
1.50K
LM350 GND
5 0.1 30V TO PULSE
30V
R7 INV IN 50V F TRANSFORMER
18Vac
TP1 ADJ
N.I. IN
FROM AUXILIARY
C1 J7 P7
50V 267
TRANSFORMER R3 8
15J 3300 C2
50V 243 C3 R8 J7 P7
P7 J7 7
6 150 E
2.67K
50V Vin + Vc
R2
DZ5 OUT
D2 D4
DZ4
12V 12V X68 GND
C9 D7 D6
1W 1W
INV IN 0.1 1.0A 1.0A
50V 30V 30V
N.I. IN
J7 J6 J6 J6 J6 J7
3 6 8 3 1 1
P7 P6 P6 P6 P6 P7
TO TO PWM PWM TO TO
PILOT CONTROL SIGNAL SIGNAL CONTROL PILOT
LIGHT BOARD BOARD LIGHT
+24V
(+) (+15V) (COM) (-)
+24V
J7 P7
150K
2
R9
RELAY COILS D
B D14
10K
R41
475K J7 P7
1N4936 267K
4
R12
10K D R20
DZ6 5 Q5
33.2K 33.2K D13 10K
6.2V 1W R42 R11
100 7 G 10
Q40 100 X4 R15 R17 R19 2.21K J6 P6
J14 IRF513 2
1 R43 600mA 6 S 8
C5 DZ1 X4 R21
40V C6 1 5
33.2K
15V
100K
39 9
R16
R10
1.8 OCI1
1W
R18
FROM PROTECTION BD.

C14
20V
20V
CONTROL
26.7K
CNY17-3
TRIGGER
J14
2 2 6 4
COM
COM
J14 COM 100K

3
R22
+24V
33.2K
+24V
J14 J6 P6
4
A R13 7
COM
D12
NOTES :
15.0K
R14
D8 D10 N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
P6 J6
5 +24V WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS
IN X5 OUT
3 DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS
P6 J6
4 COM HAVING A COMMON CODE NUMBER.
LM350 4 1
X4
TP2
5.11K
R25
24Vac C10 C11 2

50V ADJ GENERAL INFORMATION LAST NO. USED
500
15J R24 C7 X4
P6 J6 50V UNUSED ELECTRICAL SYMBOLS PER E1537 R- 69
9 267 12 C- 14
LM224 CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
R23
4.75K
P6 J6 14 LABELS D- 16 DZ- 6
10 C X4
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
D9 D11 11 13 DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
SUPPLY VOLTAGE NET
COM POWER SUPPLY SOURCE POINT

COM COM
COMMON CONNECTION
J14 J7 J6
1 2 1 4 1 5 FRAME CONNECTION
FILENAME: M16018_6JA
EARTH GROUND CONNECTION
UNLESS OTHERWISE SPECIFIED TOLERANCE Ch'ge.Sht.No. 4-13-95C EQUIP.

