Lincoln Electric INVERTEC CC400-S Service Manual
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Lincoln Electric INVERTEC CC400-S Service Manual

Lincoln Electric INVERTEC CC400-S Service Manual

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SVM 7005
January, 2014
Rev. 1
®
INVERTEC
CC400-S/-S PLUS
For use with machine Part Number K60060-1, Code 76115 / K60060-3, Code 76135
Safety Depends on You
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
you part. DO NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED
THROUGHOUT. And, most importantly,
think before you act and be careful.
Copyright © 2013 The Shanghai Lincoln Electric Company
• World's Leader in Welding and Cutting•
THE SHANGHAI LINCOLN ELECTRIC COMPANY
No. 195, Lane 5008, Hu Tai Rd. Baoshan, Shanghai, PRC 201907
www.lincolnelectric.com.cn
®
INVERTEC
CC400-S/-S PLUS

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Summary of Contents for Lincoln Electric INVERTEC CC400-S

  • Page 1 SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful. Copyright © 2013 The Shanghai Lincoln Electric Company • World’s Leader in Welding and Cutting• THE SHANGHAI LINCOLN ELECTRIC COMPANY No. 195, Lane 5008, Hu Tai Rd. Baoshan, Shanghai, PRC 201907 www.lincolnelectric.com.cn...
  • Page 2 SAFTY WARNING ARC WELDING CAN BE HAZADOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Safety

    SAFETY WELDING SPARKS FUMES AND GASES can cause fire or can be dangerous. explosion. 4.a Welding may produce fumes and gases 6.a Remove fire hazards from the welding area. If this is not hazardous to health. Avoid breathing these possible, cover them to prevent the welding sparks from fumes and gases.

  • Page 4: Table Of Contents

    Master Table of Content Content Page Safety ..................... i-ii …………….………..………………………….…..…..Installation Operation ……………..…………………….…………..……..…..Accessories ………..…………….……………………...…………... Maintenance ………………..………….…………….…….………………. D ...………………….……………………………… E Theory of Operation Trouble Shooting and Repair ……………....……………………. …………………..…….………………...……………… Circuit Diagram ® INVERTEC CC400-S/-S PLUS...
  • Page 5 Installation Installation……………………………………………………………………... A-1 Technical Specification ................. A-2 …..………………………….…..…....Safety and Precautions ……………….…………..……..…..... A-3 Select Suitable Position ……...…………....A-3 Input Power and Grounding Connections ….…….…………….…….………………. Gun and Cable Connections Shielding Gas Connections ...………….………………..………………..A-4 Cable Connections …………….……………....……………………... ® INVERTEC CC400-S/-S PLUS...

  • Page 6: Installation

    INSTALLATION Technical Specification – ® INVERTEC CC400-S/-S PLUS INPUT – THREE PHASE ONLY 380V (± 10%) / 3 / 50 、60 Hz Standard Voltage/Phase/Frequency RATED OUTPUT – DC ONLY Input Power at Rated Max. output 17 KW (60%Duty Cycle) Mode Duty Cycle Amperes Volts at Rated Amperes...

  • Page 7: Safety And Precautions

    INSTALLATION Open the input box on the rear of the case. Use a SAFETY PRECAUTIONS three-phase supply line, the three live wires should go Read the entire installation section before starting through the three holes of the input wire holder and be installation.

  • Page 8: Shielding Gas Connections

    INSTALLATION WARNIGN Work and electrode Cable Sizes Do not stand in front of or behind the cylinder are as follows: when you open the valve. Make sure stay on one Table A.1 side of the cylinder. You can adjust the regulator. Current (60% Duty Minimum Copper Work Before start welding, the flow rate should be set at...

  • Page 9: Cable Connections

    INSTALLATION Cable connections TIG（CC mode）Connection (figure A.2 ): figure A.2 SMAW（CC mode）Connection (figure A.3 ): Note: When a Basic Electrode is used, the output connection must be reversed! figureA.3 ® INVERTEC CC400-S/-S PLUS...

