Lincoln Electric INVERTEC IM526-B User's Manual

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INVERTEC V300-PRO
™
IM526-B
December,1999
For use with machines Code 10256 and 10257.
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 your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
WARNING
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.
ELECTRIC SHOCK can
kill.
FUMES AND GASES
can be dangerous.
1.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these
fumes and gases.When welding, keep your
head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
with electrodes which require special ventilation such
as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and
other metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and below
Threshold Limit Values (TLV) using local exhaust or
mechanical ventilation. In confined spaces or in some
circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
3.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating products.
3.c. 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.
3.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your
welding distributor or from the manufacturer.
1.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing;
on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire)
Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
1.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically“hot”.
1.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Also see item 7b.
1.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
WELDING SPARKS can
cause fire or explosion.
1.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
4.a..Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
1.g. Never dip the electrode in water for cooling.
1.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
1.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
4.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the equipment being used.
1.j. Also see Items 4.c. and 6.
4.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
ARC RAYS can burn.
2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned.” For information purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
2.c. Protect other nearby personnel with suitable non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
Apr. ‘93
4.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
–2–
4.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a welding area.
7.c.Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting.
Do not spill fuel when filling tank. If fuel is
spilled, wipe it up and do not start engine
until fumes have been eliminated.
---------------------------------------------------------------------------------------
4.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until
they fail.
7.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
4.h. Also see item 7c.
CYLINDER may explode
if damaged.
7.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
5.a. Use only compressed gas cylinders containing the correct shielding gas for the process
used and properly operating regulators
designed for the gas and pressure used. All
hoses, fittings, etc. should be suitable for the application and
maintained in good condition.
7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.
5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
---------------------------------------------------------------------------------------
5.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
5.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
ELECTRIC AND MAGNETIC
FIELDS
may be dangerous
5.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,”available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
8.a. Electric current flowing through any conductor causes localized Electric and
Magnetic Fields (EMF). Welding current
creates EMF fields around welding cables
and welding machines.
FOR ELECTRICALLY
powered equipment.
8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
6.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s recommendations.
8d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
8.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
8.d.2. Never coil the electrode lead around your body.
FOR ENGINE
powered equipment.
8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right side,
the work cable should also be on your right side.
7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
---------------------------------------------------------------------------------------
8.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
8.d.5. Do not work next to welding power source.
7.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes outdoors.
---------------------------------------------------------------------------------------
–3–
Mar. ‘93
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue ou
les vétements mouillés. Porter des gants secs et sans trous
pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher
à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
–4–
Mar. ‘93
TABLE OF CONTENTS
Page
Safety Precautions .............................................................................................................2-4
Introductory Information .......................................................................................................6
Product Description..............................................................................................................7
Specifications.......................................................................................................................7
Installation .........................................................................................................................7-10
Safety Precautions ........................................................................................................7
Location .........................................................................................................................7
Electrical Installation......................................................................................................7
Input Voltage Setup .......................................................................................................8
Power Cord Connection ................................................................................................8
Connection of Wire Feeders to Invertec .....................................................................8-10
Output Cables & Plugs .................................................................................................10
Operating Instructions ......................................................................................................11-13
Safety Precautions .......................................................................................................11
Controls Description and Function.............................................................................11-13
Maintenance.....................................................................................................................13-14
Capacitor Discharge Procedure ...................................................................................13
Routine Maintenance....................................................................................................13
Periodic Maintenance ...................................................................................................14
Troubleshooting Guide .....................................................................................................14-20
Matched Parts.....................................................................................................................20
Switch P.C. Board Replacement Procedure .......................................................................20
Replacement of Power Modules and Output Diodes .......................................................20-21
Connection Diagrams.......................................................................................................22-31
Wiring Diagrams...............................................................................................................32-33
Parts Lists ......................................................................................................................appendix
–5–
Thank You
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase
_____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
–6–
PRODUCT DESCRIPTION
The Invertec V300-PRO is a 300 amp arc welding
power source that utilizes single or three phase input
power to produce either constant voltage or constant
current outputs. The V300-PRO is designed for 60 Hz
supply systems. The welding response of the Invertec
has been optimized for GMAW, SMAW, TIG and
FCAW processes. It is designed to be used with the
LN-25 and LN-7 semiautomatic wire feeders.