ON HOLES SIZES PER E-2056
3-22-91 THE LINCOLN ELECTRIC CO. TYPE
INVERTEC
3 4 5 8 6 10
ON 2 PLACE DECIMALS IS + .O2 3-29-96L
9-11-92B 9-27-96F CLEVELAND, OHIO U.S.A. SUBJECT POWER BD SCHEMATIC
ON ALL ANGLES IS + .5 OF A DEGREE
MATERIAL TOLERANCE ("t") TO AGREE 6-25-93A 10-25-96 SCALE NONE
SHT.
9-24-93D DR. MJH DATE 11/10/92 CHK. SUP'S'D'G. NO. M 16018
PC Board Assembly - Power - All Codes - (L8033)
ITEM REQ'D PART NO. IDENTIFICATION
J7
J14 J6
L8033-[ ]
D14
R5
R6 X5 D12 R41 C10
D1
C14
C11
OCI1
D2
D4
DZ6
R22
R8
D3 TP2
D15 DZ4
TP1
E D7
R43 D11 D10
C5
POWER BOARD
D16 D6
D9 D8
C9 C8
B
R2
R4
R3
DZ5
R16
R7
Q40
R15
C6
R14
R42
R10
R21
R18
R17
DZ1
C1 Q5 D13
X1
R19
C
X68 X67 R20
D
C3
R25
R13
R12
R11
D5
C7
R9
X4
R24
R44
R23
R1
R69
C2
INDUCTANCE = HENRYS
Schematic - Darlington Drive Board - Codes 10151 - 10383 - (M17581)
+V
M 17581
+V
.5 5W
R1
AUXILLARY
TRANSFORMER D4 D1 DZ1 C17
WINDING 8A 8A 18V 500p
400V 400V 1W 1000V
J13 POWER 10.0 3
C12 1 Q1
2 C15 SUPPLY R6
3300 C16 6A
3300
10VAC J13 50V
50V 100V
3 2
D3 D2
10W
10W
8A 8A
400V 400V
R11
R9
2.7
2.7
R J13
6
GND
2 AMP
6VAC
10W
10W
J13 BASE
R10
R12
5
DRIVE
2.7
2.7
NEGATIVE BIAS
for DARLINGTON
C
DARLINGTON MODULE
HOLD - OFF 2.7 10W
R13 J12
BLUE B
2.7 10W 1
D6
R14
1N5402
TWISTED
D10 D12
1.00K
1.00K
1.00K
1.00K
R15
R17
R16
R18
C10 PAIR
1N5402 1N5402 D7
E
1N5402 .33
200V 2
D8 BLACK
J12
1N5402
C9
D11 D13
Symmetric Gate Drive Layout

3300
1N5402 1N5402 3
STT CONTROL BOARD +V D9 50V J12
1N5402 4
J12
+15V
R8
20 5W D
J13 Q2
1 R2
1K
10.0 4A
1.50K G
3.92K
R7 100V
R4
OCI1 1 VS VS 8 S
267 C8
2 DZ3
7 2 IN OUT 7
18V 500p
D5 R5 X2
1W 1000V
C5 3 NC OUT 6
3
HP2201 DZ2 0.1
4 GND GND 5
ON = Darlington ON 12V 50V C6
1W 4429
OFF = Darlington OFF 0.1
J13 GND
4 R3 50V
1.50K
GND
GENERAL INFORMATION LAST NO. USED
R- 18 DZ- 3
ELECTRICAL SYMBOLS PER E1537
C- 17
CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
+V
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- 13

SUPPLY VOLTAGE NET

NOTES :
8 J13 J12 COMMON CONNECTION

Vcc N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY FRAME CONNECTION
1 3 1 2
C14 OCI1 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
0.1 NUMBER.
FILE: M17581_1AB
50V
HP2201
UNLESS OTHERWISE SPECIFIED TOLERANCE Ch'ge.Sht.No.
EQUIP.
GND
4 6 3 4 ON HOLES SIZES PER E-2056
INVERTER WELDERS
5 ON 2 PLACE DECIMALS IS + .O2
3-29-96L CLEVELAND, OHIO U.S.A. SUBJECT SCHEMATIC, DARLINGTON DRIVE
MATERIAL TOLERANCE ("t") TO AGREE SCALE NONE
GND SHT.
DR. MLD DATE 03/23/94 CHK. BS SUP'S'D'G. NO. M17581
PC Board Assembly - Darlington Drive - Codes 10151 - 10383 - (G2778)
ITEM REQ'D PART NO. IDENTIFICATION

STT DARLINGTON DRIVE

J13 J12
G2778-[ ]
D10 D6 D7 D8 R18 R15

R17 R16
D12 D9
XXX
XXX
XXX
XXX
D1
D2
R8 R14
D11
C10
R2
R3
D13
XXX
XXX
R13
D4
D3
XX X X X
XXXX X
D5
XXX
XXX
C9 R10
XXX
OCI1
X
X
X
X
C14
XX X
XXX
XXX
X
R12
X
DZ1
C17
DZ2
R1
R4
R5
C5
R6
C15 C12 X2
XXX
XXX
C6
R7 R9
Q1
C16
X
XXX
X X
X X
X
XXX
XXX
X
DZ3
X X
C8
R11
Q2
RESISTORS = OHMS
Schematic - IGBT Drive Board - Codes 11090 - 11116 - (L12144)
PC Board Assembly - IGBT Drive - Codes 11090 - 11116 - (L12145)
Schematic - Switch Board - All Codes - (L8440)
L 8440
SWITCH BOARD SCHEMATIC