  • Page 10: Operation

    OPERATION B- 1 Operation………………………………………..…………..…………………. Safety and Precautions................... Operation Features and Controls …………...………..…………..….……… B-2 …….…………..….………………………….…………. Advanced Function ………….…………..….………………………….……. Parts & Accessories ® INVERTEC CC400-S/-S PLUS...
  • Page 11 OPERATION 1 B- 2 gone into thermal overload, the output will be Safety Precautions turned off and the thermal indicator light will be Read this entire section of operating turned “ON“. When the machine has cooled to a instructions before operating the safe temperature, the Thermal Indicator Light will machine.
  • Page 12 OPERATION 1 B- 3 Note: arc force. The arc is soft at the minimum settings and more forceful or driving at the maximum The switch is unavailable on CC400-S settings. Higher spatter levels maybe present at machine. the maximum settings 4.
  • Page 13 OPERATION 1 B- 4 15. INPUT CABLE HOLDING BRACKET current will phase back to 20A until electrode is This bracket securely holds the three phase power taken off the workpiece, circuitry activated. cables in place. AIR CARBON ARCGOUGING 16. GROUND CABLE CONNECTION Air carbon arc gouging maybe performed with the Connect the ground cable to the paint-free INVERTEC®...

  • Page 14: Maintenance

    MAINTENANCE ………………………………….…………………………………….. Maintenance Safety Precautions ……………….……………………...….………………………. Routine Maintenance ….…………………….……………………………………. Thermal Protection …………..………………………………………………..Major Component Locations ...……………………….………………………… ® INVERTEC CC400-S/-S PLUS...
  • Page 15 4 wire system with earthed neutral. WARNING For any maintenance or repair operations it is recommended to contact the nearest technical service center or Lincoln Electric. Maintenance or repairs performed by unauthorized service centers or personnel will null and void the manufacturers warranty. ROUTINE MAINTENANCE The frequency of the maintenance operations may vary in accordance with the working environment.
  • Page 16 MAINTENANCE MAJOR COMPONENT LOCATIONS FIGURE D.1 MAJOR COMPONENT LOCATIONS Cover Control Board Pre-charge Board 预充电板 Intermediate Board Filter Capacity Input Rectifier Auxiliary Transformer Input Cable Holder Left Panel Back Panel IGBT Module& Heat Radiator Front panel Right Panel Main Transformer Output inductor Output Diode&...

  • Page 17: Theory Of Operation

    Operating Theory Theory of Operation ………………………………...………………………..…………….. General Description ………………….………………………….…….………..…..... Input Power & Rectifier, Pre-charge Board, Auxiliary Transformer, Fan Motor…… E-2 Switch Board Control Board, IGBT Module, Main Transformer Diode……………... Definition of INVERTEC………………………………………………………………………. Description for Main Circuit and Components Function……………………………….. ® INVERTEC CC400-S/-S PLUS...

  • Page 18: General Description

    Operating Theory FIGURE E.1- INPUT POWER, RECTIFIER, PRE-CHARGE BOARD, AUXILIARY TRANSFORMER AND FAN MOTOR input are connected to the auxiliary transformer and other two phases are connected to fan motor. GENERAL DESCRIPTION Auxiliary transformer has two secondary AC16V ® CC400-S Invertec is an inverter based output to the whole machine circuit.

  • Page 19: Switch Board , Control Board, Igbt Module, Main Transformer Diode

    Operating Theory FIGURE E.2- SWITCH BOARD, CONTROL BOARD, IGBT MODULE, MAIN TRANSFORMER AND DIODE. IGBT. Control board is working as the power of SWITCH BOARD, CONTROL BOARD, pre-charge board. IGBT MODULE, MAIN After receive the signal from IGBT model, IGBT TRANSFORMER AND DIODE.

  • Page 20: Definition Of Invertec

    Operating Theory Definition of INVERTEC: Compare to the Converter process, the process of rectifying output power from AC to DC is called Inverter. Figure of Main Circuit and Function of Key Components 50/60 HZ 20 kHZ High Volt Low Volt Low Current High Current Rectifie...
  • Page 21 Troubleshooting and Repair Trouble Shooting and Repair …….….…………...…………….………………. F-1 How To Use Trouble Shooting guide..….………..….………..……………….. F-2 PC Board Trouble Shooting Procedures..……………………..……………… F-3 Troubleshooting Guides ……………………………..……..…...………………. F-4 Case Cover Removal and Filter Capacitor Discharge Procedure……….… F-5 Input Rectifier Removal Procedure…………………..…..…….………………. F-10 Priming Plate and Filter Capacitor Removal Procedure…..……………...

