Lincoln-electric INVERTEC SVM129-B Manuel d'utilisateur

SVM129-BApril, 2011Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However,your overall safet

INSTALLATIONA-4 A-4INVERTEC® STT® & STT® IIELECTRIC SHOCK can kill.• Only qualified personnel should perform this installation.• Turn the input po

TROUBLESHOOTING & REPAIRF-62 F-62INVERTEC® STT® & STT® IISWITCH BOARD REPLACEMENT (continued)TEST AFTER REPAIR OF SWITCHBOARDS AND/OR CAPACITO

TROUBLESHOOTING & REPAIRF-63 F-63INVERTEC® STT® & STT® IISWITCH BOARD REPLACEMENT (continued)ELECTRIC SHOCK cankill.• With input power ON, the

NOTESF-64 F-64INVERTEC® STT® & STT® IIReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

CAPACITOR REMOVAL ANDREPLACEMENT PROCEDUREService and repair should be performed by only Lincoln Electric factory trained personnel.Unauth

TROUBLESHOOTING & REPAIRF-66 F-66INVERTEC® STT® & STT® IICAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued)FIGURE F.30 – OUTPUT CHOKE LEA

TROUBLESHOOTING & REPAIRF-67 F-67INVERTEC® STT® & STT® IICAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued)FIGURE F.31 – PLUG J1 DISCONNE

TROUBLESHOOTING & REPAIRF-68 F-68INVERTEC® STT® & STT® IICAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued)FIGURE F.33 – STT PLACED ON IT

TROUBLESHOOTING & REPAIRF-69 F-69INVERTEC® STT® & STT® IICAPACITOR REPLACEMENTNOTE: Capacitors must always be replaced inmatched sets (C

TROUBLESHOOTING & REPAIRF-70 F-70INVERTEC® STT® & STT® II15. Place the machine on its side as shown inFigure F.35. Slide the plastic

TROUBLESHOOTING & REPAIRF-71 F-71INVERTEC® STT® & STT® II17. Remove the two 7/16” hex bolts that hold thecapacitor to the switch board.

INSTALLATIONA-5 A-5INVERTEC® STT® & STT® IIINPUT CABLE INSTALLATION AND CON-NECTIONA cable strain relief is provided at the supply line entryand

TROUBLESHOOTING & REPAIRF-72 F-72INVERTEC® STT® & STT® II19. Install the new capacitor and tighten the two7/16” hex bolts to a torque of 55 in

OUTPUT RECTIFIER REMOVAL AND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthor

TROUBLESHOOTING & REPAIRF-74 F-74INVERTEC® STT® & STT® IIOUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)FIGURE F.39 – CHOKE LEAD/HEAT SI

TROUBLESHOOTING & REPAIRF-75 F-75INVERTEC® STT® & STT® IIOUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)FIGURE F.40 – MAIN TRANSFORMER D

TROUBLESHOOTING & REPAIRF-76 F-76INVERTEC® STT® & STT® IIOUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)FIGURE F.41 – SWITCH BOARD/CAPAC

RETEST AFTER REPAIRRetest the INVERTEC® STT® & STT® II:• If it fails any test and the test requires removing or replacing any mechanical part tha

INPUT FILTER CAPACITOR CONDITIONINGIf the machine will not produce output when turned onand the following two conditions exist:The machine is conne

INVERTEC® STT® & STT® IISection G-1 Section G-1TABLE OF CONTENTS- ELECTRICAL DIAGRAMS SECTION -Electrical Diagrams...

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  77 7R32A32B1516J22RB18V32C43ARU318V501B504W455275186331110J61212A97212352212B503AY30130524522381131350324V351

A-6INSTALLATION A-6INVERTEC® STT® & STT® II IIFIGURE A.2 RECONNECT PANELINPUT VOLTAGE RECONNECTPROCEDUREAs shipped from the factory, multiple vo

  77 7R32A32B1516J22RB18V32C43ARU318V501B504W455275186331110J61212A97212352212B503AY30130524522381131350324V351

  77 7+-ELECTRICALSYMBOLSPER E153712341 34616105{1485H1T1 FANMOTORGFEJAIKCDMLBNH7576773132414224818221GNDSPARE4

  77 7J281150V0.1C41 3+15 V_REM50V0.1C41 1+15 V_REMREMREM3.9 2KR46 3MET ER_2MET ER_1PB_ SCALE D1.0 0KR43 63.9 2

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  77 7$)&,"2*$.-20.+8."0%.%&1)&&2.&apos

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  77 7L8033-8INVERTEC & METAL CUTTERSPOWER P.C. BOARD ASSEMBLYNONEL8033-7FI-UNLESSOTHERWISE SPECIFIED TOLERANC

Section B-1 Section B-1INVERTEC® STT® & STT® IITABLE OF CONTENTS- OPERATION SECTION -Operation...

