Lincoln Electric INVERTEC 270SX Service Manual
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Lincoln Electric INVERTEC 270SX Service Manual

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SVM 2025
Rev.01 03-2013
®
INVERTEC
270SX & 400SX
For use with machines having code numbers: 52077, 52078, 52081, 52082
LINCOLN ELECTRIC EUROPE
www.lincolnelectric.eu

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  • Page 1 SVM 2025 Rev.01 03-2013 ® INVERTEC 270SX & 400SX For use with machines having code numbers: 52077, 52078, 52081, 52082 LINCOLN ELECTRIC EUROPE www.lincolnelectric.eu...

  • Page 2: Table Of Contents

    INDEX OF CONTENTS   INDEX OF CONTENTS ............................. 2   TECHNICAL SPECIFICATIONS AND ACCESSORIES ................... 3   SAFETY ..................................4   INSTALLATION AND OPERATOR INSTRUCTIONS ....................5   MAINTENANCE ................................ 9   THEORY OF OPERATION ............................. 12   TROUBLESHOOTING AND REPAIR SECTION ....................19  ...

  • Page 3: Technical Specifications And Accessories

    TECHNICAL SPECIFICATIONS AND ACCESSORIES INPUT Input Power at Rated Output EMC Class Input Voltage 6.3kW @ 100% Duty Cycle 270SX Frequency 400V ± 15% 9.5kW @ 35% Duty Cycle 50/60Hz Three Phase 10.9kW @ 100% Duty Cycle 400SX 16.4kW @ 35% Duty Cycle RATED OUTPUT AT 40°C Duty Cycle Output Current...

  • Page 4: Safety

    Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible for damages caused by improper installation, improper care or abnormal operation.

  • Page 5: Installation And Operator Instructions

    SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in an environment with increased hazard of electric shock. EQUIPMENT WEIGHT OVER 30kg: Move this equipment with care and with the help of another person. Lifting may be dangerous for your physical health. CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used.
  • Page 6 workpiece as to guarantee the arc stability, but not too high TIG Welding to avoid spatters around the welding puddle. That means: • This machine does not include a TIG torch necessary for TIG Electrode / workpiece sticking prevention, also with low welding, but one may be purchased separately.
  • Page 7 A flashing dot on the Display indicates that the value read is For others machines this function is disabled (the LED is the average value (V or A) of the previous welding time. This always OFF). feature shown the average value for 5seconds after every welding time.
  • Page 8 Lincoln Electric. Before installing the machine, the operator must check the work area for any devices that may malfunction because of electromagnetic disturbances.

  • Page 9: Maintenance

    MAINTENANCE WARNING INPUT FILTER CAPACITOR DISCHARGE PROCEDURE ® Remove input power to Invertec 270SX and 400SX machine ELECTRIC SHOCK can kill Remove the cover following the instruction available in this Service manual. Have an electrician install and service this equipment Obtain a high resistance and high wattage resistor ( 25- Turn the input power off at the fuse box before working on 1000 ohms and 25 watts minimum ).
  • Page 10 ROUTINE MAINTENANCE THERMAL PROTECTION Keep the welding area around the machine clean and Thermal detection device protect the machine from free of combustible materials. No debris should be excessive operating temperatures. Excessive temperatures allowed to collect which could obstruct air flow to the may be caused by a lack of cooling air or operating the machine machine beyond the duty cycle and output rating.
  • Page 11 ® INVERTEC 400SX 1. Input Board 7. Control Board 2. Input Rectifier Diode Module 8. Output Transformer 3. Output Board 9. Output Studs 4. Inverter Board 10. Input Filter Capacitors 5. Fan 11. Output Choke 6. Mains Switch     Page11 ...