  • Page 22: Trouble Shooting And 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 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.

  • Page 23: Pc Board Troubleshooting Procedures

    - If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete. - If you return a PC Board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.
  • Page 24 Misadjustment (s) Output Problems Major physical or electrical Contact your local authorized None damage is evident when the Lincoln Electric Field Service sheet metal covers Facility for technical assistance. Make certain that fuses or breakers are properly sized. See Installation section of this manual for recommended fuse and breaker sizes.

  • Page 25: Case Cover Removal And Filter Capacitor Discharge Procedure

    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 tests/repairs safely, contact Lincoln Electric (China) Service Department for technical troubleshooting assistance before you proceed.
  • Page 26 Troubleshooting and Repair CASE COVER REMOVAL AND FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED) FIGURE F.1 –TOP PANEL SCREW LOCATIONS Self Tapping Screws Self Tapping Screws PROCEDURE ® 1. Disconnect power to the INVERTEC Note： There’re 2 self tapping screws on two sides of 400-S/CC400-S PLUS.
  • Page 27 Troubleshooting and Repair CASE COVER REMOVAL AND FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED) FIGURE F.2 – RIGHT PANEL SCREW LOCATIONS Self Tapping Screws 3. Use 8mm nut driver to remove 5 screws on 4，Use 8mm nut driver to remove 5 screws on left right panel.
  • Page 28 Troubleshooting and Repair CASE COVER REMOVAL AND FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED) FIGURE F.3 – LEFT PANEL SCREW LOCATIONS Self Tapping Screws FIGURE F.4 – PRIMING PLATE AND FILTER CAPACITOR LOCATION IN THE WELDING MACHINE RECHARGE BOARD AND FILTER CAPACITOR ®...
  • Page 29 Troubleshooting and Repair CASE COVER REMOVAL AND FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED) Filter Capacitor Discharge Procedure 3，Use Digital Multi-meter, DC voltage to get ® 1， Disconnect power to the INVERTEC the voltage between 207（-）and 209（+）. 400-S/CC400-S PLUS. 2， Locate Priming Plate and Filter Capacitor. If the voltage exists, Filter Capacitor See Figure F.4.

  • Page 30: Input Rectifier Removal Procedure

    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 tests/repairs safely, contact Lincoln Electric (China) Service Department for technical troubleshooting assistance before you proceed.
  • Page 31 Troubleshooting and Repair F-11 F-11 INPUT RECTIFIER REMOVAL PROCEDURE (CONTINUED) FIGURE F.6 – INPUT RECTIFIER LEADS LOCATION 5 (207) 1 (201) 2 (202) 3 (203) 4 (209) PROCEDURE ® 1， Disconnect power to the INVERTEC Note: 400-S/CC400-S PLUS. a. To re-install all these leads onto the Rectifier, 2.0N/M torque is needed.
  • Page 32 Troubleshooting and Repair F-12 F-12 INPUT RECTIFIER REMOVAL PROCEDURE (CONTINUED) FIGURE F.7 – INPUT RECTIFIER LOCATION M5 Screw INPUT RECTIFIER 5， Loosen two hex head screws at both sides of the module by using 8mm nut driver. WARNING See Figure F.7 6，...
  • Page 33 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact Lincoln Electric (China) Service Department for technical troubleshooting assistance before you proceed. Tel： 86-21-6673-4530 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Priming Plate and Filter Capacitor.