VOLTAGE NET
COMMON CONNECTION
FRAME CONNECTION
LAST NO. USED
SHT.
NO.
INVERTEC V300
42
10
8
C-
D-
R-
SUPPLY
D4
1N4936
LABELS
W
221
D2 Q2
R4
100
R3
SUP'S'D'G.
1N4936 D3
1A
100V 1N4936
R35
47.5
IRFD110
UNLESS OTHERWISE SPECIFIED)
SUBJECT
1
22.1K
EQUIP.
Q7
UNLESS OTHERWISE SPECIFIED)
TYPE
1/2W
R15
R16 600mA
BS
DZ6
40V
2N4403
(UNLESS OTHERWISE SPECIFIED)

1.00K
POSITIVE
6.2V 1W
D9 9 INPUT
CHK.
B
R14
1.00K 1N4936
R12
Q6
Q3 600mA
THE LINCOLN ELECTRIC CO.

C1 DZ1
1A 40V
11-25-91
FILE NO. L8440-1AA
D1 D2 D3 D4 D5
10V
2N4403 R8 G1
NONE
100V
CLEVELAND, OHIO U.S.A.

DZ5 1W A1
SNUBBER
MFD ( .022/50V
3.3V 10.0

G2
IRFD110
1/4W
A2
A2
RESISTOR
GENERAL INFORMATION
1W Q5
DZ4 G3 IRFP460
600mA BYT12P600
15V R17
1 40V G4
Q4 1W 10.0
SCALE
2N4403 C1
DATE
600mA 1/2W
G5
R11
1A, 400V
DZ3 S1 S2 S3 S4 S5
RESISTORS = Ohms (
40V R6
10V 1W 15.0K
2N4401
10.0
CAPACITORS =
R10
20
402
D5 475 475 ---
DIODES =
R9
R42
R18
M. A. P.
1N4936
404
R13
C2 10.0
2700p
50V R33
100 C3
DR.
10.0
R7
1.50K .047
1200V
C7
R5
4 TRANSFORMER
R -
5 PRIMARY
C2
A2
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
BYT30P600
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY

A2
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

R38 R39 INPUT
D1
1N4936 39.2K 39.2K
FILTER
W R41 R40
CAPACITOR
10-8-93A
9-11-92
39.2K 39.2K
Ch'ge.Sht.No.
221
D6 100
Q1
R1
R2
1N4936 D7
1A
100V 1N4936 C2
47.5
R36
A1
IRFD110
BYT30P600
UNLESS OTHERWISE SPECIFIED TOLERANCE

22.1K Q11 1/2W A2
R22

600mA DZ9

R23

ON 2 PLACE DECIMALS IS + .O2

40V
1 TRANSFORMER
2N4403 -
1.00K 6.2V 1W 8 PRIMARY
D10
R21
1.00K 1N4936 A
R20
Q9
NUMBER.
Q10 600mA C4
C5 DZ2
1A 40V .047
10V D1 D2 D3 D4 D5 1200V
100V 2N4403
DZ8 1W R19 G1
NOTES :
3.3V
IRFD110 Q8 10.0 G2 A1
1W DZ7
600mA IRFP460 401
N.A.
15V G3
1 40V
1W
R26 ---
Q12
600mA 1/2W 2N4403 10.0
G4
403
R28
DZ12 G5
40V S1 S2 S3 S4
10V 1W 15.0K S5
R25
2N4401
R32
20 10.0
D8 A1
475 475 R27 SNUBBER
R29
R37
1N4936
R31
C8
2700p
10.0 A1
BYT12P600
RESISTOR
50V
C1
R34
100
R30
1.50K 10.0
R24
C6
NEGATIVE
R 12
INPUT
L 8440
FRANCE CANADA AUSTRALIA
PC Board Assembly - Switch - All Codes - (L8441)
21B 11B 9B 01B 3B 7B 5B 6B 2B 1B ITEM REQ'D PART NO. IDENTIFICATION