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  77 7L12145-2STT II WELDERS IGBTDRIVEPC BD ASSEMBLYNONEL12145-1DO NOT SCALE THISDRAWINGEQUIPMENTTYPE:SUBJECT:UFCR

  77 7WWR600mA40VQ71W3.3VDZ51.00KR121/2W1R15100V1AQ2600mA40VQ615.0KR1050V2700pC247.5R351N4936D9600mA40VQ51W10V

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  77 78."0%11&,#+60*4&0++.%&1 Lincoln Electric assumes no responsib

  77 7$)&,"2*$0.2&$2*.-8."0%.%&1 Lincoln

  77 78."0%11&,#+60.2&$2*.-.%&1 Lincoln Electric assume

B-2 B-2INVERTEC® STT® & STT® IIELECTRIC SHOCKcan kill.• Do not touch electrically live partsor electrode with skin or wetclothing.• Insulate yours

  77 7$)&,"2*$0.2&$2*.-8."0%.%&1 Lincoln

  77 7L12235-2INVERTER WELDERSPROTECTION PC BOARD ASSEMBLY1:1L12235-1FEI-UNLESSOTHERWISE SPECIFIED TOLERANCEMANUFA

  77 7$)&,"2*$300&-2&-1&8."0%++.%&1 Lincoln

  77 78."0%11&,#+6300&-2&-1&++.%&1 Lincoln Electric assu

  77 7$)&,"2*$&,.2&0.2&$2*.-8."0%++.%&1 Lin

  77 78."0%11&,#+6&,.2&0.2&$2*.-++.%&1 Lincoln Electric a

OPERATIONB-3 B-3INVERTEC® STT® & STT® IIGENERAL DESCRIPTIONThe Invertec STT II is a 225-ampere inverter based arcwelding power source specifically

OPERATIONB-4 B-4INVERTEC® STT® & STT® II1. POWER SWITCH: Turns outputpower ON and OFF. This switchalso controls auxiliary poweravailable thr

OPERATIONB-5 B-5INVERTEC® STT® & STT® II6. WIRE SIZE SELECT SWITCH: This toggle switchselects between electrode diameters of .035” (1 mm)and s

OPERATIONB-6 B-6INVERTEC® STT® & STT® IIWELDING PARAMETERS AND GUIDE-LINESThe Invertec STT II is neither a constant current (CC)nor a constant

OPERATIONB-7 B-7INVERTEC® STT® & STT® IIWELDING PROCEDURES FOR STT II -(Steel) Horizontal Fillet (See Table B.1 and B.2)Table B.1 100% CO2 Gas Shi

INVERTEC®STT®& STT®IISAFETYi iFOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenan

NOTESB-8 B-8INVERTEC® STT® & STT® IIReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Re

TABLE OF CONTENTS- ACCESSORIES -Accessories ...

ACCESSORIESC-2 C-2INVERTEC® STT® & STT® IIGROUND inputs on this connector rather than fromthe front panel controls. If this short is removed, th

ACCESSORIESC-3 C-3INVERTEC® STT® & STT® IILN-742 or STT-10 WIRE FEEDERCONNECTION INSTRUCTIONSThe LN-742 or STT-10 is the recommended wire feed

C-4 C-4INVERTEC® STT® & STT® IIACCESSORIES CONNECTION DIAGRAM - INVERTEC STT II 4-9-99 M17657-3CABLES AND LEADS SHOULDELECTRODE LEADBE T

Section D-1 Section D-1INVERTEC® STT® & STT® IITABLE OF CONTENTS-MAINTENANCE-Maintenance...