  • Page 34: Priming Plate And Filter Capacitor Removal Procedure

    Troubleshooting and Repair F-14 F-14 PRIMING PLATE AND FILTER CAPACITOR REMOVAL PROCEDURE (CONTINUED) FIGURE F.8 –PRIMING PLATE AND FILTER CAPACITOR LOCATIONS PRECHARGE BOARD MAIN CONTROL BOARD FILTER CAPACITOR （ ） electrolytic capacitor PROCEDURE ® b. Make sure all the plugs and connections are correct 1，...
  • Page 35 Troubleshooting and Repair F-15 F-15 PRIMING PLATE AND FILTER CAPACITOR REMOVAL PROCEDURE (CONTINUED) FIGURE F.9 –PRIMING PLATE AND FILTER CAPACITOR TERMINAL LOCATIONS 207A 207B 209A 209B PROCEDURE Use 8mm to disconnect screws of nut driver two Filter Capacitors on Priming Plate. See Figure F.10.
  • Page 36 Troubleshooting and Repair F-16 F-16 PRIMING PLATE AND FILTER CAPACITOR REMOVAL PROCEDURE (CONTINUED) FIGURE F.10 –PRIMING PLATE AND FILTER CAPACITOR FILTER FIXED SCREW FILTER FIX SUPPORT PROCEDURE Use 7mm nut driver to disconnect 3 screws WARNING fixing support of Filter capacitors. See Figure F.10.
  • Page 37 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact Lincoln Electric (China) Service Department for technical troubleshooting assistance before you proceed. Tel： 86-21-6673-4530...
  • Page 38 Troubleshooting and Repair F-18 F-18 INSULATED GATE BIPOLAR TRANSISTOR MODULE（IGBT Module） REMOVAL PROCEDURE (CONTINUED) FIGURE F.11 –IGBT, PRIMING PLATE AND MAIN TRABSFIRNER LEADS CONNECTION Insulated Gate Bipolar Transistor Module （IGBT Module） PROCEDURE ® 1， Disconnect power to the INVERTEC 400-S/CC400-S PLUS. Note: a.
  • Page 39 Troubleshooting and Repair F-19 F-19 INSULATED GATE BIPOLAR TRANSISTOR MODULE（IGBT Module） REMOVAL PROCEDURE (CONTINUED) FIGURE F.12 –IGBT MODULE TERMINAL LOCATIONS b. There’s a label attached with each lead, don’t 5，Use 10mm nut driver to disconnect 2 M6 mix-up them when reinstallation. Screws on IGBT Module.
  • Page 40 Troubleshooting and Repair F-20 F-20 INSULATED GATE BIPOLAR TRANSISTOR MODULE（IGBT Module） REMOVAL PROCEDURE (CONTINUED) FIGURE F.13 –IGBT REMOVAL Note: When IGBT Module is reinstalled, 0.88CC WARNING Thermal Joint Compound E1868 should be used between the IGBT Module and heat-sink. The driven signal should be tested and confirmed correct, then the IGBT Module is able to be installed.
  • Page 41 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact Lincoln Electric (China) Service Department for technical troubleshooting assistance before you proceed. Tel： 86-21-6673-4530 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of output rectifier diodes module.

  • Page 42: Output Rectifier Diodes Module Removal Procedure

    Troubleshooting and Repair F-22 F-22 OUTPUT RECTIFIER DIODES MODULE REMOVAL PROCEDURE (CONTINUED) FIGURE F.14 –OUTPUT RECTIFIER DIODES MODULE OUTPUT RECTIFIER DIODES MODULE PROCEDURE ® 1， Disconnect power supply to the INVERTEC 3， Locate output rectifier diodes module and CC 400-S/CC400-S PLUS. leads S1, S2 and S3.
  • Page 43 Troubleshooting and Repair F-23 F-23 OUTPUT RECTIFIER DIODES MODULE REMOVAL PROCEDURE (CONTINUED) FIGURE F.15 –OUTPUT RECTIFIER DIODES LEADS LOCATION 4， Use 10mm nut driver to disconnect input leads 5， Use 10mm nut driver to disconnect 2 pieces of S1 and S2 (4 N/M torque is needed), then M6 screws, remove the copper connectors disconnect lead S3 ( 8 N/M torque is needed).
  • Page 44 Troubleshooting and Repair F-24 F-24 OUTPUT RECTIFIER DIODES MODULE REMOVAL PROCEDURE (CONTINUED) FIGURE F.16 –OUTPUT RECTIFIER DIODES LEADS LOCATION 6， Use 10mm nut driver to disconnect 4 M6 Note：a. Reinstall the Module onto the machine, screws, remove the Module from the machine. 4.0N/M torque is needed.
  • Page 45 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact Lincoln Electric (China) Service Department for technical troubleshooting assistance before you proceed. Tel： 86-21-6673-4530 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of control PC board.