C1, C5, C6, C7 4 S16668-5 .022/50
C2, C8 2 S16668-4 2700pF/50
C3 C4 C3, C4 2 S13490-112 .047/1200
D1, D2, D3, D4, D5, D6,
10 T12705-34 1N4936
D7, D8, D9, D10

D2
D4
C1
C5
R1
D1
D6
T12702-27
R3
DZ1, DZ2, DZ3, DZ12 4 1N4740

DZ4, DZ7 2 T12702-29 1N4744A
DZ6, DZ9 2 T12702-40 1N4735
R16
R14
R21
R23
D5
B8 B4
Q11
D8
Q7
DZ5, DZ8 2 T12702-53 3.3V 1W

Q1, Q2, Q3, Q10 4 T12704-73 IC PKG MOSFET
R12
R30
R20
Q12
R7
DZ5
DZ8
2
Q4
Q4, Q12 T12704-68 2N4401

Q5, Q6, Q7, Q8, Q9, Q11 6 T12704-69 2N4403
4
R31
S19400-1000 100 1/4W
R13
Q3 Q2 Q1 Q10
R1, R3, R5, R24
R2, R4 2 S19400-2210 221 1/4W
R6, R8, R9, R17, R19, R25

R11
10 S19400-10R0 10 1/4W
R15
R22
DZ12
R28
R24
R5
R4
R2
R26, R27, R33, R34
DZ3
R7, R30 2 S19400-1501 1.5K 1/4W

R38
R39
R40
R41
R10, R32 2 S19400-1502 15K 1/4W

R35
R33
R27
R25
R34
R36
D3
R6
R9
D7
DZ6
DZ9
R11, R15, R22, R28 4 T14231-20 1 1/2W
R12, R14, R20, R21 4 S19400-1001 1K 1/4W
R13, R31 2 S19400-20R0 20 1/4W

R18
R42
R17
R19
R26
R29
R37
C7
C6
DZ4
DZ7
R8
R16, R23 2 S19400-2212 22.1K 1/4W

R18, R29, R37, R42 4 S19400-4750 475 1/4W
Q5
Q8
R35, R36 2 S19400-47R5 47.5 1/4W
R10
R32
C2
DZ1
D10
C8
D9
DZ2
L8441-[ ] SWITCH R38, R39, R40, R41 4 S19400-3922 39.2K 1/4W
Q9
Q6
Schematic - Driver Board - All Codes - (S20799)
20799 S
J16
R3 R4
3 J9 150K 150K
4 G1
250 150K
R5
GATE
R1
20W
10 J9
1 S1
4 R2
J9
G2
T1
3 TO 250
J11
1 GATE 150K
3 20W
R6
9 J9
6 S2 SWITCH
DRIVE 5
J11
J10
1 S3 BOARD Q1
1 4A
GATE
12 R7 1
J10 900V
8 G3
TO POWER 6
4 100 J16 FROM
J10
S4
BOARD 6 DZ1 PROTECTION
GATE 12V
7 J10 1W BD.
3 G4
2
J16
Power Switch Drive Transformer Capacitor Pre-charging Circuits 3
J16
J16
R8 R9
150K 150K
250 150K
R10
20W
R13
R14
1 2 1 3 1 7 250
150K
20W
R11
Q2
4A R12 14
900V
3 4 8 100 J16 FROM
4 6 14
DZ2
PROTECTION
J11 J9,J10 J16 12V
1W BD.
13
NOTES : J16
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 12

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
J16
NUMBER.
FILE: S20799-1AA
EQUIP.
INVERTER WELDERS
ON HOLES SIZES PER E-2056 THE LINCOLN ELECTRIC CO. TYPE
ON 2 PLACE DECIMALS IS + .O2 6-25-93C
ON 3 PLACE DECIMALS IS + .OO2 CLEVELAND, OHIO U.S.A. SCHEMATIC, DRIVER BOARD
SUBJECT
SCALE NONE
MATERIAL TOLERANCE ("t") TO AGREE SHT.
WITH PUBLISHED STANDARDS DR. LC DATE 11-4-92 CHK. BS SUP'S'D'G. NO. S 20799
PC Board Assembly - Driver - All Codes - (L9134)
XXXX XXXX XXXX XXXX DRIVER L9134-[ ] ITEM REQ'D PART NO. IDENTIFICATION
R7
R8
DZ1
Q1
XXXX
XXXXX
XXXXXXX
R9
R6
R2 R1
R13 R14
R5
R10
T1
Q2
R4
R11
XXXXXXX RESISTORS = OHMS/WATTS