SPECIFICATIONS
Product
Name
Invertec
V300PRO
Ordering
Information
Input AC
Voltage
Rated DC Output
Amps/Volts/Duty Cycle
208/230/460
3 Phase
Input Amps at Rated DC Output
575
Output
Range
(continuous)
Weight
with Gun
(net)
208
230
460
48
43
24
60 Hz
300A / 32V / 60%(1)
250A / 30V / 100%(1)
300A / 35/39/41V /60%(2)
37
49
33
48
19
28
208/230/460
1 Phase
250A / 30V / 60%(1)
160A / 28V / 100%(1)
69
62
38
AMPS
64 lbs.
18.7*x10.8x
22.2”
(475x274x
29
42
(29 kg)
564 mm)
250A / 37/41/43V / 60%(2)
47
67
5-350
60 Hz
53
75
575
3 Phase
300A / 32V / 60%(1)
250A / 30V / 100%(1)
60 Hz
300A / 36V / 60%(2)
K1349-3
K1349-4
Dimensions
HxWxD
20
* Includes
handle
16
22
NEMA Class I Rated Output / Based on a 10 min. Period .
(1 )
Lincoln plus rating.
(2 )
* Overall Height Including Handle, (16.4” (417mm without handle).
INSTALLATION
WARNING
ELECTRICAL INSTALLATION
ELECTRIC SHOCK can kill.
• Have an electrician install and service
this equipment.
• Turn the input power off at the fuse
box before working on equipment.
• Do not touch electrically hot parts.
--------------------------------------------------------------------LOCATION
1. The Invertec should be connected only by a qualified electrician. Installation should be made in
accordance with the U.S. National Electrical Code,
all local codes and the information detailed below.
2. Single voltage, 575 VAC machines, can only be
connected to 575 VAC. No internal reconnection
for other input voltages is possible.
The Invertec has been designed with many features to
protect it from harsh environments. Even so, it is
important that simple preventative measures are followed in order to assure long life and reliable operation.
• The machine must be located where there is free
circulation of clean air such that air movement into
the sides and out the bottom and front will not be
restricted. Dirt and dust that can be drawn into the
machine should be kept to a minimum. Failure to
observe these precautions can result in excessive
operating temperatures and nuisance shutdown of
the Invertec.
3. Initial 208 VAC and 230 VAC operation will require
a voltage panel setup, as will later reconnection
back to 460 VAC:
a.
b.
c.
• Keep machine dry. Shelter from rain and snow. Do
not place on wet ground or in puddles.
–7–
Open the access panel on the right side of
the machine.
For 208 or 230: Position the large switch to
200-230.
For 460: Position the large switch to 380-460.
Move the “A” lead to the appropriate terminal.
INPUT VOLTAGE SETUP
Recommended Fuse Sizes Based On The U.S.
National Electrical Code And Maximum
Machine Outputs
CAUTION
DO NOT ATTEMPT TO POWER THIS UNIT
FROM THE AUXILIARY POWER SUPPLY
OF AN ENGINE WELDER.
• Special protection circuits may operate, causing
loss of output.
• The supply from engine welders often has excessive voltage peaks because the voltage waveform
is usually triangular shaped instead of sinusoidal.
• If voltage peaks from the engine welder exceed
380V, the input circuits of this machine protecting
the filter capacitors, FETS and other components
from damage will not be energized .
---------------------------------------------------------------------
(1)
(2)
Input Volts(1)
Fuse Size in Amps
(Time Delay Fuses)
3 phase
50/60 Hz
208
230
460
60
60
40
1 phase
50/60 Hz
208(2)
230(2)
460
85
80
50
3 phase
60 Hz
575
30
Input voltage must be within ±10% of rated value.
When operating on these inputs, at outputs exceeding 200A/60%
or 165A/100%, the input line cord should be changed to an input
conductor of 6 AWG or larger.
RECONNECT PROCEDURE
. Disconnect input power
before
inspecting or servicing machine.
1. BE SURE POWER SWITCH IS OFF.
CONNECTION OF WIRE FEEDERS TO THE
INVERTEC
(Note: IEC units do not have 110 VAC auxiliary
power).
LN-25 Connection Instructions
. Do
not operate with wraparound
removed.
2. CONNECT LEAD ’A’ TO DESIRED
INPUT VOLTAGE RANGE.
. Do
not touch electrically live parts.
440-460V
.
380-415V
’A’
220-230V
Only qualified persons should install,
use or service this equipment.
IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)
AND THERE IS NO OTHER KNOWN FAILURE:
200-208V
CHECK FUSE;
REPLACE WITH A 3 AMP SLOW BLOW ONLY.
3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.
1. Turn the Invertec power switch “off”.
VOLTAGE=380-460V
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO
U.S.A.
VOLTAGE=200-230V
9-11-92
2. Connect the electrode cable to the output terminal
of polarity required by electrode. Connect the work
lead to the other terminal.