  • Page 46: Control Pc Board Removal Procedure

    Troubleshooting and Repair F-26 F-26 CONTROL PC BOARD REMOVAL PROCEDURE (CONTINUED) FIGURE F.17 –CONTROL PC BOARD LOCATION CONTROL PC BOARD PROCEDURE ® Disconnect power to the INVERTEC IGBT module. See Figure F.17 and Figure 400-S/CC400-S PLUS. F.18. Note: Don’t mix-up the connectors when Perform Case Cover...
  • Page 47 Troubleshooting and Repair F-27 F-27 CONTROL PC BOARD REMOVAL PROCEDURE (CONTINUED) FIGURE F.18 –CONTROL PC BOARD LOCATION Note： 4， Use 7mm nut driver to disconnect 4 screws on 6， When control PC board reinstallation, the back. See Figure F.19. 2.0N/M torque needed.
  • Page 48 Troubleshooting and Repair F-28 F-28 CONTROL PC BOARD REMOVAL PROCEDURE (CONTINUED) FIGURE F.19 –CONTROL PC BOARD REMOVAL ® INVERTEC CC400-S/-S PLUS...
  • Page 49 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact Lincoln Electric (China) Service Department for technical troubleshooting assistance before you proceed. Tel： 86-21-6673-4530 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of auxiliary transformer.

  • Page 50: Auxiliary Transformer Removal Procedure

    Troubleshooting and Repair F-30 F-30 AUXILIARY TRANSFORMER REMOVAL PROCEDURE (CONTINUED) FIGURE F.20 –AUXILIARY TRANSFORMER LOCATION AUXILIARY TRANSFORMER PROCEDURE ® 1. Disconnect power to the INVERTEC 400-S/CC400-S PLUS. Note: When auxiliary transformer replacement or reinstallation, please pay attention to the labels 2.
  • Page 51 Troubleshooting and Repair F-31 F-31 AUXILIARY TRANSFORMER REMOVAL PROCEDURE (CONTINUED) FIGURE F.21 –AUXILIARY TRANSFORMER LEADS LOCATION output output input 202A 203A 2.0N/M torque is needed. 4， Use 7mm nut driver to disconnect 2 screws on both sides of the auxiliary transformer. See Figure F.22.
  • Page 52 Troubleshooting and Repair F-32 F-32 AUXILIARY TRANSFORMER REMOVAL PROCEDURE (CONTINUED) FIGURE F.22 –AUXILIARY TRANSFORMER LEADS LOCATION ® INVERTEC CC400-S/-S PLUS...
  • Page 53 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact Lincoln Electric (China) Service Department for technical troubleshooting assistance before you proceed. Tel： 86-21-6673-4530 TEST DESCRIPTION This procedure will help determine if the input rectifier has “shorted”...

  • Page 54: Input Rectifier Test

    Troubleshooting and Repair F-34 F-34 INPUT RECTIFIER TEST (CONTINUED) FIGURE F.23 –INPUT RECTIFIER LOCATION INPUT RECTIFIER PROCEDURE ® Disconnect power to the INVERTEC Note: RTV is used on between buffer and terminal, 400-S/CC400-S PLUS. environmental. When input rectifier reinstallation, RTV should be used on again. Perform Case Cover...
  • Page 55 Troubleshooting and Repair F-35 F-35 INPUT RECTIFIER TEST (CONTINUED) FIGURE F.24 –TERMINAL LOCATION 5 (207) 4 (209) 1 (201) 2 (202) 3 (203) + 4 (209) 380V 3~ AC 1 (201) 2 (202) 3 (203) - 5(207) faulty, Replace if necessary. 6，...
  • Page 56 Troubleshooting and Repair F-36 F-36 INPUT RECTIFIER TEST (CONTINUED) TABLE F.1 – INPUT RECTIFIER TEST POINT DIGITAL MULTI-METER TEST POINT TERMINALS DIODE MODE + PROBE - PROBE ACCEPTABLE READINGS 1 (201) 0.2－0.7V 2 (202) 4 (209) 0.2－0.7V 3 (203) 0.2－0.7V 1 (201) None 4 (209)
  • Page 57 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact Lincoln Electric (China) Service Department for technical troubleshooting assistance before you proceed. Tel： 86-21-6673-4530 TEST DESCRIPTION This part will help determine if the IGBT module is in good condition.
  • Page 58 Troubleshooting and Repair F-38 F-38 INSULATED GATE BIPOLAR TRANSISTOR MODULE（IGBT Module） STATIC TESTING(CONTINUED) FIGURE F.25 – MAIN TRANSFORMER , PRIMING PLATE AND IGBT MODULE WIRING DIAGRAM INSULATED GATE BIPOLAR TRANSISTOR MODULE（IGBT Module） PROCEDURE ® Disconnect power to the INVERTEC Note: Make sure the connectors are correct set up 400-S/CC400-S PLUS.
  • Page 59 Troubleshooting and Repair F-39 F-39 INSULATED GATE BIPOLAR TRANSISTOR MODULE（IGBT Module） STATIC TESTING(CONTINUED) FIGURE F.26 – IGBT MODULE LOCATION Use Digital Multi-meter in diode check mode to the driving signal is incorrect, the IGBT Module perform the tests detailed in Table F.2 will be damaged once again.
  • Page 60 Troubleshooting and Repair F-40 F-40 IGBT MODULE STATIC TEST (CONTINUED) TableF.2 –IGBT MODULE MEASURED VALUE Digital multi-meter TEST POINT TERMINALS DIODE MODE + PROBE - PROBE ACCEPTABLE READINGS 207A（2） 0.2－ 0.7V P1（1） 209A（3） None 207A（2） None P1（1） 209A（3） 0.2－ 0.7V 207B（2）...
  • Page 61 IGBT MODULE DYNAMIC 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.