  • Page 12: Theory Of Operation

    THEORY OF OPERATION General description Input Line Voltage, Auxiliary Voltage, Precharge Inverter Board , Main Transformer, Output Section Control Board Protection Circuits IGBT operation BLOCK DIAGRAM (showing 270SX block diagram)     Page12     ...
  • Page 13 INPUT SECTION the auxiliary power supplies (+24, +15V, -5V) GENERAL DESCRIPTION to all the boards will be generated. a uController on the input board manages the ® The Invertec 270Sx and 400SX are inverter based soft stat and pre-charge operation. If the welding power sources that offers multi-mode (TIG and uController is correctly programmed LED LD1 Stick) constant current welding.
  • Page 14 INVERTER SECTION AND MAIN TRANSFORMER Inverter and Main Transformer When the input filter capacitors are fully charged they inverter heatsink, to protect the IGBTs from act as power supplies for the IGBT switching circuit. overheating conditions. The IGBT switch the DC power from the input capacitors "on and off,"...
  • Page 15 OUTPUT SECTION Output Section The output board receives the AC output from the main transformer secondary windings and rectifies it to a DC voltage level. Since the output choke is in series with the positive leg of the output rectifier and also in series with the welding load, a filtered DC output current is applied through the machine’s output terminals.
  • Page 16 CONTROL BOARD AND REMOTE BOARD On the remote board is located the remote control Control Board (User Interface) and connector and the PTCs that protect the control board Remote Board in the event that a remote cable is damaged. The control board receives status and analog feedback signals from the inverter board, input board and various sensors.
  • Page 17 temperature should occur, the Thermal LED indicator on the control board, will turn ON and the thermostat OVERLOAD PROTECTION will prevent output current. The thermal protection device is self-resetting once the ® Invertec 270SX and 400SX are electrically protected machine cools sufficiently. If the shut down was from producing higher than normal output currents.
  • Page 18 INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION Drawing B shows the IGBT in an active mode. An IGBT is a type of transistor. IGBTs are When the gate signal, a positive DC voltage semicon-ductors well suited for high frequency relative to the source, is applied to the gate switching and high current applications.

  • Page 19: Troubleshooting And Repair Section

    TROUBLESHOOTING AND REPAIR SECTION How to use troubleshooting Guide Troubleshooting Guide Case cover removal and capacitor discharge procedure Input board resistance test Inverter board resistance test Output board resistance test Input board voltage test Inverter board voltage test Output board voltage test  ...

  • Page 20: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE 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.
  • Page 21 WARNING NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature. 5. Remove the replacement PC board and ELECTRIC SHOCK can kill substitute it with the original PC board to recreate the original problem. •...
  • Page 22 TROUBLESHOOTING !! WARNING !! BEFORE CONNECT POWER SUPPLY, MAKE A CAREFUL VISUAL INSPECTION INSIDE THE MACHINE , CHECK ALL THE BOARDS AND HARNESS. PROBLEMS / SYMPTOMS CHECKS RECOMMENDED COURSE OF ACTION • CHANGE THE PART BROKEN AND A VISUAL DAMAGE IS EVIDENT ------------------------------------------- PERFORM THE TESTS FOR THE WHEN YOU OPEN THE COVER...

  • Page 23: Case Cover Removal And Dc Link Capacitor Discharge Procedure

    DISCHARGE PROCEDURE WARNING Service and repair should be performed only by 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 24: Invertec 270Sx - Case Cover Removal

    ® INVERTEC 270SX - CASE COVER REMOVAL Procedure: 1. Turn on/off switch to off position. 2. Disconnect Input Power from the machine ! 3. Remove the 2 screws of the alluminum handle (A). 4. Remove the 16 screws of the plastic handle (B). 5.

  • Page 25: Invertec 400Sx - Case Cover Removal

    ® INVERTEC 400SX - CASE COVER REMOVAL Procedure: 1. Turn on/off switch to off position. 2. Disconnect Input Power from the machine ! 3. Remove the 16 screws from the plastic handle + 4 from the cover (A). 4. Remove the 4 screws on the rubber corners (B). 5.