XXXXX
R3
XXXX XXXX XXXX XXXX XXXX CAPACITORS = MFD/VOLTS

R12 DZ2
J10
J9 J11 INDUCTANCE = HENRYS
J16
Schematic - Protection PC Board - Codes 10151 - 11092 - (M16097)
M 16097
+5V
+5V
10K
FROM (+) UPPER CAPACITOR
R18
B52 10
8 J8
X1 R15 1
56.2K 150K 1 5
15.0K 9
R5
R6
475
OCI2
D1 CNY17-3V TO POWER BD.
3.32K
R21
(Over Voltage)
R19
2 6 4
56.2K 150K R14
R27
R4
C6 J8
100K
10K 681K 3
5
R2
R32
7
X1
56.2K 6
D5
R8
D7
56.2K CW
FROM BLEEDER RESISTOR
R10
+5V
R20
R37 1
X2 5K 1 5
IN OUT 332 J15

B14 OCI3
C2
1.82K
27
CNY17-3V TO DRIVER BD.
GND
DZ1 35V 56.2K 1.82K (Over Voltage)
2 6 4
10V
R16
10K
R26
R9
R3
1W
4
C3
.022 267K J15
R34
50V
B53
FROM (-) UPPER CAPACITOR

+5V
R35 3
1 5
332 J15
R28 R22 OCI4
TO DRIVER BD.
10K 332K D6 CNY17-3V
CW
(Over Voltage)
1.82K 2 6 4
3
R13
R7
FROM (-) LOWER CAPACITOR 5K
X1
1 6
C4 J15
2
R12 R11 .022 267K
R36
B51 50V
150K 150K
D4 15.0K
R33
J8
4
D8 1 5
1N4007
FROM CENTER LEG OF INPUT
D3
OCI1
F I L E : M 16097-2F1
CNY17-3V
R30 R31 R29 R25 R24 R23
H5 2 6 4 GENERAL INFORMATION
15.0K 15.0K 15.0K 15.0K 15.0K 15.0K TO CONTROL BD.
LAST NO. USED
R- _
C5 681K (Single Phase) CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
C- _
LABELS
R1
D- _
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
J8 SUPPLY VOLTAGE NET
2
+5V NOTES :
4
COMMON CONNECTION
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
12
C1 X1 EARTH GROUND CONNECTION
14 NUMBER.
X1
LM224 13
EQUIP.
THE LINCOLN ELECTRIC CO. INVERTEC V300
11
ON 2 PLACE DECIMALS IS + .O2 1-25-91 TYPE
9-11-92B CLEVELAND, OHIO U.S.A. SUBJECT PROTECTION
MATERIAL TOLERANCE ("t") TO AGREE 12-10-93A SCALE NONE
SHT.
DR. BS/DB DATE 9-7-89 CHK. TJP SUP'S'D'G. NO. M 16097
PC Board Assembly - Protection - Codes 10151 - 11092 - (L7915)
R1 R2
J8
C5 C6
L7915-[ ]
OCI1 OCI2
R12
D3
51
D8
B51
R23
R24
PROTECTION
R25 R26
R29 R21
R31
R11
H5
R3
D1
R30 R20
D4
B5
R33
R13
R4
B52
R14
R5
R7
X1
R15
R8
C1
D5
52
R27
R6
R10
D6
R22
R35 R32 R28
R37 R19
53
R9
R18
B53 C2
B14 DZ1
14
R16 X2
D7
OCI3
OCI4
J15
R34
R36
C3
C4
Schematic - Protection PC Board - Codes 11115 - 11116 - (M20352)
PC Board Assembly - Protection - Codes 11115 - 11116 - (L12235)
Schematic - Current Sense PC Board - All Codes - (S21410)
S 21410
+15V
681K
EXCITATION CURRENT MIN OFF SET
SOURCE ADJUSTMENT
R11
1.00K
100A/V CURRENT OUT
R10
R3
CURRENT CAL 6 J18
X1
13.7K 1
3.8V = 38 mA 1014 7
100 R9
R5
5
CW
VREF 13.7K
3
R16
R2
2K
10.0K
Q1
R8
X1 1 681K
R4
1014 3A
2
1.6V = 16 mA
1.00K 100V 20K
R6
C1 CW
1.50K
R1
C2
150p +IC
4
50V
R7
6.81K
-VH
3
10
+15V X1 8
HALL EFFECT +VH 2
SENSOR 9 1014
X2 -IC 1 10.0
J18
2 R15
4
R14
1.50K 12
1
X1 14
X3
100
8 C4 C3 C5
R12
X1 1014
REF 0.1 50 13
TL431
50V 50V
6 J18 LT1014
2.94K
R13
J18
J18 11 1 2
3 4
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO. AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO.
NOTES : FILE: S21410_1BA