  • Page 62: Igbt Module Dynamic Test

    Troubleshooting and Repair F-42 F-42 IGBT MODULE DYNAMIC TEST (CONTINUED) F.27– IGBT module Location IGBT module PROCEDURE 4. Remove 240 and 241,242 and 243,244 and 1．Disconnect power to the INVERTEC® 245,246 and 247 from IGBT module. See figure C400-S/-S PLUS. F.27 and F.28.
  • Page 63 Troubleshooting and Repair F-43 F-43 IGBT MODULE DYNAMIC TEST (CONTINUED) F.28– IGBT Module Location Use the 8mm Nut Driver to remove 207A and Turning on the switch，The bulb should be light. Light bulb presents that the IGBT is function 209A，207B and 209B, P1 and P2 from IGBT properly.
  • Page 64 Troubleshooting and Repair F-44 F-44 IGBT MODULE DYNAMIC TEST (CONTINUED) Figure F.29– IGBT MODULE DYNAMIC TEST Bulb 12VDC Switch Resistance 1K 1/4W Power 12VDC Resistance 10K 1/4W WARNING WARNING High voltage is present at IGBT Module！ IGBT Module drive signal should be tested by oscilloscope before replacing with a High voltage can kill! new Module .Make sure the drive signal is...
  • Page 65 Troubleshooting and Repair F-45 F-45 IGBT MODULE DYNAMIC TEST (CONTINUE) Table F.3-SINGLE IGBT MODULE DYNAMIC TEST Wiring Switch status Bulb status D connects to IGBT module foot 1 Turn on G connects to IGBT module feet 6 Turn off S connects to IGBT module feet 7 D connects to IGBT module feet 3 Turn on G connects to IGBT module feet 4...
  • Page 66 OUTPUT RECTIFIER DIODE 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.
  • Page 67 Troubleshooting and Repair F-48 F-48 ® INVERTEC CC400-S/-S PLUS...

  • Page 68: Output Rectifier Diode Test

    Troubleshooting and Repair F-47 F-47 OUTPUT RECTIFIER DIODE TEST (CONTINUED) Figure F.30 – OUTPUT RECTIFIER DIODE LOCATION OUTPUT RECTIFIER DIODE MODULE PROCEDURE Disconnect power INVERTEC®CC NOTE: RTV is applied to snubber and 400-S/CC400-S PLUS. terminals as environmental protection, after reconnecting the output rectifier and Perform the Case Cover Removal and Filter snubber, RTV needs to be reapplied.
  • Page 69 Troubleshooting and Repair F-48 F-48 OUTPUT RECTIFIER DIODE TEST (CONTINUED) Figure F.31 – OUTPUT RECTIFIER DIODE CONNECTION DIAGRAM S1-1 S1-2 S2-1 S2-2 Remove copperplate from OUTPUT RECTIFIER DIODE. See Figure F.30. Perform the tests detailed in Table F.4 by digital multi-meter.
  • Page 70 Troubleshooting and Repair F-49 F-49 OUTPUT RECTIFIER DIODE TEST (CONTINUED) Table F.4 – OUTPUT RECTIFIER DIODE MEASURED VALVE DIGITAL MULTI-METER TEST POINT TERMINALS DIODE MODE + PROBE - PROBE ACCEPTABLE READINGS S1-1 0.1-0.7V S1-2 0.1-0.7V S1-1 None S1-2 None S2-1 0.1-0.7V S2-2 0.1-0.7V...
  • Page 71 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.