  • Page 26: Dc Link Capacitors Discharge Procedure

    DC LINK CAPACITORS DISCHARGE PROCEDURE INPUT FILTER CAPACITOR WARNING DISCHARGE PROCEDURE 1. Remove input power to 270SX & 400SX machine 2. Remove the cover following the instruction ELECTRIC SHOCK can kill available in this Service manual. 3. Obtain a high resistance and high wattage Have an electrician install and service this equipment resistor ( 25-1000 ohms and 25 watts Turn the input power off at the fuse box before working...

  • Page 27: Input Board Resistance Test

    INPUT BOARD 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 28 6. Check the PTC1 for 100 ohms +/- 20%. If PTC1 doesn not pass the test may be a failure (short) on capacitors or IGBT is present. 7. Check the fan resistence across the fan connector. For Invertec 270SX fan resistance should be 260 ohm +/- 20%, while for Invertec 400SX should be 370 ohms +/- 20%.

  • Page 29: Inverter Board Resistance Test

    INVERTER BOARD 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 30 INVERTER BOARD RESISTANCE TEST (continued) Connector for thermostat TH1 4 IGBT modules located under the inverter printed circuit W05X0857-4 on 270SX W05X0857-5 on 400SX TEST PROCEDURE ® 1. Remove main input power to the INVERTEC 270SX or 400SX. 2. Perform the Discharge procedure 3.

  • Page 31: Output Board Resistance Test

    OUTPUT BOARD 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 32 OUTPUT BOARD RESISTANCE TEST (continued) ® for INVERTEC 270SX Connector for thermostat Output diode modules TEST PROCEDURE ® 1. Remove main input power to the INVERTEC 270SX 2. Perform the Discharge procedure 3. Visually check for burned or damaged components. If any components are physically damaged the input board should be replaced 4.
  • Page 33 OUTPUT BOARD RESISTANCE TEST (continued) ® for INVERTEC 400SX Connector for thermostat Output diode modules TEST PROCEDURE ® 1. Remove main input power to the INVERTEC 400SX 2. Perform the Discharge procedure 3. Visually check for burned or damaged components. If any components are physically damaged the input board should be replaced 4.

  • Page 34: Input Board Voltage Test

    INPUT BOARD VOLTAGE 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 35 INPUT BOARD VOLTAGE TEST (continued) DC BUS - 400VAC +/- 15% DC BUS + 3 Phase INPUT to inverter bd not used to fan Use this heatsink as to control bd SGND reference for voltage tests W05X0855-1 on 270SX W05X0855-2 on 400SX to output bd Not used TEST PROCEDURE...
  • Page 36 INPUT BOARD VOLTAGE TEST (continued) J4: Fan connector Pin# Description Value Notes 15 Vac in idle mode Fan is switch ON by signal 230Vac when fan ON coming from control board J2: Input/Control connector Pin# Description Value (use SGND as 0V ref.) Notes +15V +15Vdc...

  • Page 37: Inverter Board Voltage Test

    INVERTER BOARD VOLTAGE 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 38 BLUE= V at 60A/105V output RED = V 60A/105V output GE at to input bd W05X0857-4 on INVERTEC 270SX W05X0857-5 on INVERTEC 400SX TEST PROCEDURE ® 1. Apply 400V +/- 15% to the INVERTEC 270SX or 400SX 2. Turn the machine input swith to ON position, and wait till the power LED on front panel is stady green.

  • Page 39: Output Board Voltage Test

    OUTPUT BOARD VOLTAGE 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 40 OUTPUT BOARD VOLTAGE TEST (continued) ® for INVERTEC 270SX to input bd HCS1Current Workpiece Hall Sensor Transducer TEST PROCEDURE ® 1. Apply 400V +/- 15% to the INVERTEC 270SX 2. Turn the machine input swith to ON position, and wait till the power LED on front panel is stady green. 3.
  • Page 41 OUTPUT BOARD VOLTAGE TEST (continued) ® for INVERTEC 400SX to input bd Hall sensor TEST PROCEDURE ® 1. Apply 400V +/- 15% to the INVERTEC 400SX 2. Turn the machine input swith to ON position, and wait till the power LED on front panel is stady green. 3.