MAINTENANCED-2 D-2INVERTEC® STT® & STT® IIWARNINGFailure to follow thiscapacitor discharge proce-dure can result in electricshock.INPUT FILTER CAP

MAINTENANCED-3 D-3INVERTEC® STT® & STT® IIPREVENTIVE MAINTENANCE1. Perform the following preventive mainte-nance procedures at least once every si

MAINTENANCED-4 D-4INVERTEC® STT® & STT® II12417569871016151318141911132FIGURE D.2 – MAJOR COMPONENT LOCATIONS1. BASE ASSEMBLY2. REAR NAMEPLATE3. R

Section E-1 Section E-1INVERTEC® STT® & STT® IITheory of Operation ...

SAFETYii iiINVERTEC® STT® & STT® IIFUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathi

GENERAL DESCRIPTIONThe INVERTEC® STT® & STT® II is a 225 ampere,inverter based, arc welding power supply specificallydesigned for the

RECONNECT, PROTECTIONBOARD, RECTIFICATION ANDPRECHARGEThe reconnect panel allows the user to switch to low orhigh input voltage to match the input lin

THEORY OF OPERATIONE-4 E-4INVERTEC® STT® & STT® IINOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.FIGURE E.4 – SWITCH B

THEORY OF OPERATIONE-5 E-5INVERTEC® STT® & STT® IIFIGURE E.5 – MAIN TRANSFORMER, OUTPUT RECTIFICATION AND CHOKEMAIN TRANSFORMER, OUTPUTRECTIFICATI

THEORY OF OPERATIONE-6 E-6INVERTEC® STT® & STT® IIFIGURE E.6 – CONTROL BOARD, IGBT DRIVE AND MODULECONTROL BOARD, IGBT DRIVEAND MODULEThe control

THEORY OF OPERATIONE-7 E-7INVERTEC® STT® & STT® IIFIGURE E.7 – POWER BOARD AND REMOTE PROTECTION BOARDPOWER BOARDThe power board creates a pulse t

FIELD EFFECT TRANSISTOR (FET)OPERATIONAn FET is a type of transistor. FETs are semiconduc-tors well suited for high-frequency switching.Drawing A ab

PULSE WIDTH MODULATIONThe term PULSE WIDTH MODULATION is used todescribe how much time is devoted to conduction inthe positive and n

PROTECTIVE CIRCUITSProtective circuits are designed into the Invertecmachine to sense trouble and shut down the machinebefore the trouble damage

Section F-1 Section F-1INVERTEC® STT® & STT® IITroubleshooting & Repair Section ...

INVERTEC® STT® & STT® IISAFETYiii iiiFOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before

HOW TO USE TROUBLESHOOTING GUIDEService and repair should be performed by only Lincoln Electric Factory Trained Personnel.Unauthorized rep

ELECTRIC SHOCK can kill.Have an electrician install and servicethis equipment. Turn the machine OFFbefore working on equipment. Do n

TROUBLESHOOTING & REPAIRF-4 F-4INVERTEC® STT® & STT® IIObserve Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manual

TROUBLESHOOTING & REPAIRF-5 F-5INVERTEC® STT® & STT® IITROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual

TROUBLESHOOTING & REPAIRF-6 F-6INVERTEC® STT® & STT® IIObserve Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manual

TROUBLESHOOTING & REPAIRF-7 F-7INVERTEC® STT® & STT® IITROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual

F-8 F-8INVERTEC® STT® & STT® IITROUBLESHOOTING & REPAIRTROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual

TROUBLESHOOTING & REPAIRF-9 F-9INVERTEC® STT® & STT® IIObserve Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manual

TROUBLESHOOTING & REPAIRF-10 F-10INVERTEC® STT® & STT® IITROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manu

TROUBLESHOOTING & REPAIRF-11 F-11INVERTEC® STT® & STT® IIObserve Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manu

SAFETYiv ivINVERTEC® STT® & STT® IIPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions

TROUBLESHOOTING & REPAIRF-12 F-12INVERTEC® STT® & STT® IITROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manu

TROUBLESHOOTING & REPAIRF-13 F-13INVERTEC® STT® & STT® IIT1 AUXILIARY TRANSFORMER TESTWARNINGService and repair should be performed by only Li

TROUBLESHOOTING & REPAIRF-14 F-14INVERTEC® STT® & STT® IIT1 AUXILIARYTRANSFORMERPLUGJ31PLUGJ30FIGURE F.1 – T1 AUXILIARY TRANSFORMER AND J30/J3