LABELS
GENERAL INFORMATION
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED
ELECTRICAL SYMBOLS PER E1537 FRAME CONNECTION
CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING SUPPLY VOLTAGE NET
THE INTERCHANGEABILITY OF A COMPLETE BOARD. CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED)
OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED) COMMON CONNECTION
EQUIP.
STT-CURRENT SENSE
Ch'ge.Sht.No.
THE LINCOLN ELECTRIC CO.
UNLESS OTHERWISE SPECIFIED TOLERANCE
TYPE
ON HOLES SIZES PER E-2056 5-19-95
ON 2 PLACE DECIMALS IS + .O2 CLEVELAND, OHIO U.S.A. SCHEMATIC
ON 3 PLACE DECIMALS IS + .OO2 9-27-96F SUBJECT
11-15-96E SHT.
DR. MLD DATE 03/21/94 CHK. FV SUP'S'D'G. NO. S 21410
PC Board Assembly - Current Sense - All Codes - (M17591)
ITEM REQ'D PART NO. DESCRIPTION

XXX XXXX STT CURRENT SENSE

XXX
M17591-[ ]
X
XX C3
XX
XX
X2 R14
XX
XX
R15
XXXXXXX
R3
C4
X3 R13
R1
R16 R2
Q1 C5
C2
XX X
R4
R12
C1 J18
X
R8 X1
XX
R9
XX R10
R6
X
XX
R11
X
X
XXX
X XX
XXX R7 R5
Schematic - Remote Protection PC Board - All Codes - (M17609)
M 17609 10 PIN REMOTE

AMPHENOL
OPTIONAL REMOTE
E
L1 INTERFACE
I
J33
3
1 J
.39mH J36
L2
J33
2
6 B
.39mH J36
L3
J33 BG
10K
1
2 C POT
.39mH J36
L4
J33 PB
10K
10
7 G POT
.39mH J36
L5
J33
9
3 A
.39mH J36
L6
J33
12
8 D
.39mH J36
C1 C3 C5 TRIGGER
.0047 .0047 .0047 4
F
3KV 3KV 3KV C6 J36
C2 C4
.0047
.0047 .0047 11 GND
3KV H
3KV 3KV
J36
14 GND
C7 B
.0047 J36 2
3000V 13
L7 C
J36 TRIGGER
J34 4
6 5
D
.39mH J36
J34
5 8
I 41
C8 J36
.0047 42 VAC
J34 3000V J35
1 3 6 16
K 42
J35 J36
J34 J35
4 1 4 7
J 31
J35 J36
C9
.0047 115 VAC