  • Page 42: Control Board Test

    CONTROL BOARD 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 43 CONTROL BOARD TEST (continued) Cutting mode V - A LEDs selection Mode selection Operative button LEDs V –A push button To Input bd Output current potentiometer uController Arc Force potentiometer Hot Start potentiometer to remote board SW2 setup for CE machines: SW2 setup for AUS machines: TEST PROCEDURE ®...

  • Page 44: Disassembly Operations

    DISASSEMBLY OPERATIONS INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL REMOVAL PROCEDURE Necessary tool: - Phillips screwdriver PH02;...
  • Page 45 DISASSEMBLY OPERATIONS INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL REMOVAL PROCEDURE Necessary tools: - Phillips screwdriver PH02...
  • Page 46 DISASSEMBLY OPERATIONS INVERTER BOARD IGBT REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL REMOVAL PROCEDURE Necessary tools: - Phillips screwdriver PH02...
  • Page 47 DISASSEMBLY OPERATIONS OUTPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING ® W05X1044R for INVERTEC 270SX Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL REMOVAL PROCEDURE Necessary tools:...
  • Page 48 DISASSEMBLY OPERATIONS OUTPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) ® W05X1044R for INVERTEC 270SX WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment.
  • Page 49 DISASSEMBLY OPERATIONS OUTPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING ® W05X1043R for INVERTEC 400SX Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL REMOVAL PROCEDURE Pay attention to the...
  • Page 50 DISASSEMBLY OPERATIONS OUTPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) ® W05X1043R for INVERTEC 400SX WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment.
  • Page 51 DISASSEMBLY OPERATIONS CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE ® INVERTEC 270SX & 400SX WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL REMOVAL PROCEDURE Necessary tool:...
  • Page 52 DISASSEMBLY OPERATIONS CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL 5.

  • Page 53: Retest After Repair

    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.

  • Page 54: Electrical Diagrams

    ELECTRICAL DIAGRAMS ® INVERTEC 270SX     Page 54    ...
  • Page 55 ELECTRICAL DIAGRAMS ® INVERTEC 400SX     Page 55    ...
  • Page 56 ® ELECTRICAL DIAGRAMS – INVERTEC 270SX- 400SX INPUT BOARD SCHEMATIC X0855     Page 56    ...
  • Page 57 ® ELECTRICAL DIAGRAMS – INVERTEC 270SX- 400SX INVERTER BOARD SCHEMATIC X0857 – IGBT DRIVER SECTION     Page 57    ...
  • Page 58 ® ELECTRICAL DIAGRAMS – INVERTEC 270SX- 400SX INVERTER BOARD SCHEMATIC X0857 – IGBT SECTION     Page 58    ...
  • Page 59 ® ELECTRICAL DIAGRAMS – INVERTEC 270SX- 400SX INVERTER BOARD SCHEMATIC X0857 – CONTROL CIRCUIT SECTION     Page 59    ...
  • Page 60 ® ELECTRICAL DIAGRAMS – INVERTEC 270SX OUTPUT BOARD SCHEMATIC X1044     Page 60    ...
  • Page 61 ® ELECTRICAL DIAGRAMS – INVERTEC 400SX OUTPUT BOARD SCHEMATIC X1043     Page 61    ...
  • Page 62 ® ELECTRICAL DIAGRAMS – INVERTEC 270SX- 400SX CONTROL BOARD SCHEMATIC X1026     Page 62    ...
  • Page 63 ® ELECTRICAL DIAGRAMS – INVERTEC 270SX- 400SX CONTROL BOARD SCHEMATIC X1026 (CONTINUED)     Page 63    ...
  • Page 64 ® ELECTRICAL DIAGRAMS – INVERTEC 270SX- 400SX CONTROL BOARD SCHEMATIC X1026 (CONTINUED)     Page 64    ...
  • Page 65 ® ELECTRICAL DIAGRAMS – INVERTEC 270SX- 400SX REMOTE BOARD SCHEMATIC X0322     Page 65    ...

  • Page 66: Note

    NOTE     Page 66    ...

This manual is also suitable for:

Invertec 400sx52077520785208152082

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