TROUBLESHOOTING & REPAIRF-15 F-15INVERTEC® STT® & STT® II5. Locate the primary lead molex plug (J21)just behind the reconnect panel ass

TEST POINTSPLUG J30 PINS 1 TO 2 (LEADS 32 TO 33)PLUG J31 PINS 1 TO 4 (LEADS 501 TO 504)PLUG J31 PINS 2 TO 3(LEADS 212 TO 503)PLUG J31 PINS 2 TO 5(

TROUBLESHOOTING & REPAIRF-17 F-17INVERTEC® STT® & STT® IIELECTRIC SHOCK cankill.• With input power ON,there are high voltagesinside the

NOTESF-18 F-18INVERTEC® STT® & STT® IIReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

T4 AUXILIARY TRANSFORMER TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repair

TROUBLESHOOTING & REPAIRF-20 F-20INVERTEC® STT® & STT® IIT4 AUXILIARY TRANSFORMER TEST (continued)FIGURE F.3 – OUTPUT CHOKE/IGBT MODULE SPLIC

TROUBLESHOOTING & REPAIRF-21 F-21INVERTEC® STT® & STT® IIT4 AUXILIARY TRANSFORMER TEST (continued)5. Disconnect the current sensing Plug J1 f

MASTER TABLE OF CONTENTS FOR ALL SECTIONSv vINVERTEC® STT® & STT® IIPageSafety ...

TROUBLESHOOTING & REPAIRF-22 F-22INVERTEC® STT® & STT® IIT4 AUXILIARY TRANSFORMER TEST (continued)7. Carefully lift and tilt the INVERTEC® ST

TROUBLESHOOTING & REPAIRF-23 F-23INVERTEC® STT® & STT® IIT4 AUXILIARY TRANSFORMER TEST (continued)11. Locate and remove leads #32A, #32B and#

13. Check the secondary AC voltages accord-ing to Table F.2.14. With the correct 115VAC applied to the pri-mary winding (#32 to #33), if any or all

INPUT RECTIFIER TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performe

TROUBLESHOOTING & REPAIRF-26 F-26INVERTEC® STT® & STT® IIINPUT RECTIFIER TEST (continued)FIGURE F.9 - INPUT RECTIFIER LOCATIONINPUTRECTIFIERCA

6. Replace the input rectifier when any of thetests are NOT OK.NOTE: When installing a new input rectifier,torque the mounting nuts (in a c

NOTESF-28 F-28INVERTEC® STT® & STT® IIReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

CAPACITOR BALANCE TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs perfo

TROUBLESHOOTING & REPAIRF-30 F-30INVERTEC® STT® & STT® IICAPACITOR BALANCE TEST (continued)FIGURE F.10 – SWITCH BOARD TEST POINTSL8441L8441SW

5. Adjust the Peak and Background controls tothe minimum settings (controls on casefront).6. Jumper together pins "C" and "D&quo

TABLE OF CONTENTS- INSTALLATION SECTION -Section A-1 Section A-1INVERTEC® STT® & STT® IIInstallation...

NOTESF-32 F-32INVERTEC® STT® & STT® IIReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

SWITCH BOARD TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed

TROUBLESHOOTING & REPAIRF-34 F-34INVERTEC® STT® & STT® IISWITCH BOARD TEST (continued)FIGURE F.11 - SWITCH BOARD RESISTANCE TESTTEST PROCEDURE

TROUBLESHOOTING & REPAIRF-35 F-35INVERTEC® STT® & STT® IISWITCH BOARD TEST (continued)Apply Positive Apply NegativeTest Probe to Test Probe to

TROUBLESHOOTING & REPAIRF-36 F-36INVERTEC® STT® & STT® IIApply Positive Apply NegativeTest Probe to Test Probe toTerminal Terminal Test Result

SNUBBER RESISTORS TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs perfo

TROUBLESHOOTING & REPAIRF-38 F-38INVERTEC® STT® & STT® IISNUBBER RESISTORS TEST (continued)FIGURE F.12 - REMOVING LEADSTEST PROCEDURE1. Turn

TROUBLESHOOTING & REPAIRF-39 F-39INVERTEC® STT® & STT® IISNUBBER RESISTORS TEST (continued)FIGURE F.13 - SWITCH BOARD TEST POINTS6. Test for

NOTESF-40 F-40INVERTEC® STT® & STT® IIReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