J34 3000V J35
8 2 5 15
A 32
C12 J35 J36
C10 C11 E
.0047
J33 .0047 .0047
3000V F
5 3000V 3000V
TP1 TP2 G
TP3
B1 (+) STUD
R1 R2 L
150V
1200 1200
80J 160J 160J B2 (-) STUD M
5W 5W
320V 320V N
J33
6
4 H 21
C15 C16 J36
14 PIN WIRE
.05 .05
FEEDER AMPHENOL
600V 600V
VOLTAGE SENSE
GENERAL INFORMATION LAST NO. USED
J33
R- 8 L- 7
R3 R4 R5 1 ELECTRICAL SYMBOLS PER E1537
10 1
J37 CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
C- 16 TP- 3
332 332 332
RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- 0
J33
R6 R7 R8 3 DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
9 3 SUPPLY VOLTAGE NET
C13 C14 J37
332 332 332
.0047 .0047 POWER SUPPLY SOURCE POINT
NOTES :
3000V 3000V
COMMON CONNECTION
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
J34
7 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE EARTH GROUND CONNECTION
FILE: M17609_1BA
J34 NUMBER.
3
J34 EQUIP.
2 ON HOLES SIZES PER E-2056
STT REMOTE PROTECTION BOARD
ON 2 PLACE DECIMALS IS + .O2
J37
2 CHASSIS CHASSIS CHASSIS ON 3 PLACE DECIMALS IS + .OO2
CLEVELAND, OHIO U.S.A. SUBJECT SCHEMATIC
J37 MATERIAL TOLERANCE ("t") TO AGREE SCALE NONE
SHT.
M
4
DR. MLD DATE 04/20/94 CHK. F.V. SUP'S'D'G. NO. 17609
PC Board Assembly - Remote Protection - All Codes - (L9657)

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Safety Depends on You

Lincoln arc welding and cutting

Copyright 2006 Lincoln Global Inc.

World's Leader in Welding and Cutting Products

CALIFORNIA PROPOSITION 65 WARNINGS

FOR ENGINE 1.h. To avoid scalding, do not remove the

2.d.4. Connect the work cable to the workpiece as close as

Semiautomatic DC Constant Voltage (Wire) Welder.

sure level should be checked upon installation and periodi-

5.e. Read and understand the manufacturers instructions for this

5.f. Also see item 1.b.

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

5. Toujours porter des lunettes de scurit dans la zone de

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair ................................................................................................Section F

Electrical Diagrams ..............................................................................................................Section G

STT Parts .......................................................................................................................................P257

60% Duty Cycle 225 29

100% Duty Cycle 200 28

Peak Current 1 0 - 450 Amps 85 VDC Maximum 115 2 VAC @ 4 Amps

RECOMMENDED INPUT WIRE AND FUSE SIZES

23.2 in 13.2 in. 24.4 in. 100 lbs.

589 mm 336 mm 620 mm 46 kg

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

60% Duty Cycle 225 29

100% Duty Cycle 200 28

Peak Current 0 - 450 Amps 88 VDC Maximum 115 1 VAC @ 4 Amps

RECOMMENDED INPUT WIRE AND FUSE SIZES

23.2 in 13.2 in. 24.4 in. 100 lbs.

589 mm 336 mm 620 mm 46 kg

Section before starting installation.

parts. Provide proper electrical ground to the

SELECT SUITABLE LOCATION

should not be placed in extremely damp or dirty loca-

STACKING Be sure the voltage, phase, and frequency of the input

Some models come from the factory with an input

power cord. If your model does not include the input

INPUT CABLE RATING PLATE

INPUT CABLE INSTALLATION AND CON-

and is designed to accommodate cable diameters of

3. Route the cable through the cable hangers,

the machine, up to the power switch located on

4. Strip away 102 mm (4 in.) of the outer jacket.

to Voltage = 200 -230V

3. Move lead A to 440-460

Welding Parameters and Guidelines ..........................................................................................B-6

Do not touch electrically live parts

or electrode with skin or wet

Insulate yourself from work and

Always wear dry insulating

FUMES AND GASES

Keep your head out of fumes.

Use ventilation or exhaust to

Keep flammable material away.

Do not weld on containers that

Wear eye, ear and body

Observe additional Safety Guidelines detailed in the beginning of this manual.

RECOMMENDED EQUIPMENT WELDING CAPABILITY

Suitable for indoor use only (IEC IP21S).

State of the art inverter technology yields high power

weight and compact design.