  • Page 72: Auxiliary Transformer Test

    Troubleshooting and Repair F-51 F-51 AUXILIARY TRANSFORMER TEST (CONTINUED) Figure F.32 –AUXILIARY TRANSFORMER LOCATION AUXILIARY TRANSFORMER PROCEDURE 1. Disconnect power to the INVERTEC® CC 400-S/CC400-S PLUS. WARNING 2. Perform the Case Cover Removal and Filter Capacitor Discharge Procedure High voltage is present at primary of Auxiliary Transformer.
  • Page 73 Troubleshooting and Repair F-52 F-52 AUXILIARY TRANSFORMER TEST (CONTINUED) Figure F.33 – AUXILIARY TRANSFORMER LEADS LOCATION output output input 202A 203A 5. Connect power to INVERTEC® CC voltage is correctly applied. See Wiring Diagram. 400S/CC 400S Plus and check for the correct secondary voltages per table F.
  • Page 74 Troubleshooting and Repair F-53 F-53 AUXILIARY TRANSFORMER TEST (CONTINUED) Table F.5 – AUXILIARY TRANSFORMER MEASURED VALUE INPUT VOLTAGE/FREQUENCY: AC 380V ±10%, 50Hz LEAD No. STANDARD OCV 230 and 231 16±1 V M21437-9 231 and 232 16±1V ® INVERTEC CC400-S/-S PLUS...

  • Page 75: Output Stud Resistance Test

    OUTPUT STUD RESISTANCE 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.
  • Page 76 Troubleshooting and Repair F-55 F-55 OUTPUT STUD RESISTANCE TEST（CONTINUED） Figure F.34 OUTPUT STUD RESISTANCE TEST － ＋ PROBE PROBE Procedure Figure F.34 1． Disconnect power to the 3． Using a digital multi-meter, test the INVERTEC® CC 400-S/CC400-S resistance of output studs. Standard PLUS value :220-250 ohm 4．...
  • Page 77 CURRENT CALIBRATION PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 78: Current Calibration Procedure

    Troubleshooting and Repair F-57 F-57 CURRENT CALIBRATION PROCEDURE (CONTINUED) Figure F.22 – DIP SWITCH LOCATION Procedure INVERTEC® 1． Disconnect power to the CC400-S/-S PLUS. 5． Set the Current knob to the maximum，if the value on front panel shows less than 2．...
  • Page 79 Troubleshooting and Repair F-58 F-58 CURRENT CALIBRATION (CONTINUED) Figure F.22 – front panel switch PROCEDURE 7，Set the knob of potentiometer at the Note： Adjust the switch settings until you understand the function of switch, maximum, confirm whether the max value otherwise will cause problem for machine.

  • Page 80: Retest After Repair

    Troubleshooting and Repair F-59 F-59 RETEST AFTER REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested. It must be retested if any machine accord with the following situation.

  • Page 81: Circuit Diagram

    Note: This diagram is for reference only. It may not be accurate for all machines coved by this manual, The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, contact the Lincoln Electric Service Department for a replacement. Call： 86-21-6673-4530。...
  • Page 82 Note:This diagram is for reference only. It may not be accurate for all machines coved by this manual, The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
  • Page 83 注意事项 • World’s Leader in Welding and Cutting• THE SHANGHAI LINCOLN ELECTRIC COMPANY No. 195, Lane 5008, Hu Tai Rd. Baoshan, Shanghai, PRC 201907 www.lincolnelectric.com.cn INVERTEC CC 400-S/INVERTEC CC 400-S PLUS...

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Invertec cc400-s plus

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