POWER BOARD TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed o

RECOMMENDED INPUT WIRE AND FUSE SIZESINSTALLATIONA-2 A-2INVERTEC® STT® & STT® IISTANDARD VOLTAGE INPUT CURRENT AT RATED OUTPUT208/230/460/3/60 HZ

TROUBLESHOOTING & REPAIRF-42 F-42INVERTEC® STT® & STT® IIPOWER BOARD TEST (continued)FIGURE F.14 – REMOVING THE FRONT PANEL ASSEMBLYPOWERPC BO

TROUBLESHOOTING & REPAIRF-43 F-43INVERTEC® STT® & STT® IIPOWER BOARD TEST (continued)FIGURE F.15 – POWER PC BOARD TEST POINTSPOWER BOARDJ6J7J1

TROUBLESHOOTING & REPAIRF-44 F-44INVERTEC® STT® & STT® IIPOWER BOARD TEST (continued)FIGURE F.16 – SIMPLIFIED TRIGGER CIRCUITFROM PROTECTIONBO

PROTECTION BOARD TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs perfor

TROUBLESHOOTING & REPAIRF-46 F-46INVERTEC® STT® & STT® IIPROTECTION BOARD TEST (continued)FIGURE F.17 – PROTECTION PC BOARD TEST POINTSPROTECT

TROUBLESHOOTING & REPAIRF-47 F-47INVERTEC® STT® & STT® IIFIGURE F.18 - LEADS #309, #309A AT CR1, CR2 RELAYSCR2CR1309A309PROTECTION BOARD TEST

NOTESF-48 F-48INVERTEC® STT® & STT® IIReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

TRIGGER CIRCUIT TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs perform

TROUBLESHOOTING & REPAIRF-50 F-50INVERTEC® STT® & STT® IITRIGGER CIRCUIT TEST (continued)FIGURE F.19 – PLUG J31 LOCATIONPLUGJ31TEST PROCEDURE1

TROUBLESHOOTING & REPAIRF-51 F-51INVERTEC® STT® & STT® IITRIGGER CIRCUIT TEST (continued)FIGURE F.20 – 14 PIN AMPHENOL AND PLUG J31 PIN ASSIGN

INSTALLATIONA-3 A-3INVERTEC® STT® & STT® IISTANDARD VOLTAGE INPUT CURRENT AT RATED OUTPUT200/208/3/50/60 HZ 36/34200/208/380/400/415/3/50/60 HZ 36

TROUBLESHOOTING & REPAIRF-52 F-52INVERTEC® STT® & STT® IITRIGGER CIRCUIT TEST (continued)FIGURE F.22 – SIMPLIFIED TRIGGER CIRCUIT DIAGRAMFROM

IGBT MODULEREMOVAL AND REPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized r

TROUBLESHOOTING & REPAIRF-54 F-54INVERTEC® STT® & STT® IIIGBT MODULE REMOVALAND REPLACEMENT (continued)FIGURE F.23 – OUTPUT CHOKE LEAD DISCONN

TROUBLESHOOTING & REPAIRF-55 F-55INVERTEC® STT® & STT® IIIGBT MODULE REMOVALAND REPLACEMENT (continued)FIGURE F.24 – PLUG J1 DISCONNECTIONLOWE

TROUBLESHOOTING & REPAIRF-56 F-56INVERTEC® STT® & STT® IIIGBT MODULE REMOVALAND REPLACEMENT (continued)FIGURE F.26 – STT PLACED ON ITS RIGHT S

TROUBLESHOOTING & REPAIRF-57 F-57INVERTEC® STT® & STT® IIIGBT MODULE REMOVALAND REPLACEMENT (continued)FIGURE F.27 – IGBT MODULE CONNECTIONSEE

NOTESF-58 F-58INVERTEC® STT® & STT® IIReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

SWITCH BOARDREPLACEMENTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs perf

TROUBLESHOOTING & REPAIRF-60 F-60INVERTEC® STT® & STT® IISWITCH BOARD REPLACEMENT (continued)FIGURE F.28 – SWITCH BOARD REMOVALPROCEDURENOTE:

TROUBLESHOOTING & REPAIRF-61 F-61INVERTEC® STT® & STT® IISWITCH BOARD REPLACEMENT (continued)6. Using the 7/16" wrench, remove the two h