S20324
POWER CORD CONNECTION
3. LN-25 with remote control options K431 and K432.
Use K876 adapter with K432 cable or modify K432
cable with K867 universal adapter plug. See connection diagram S19899 and S19309 or S19405 at
the back of this manual.
A 10 ft. (3.0m) power cord is provided and wired into
the machine. Follow the power cord connection
instructions. Incorrect connection may result in equipment damage.
4. Place the local-remote switch in the “remote” position if output control is desired at the wire feeder
rather than the Invertec. (LN-25 must have K431
and K432 options for remote output control operation).
BLACK
GREEN
RED
WHITE
LN-7 Connection Instructions
Single Phase Input
1. Connect green lead to ground per U.S. National
Electrical Code.
2. Connect black and white leads to power.
3. Wrap red lead with tape to provide 600V insulation.
1. Turn the Invertec power switch “off”.
2. Connect the K480 control cable from the LN-7 to
the Invertec control cable connector. The control
cable connector is located at the rear of the
Invertec.
Three Phase Input
3. Connect the electrode cable to the output terminal
of polarity required by electrode. Connect the work
lead to the other terminal.
1. Connect green lead to ground per U.S. National
Electrical Code.
2. Connect black, red and white leads to power.
4. Place the local-remote switch in the “local” position to allow output control at the Invertec. (K864
Install in accordance with all local and national electric
codes.
–8–
–
remote control adapter and K857 remote control
are required for remote output control).
Parallel Operation
The Invertec’s are operable in parallel in both CC and
CV modes. For best results, the currents of each
machine should be reasonably well shared. As an
example, with two machines set up in parallel for a
400 amp procedure, each machine should be set to
deliver approximately 200 amps, not 300 amps from
one and 100 amps from the other. This will minimize
nuisance shutdown conditions. In general, more than
two machines in parallel will not be effective due to
the voltage requirements of procedures in that power
range.
5. Set the meter polarity switch on the rear of the
Invertec to coincide with wire feeder polarity used.
The wire feeder will now display the welding voltage.
6. If K480 is not available, see connection diagram
S19404 for modification of K291 or K404 LN-7
input cable with K867 universal adapter plug.
General Instructions for Connection of Wire
Feeders to Invertec
To set machine outputs, start with output control pots
and arc force/pinch pots in identical positions. If running in a CC mode, adjust outputs and arc forces to
maintain current sharing while establishing the proper
output current. In CV modes, the pots in identical
positions. Then switch the machine meters to amps
and adjust one of the output control pots for current
balance. Check the voltage and if readjustment is
necessary, repeat the current balancing step. Pinch
settings should also be kept identical on the
machines.
Wire feeders other than LN-7 and LN-25 may be used
provided that the auxiliary power supply capacity of
the Invertec is not exceeded. K867 universal adapter
plug is required. See connection diagram S19406 and
S19386 at the back of this manual for more information.
Remote Control of Invertec
Remote control K857, hand amptrol K963 and foot
amptrol K870 require K864 remote control adapter.
See 19309 instruction at the back of this manual for
connection information.
K900-1 DC TIG Starter Connection
This versatile new kit was made to mate with the
Invertec.
K954-1 MIG PULSER
The MIG Pulser is a hand-held “pendant” type GMAW
Pulsing option for the V300 Power Source. Refer to
the Mig Pulser’s IM manual (IM555) for connection
information.
A control cable assembly is supplied with the kit to
connect the kit to an Invertec. The cable can be connected, either end, at the DC TIG Starter kit and at
the Invertec by attaching to the 14-pin Amphenols on
the backs of each unit. Refer to diagram S20405 at
the back of this manual.
A negative output cable assembly is also supplied
with the DC TIG Starter kit to connect the kit with the
Invertec’s negative output terminal.
All Magnum™ one and two piece water-cooled torches with 7/8 left-hand threads and gas-cooled torches
with 7/8 and 5/16 right-hand threads can be connected to the starter kit.
To secure the DC TIG Starter kit to the bottom of the
Invertec and for more detailed instructions, refer to
the K900-1 manual.
–9–
MAR97
LN-9 GMA Connection Instructions
2. Slide rubber boot onto cable end. The boot end
may be trimmed to match the cable diameter.
Soap or other lubricant will help to slide the boot
over the cable.
1. Turn the Invertec power switch “off”.
BOOT
2. Connect the K596 control cable assembly from the
LN-9 GMA to the Invertec control cable connector.
The control cable connector is located at the rear
of the Invertec.
WELDING CABLE
25 mm
3. Connect the electrode cable to the output terminal
of polarity required by electrode. Connect the work
lead to the other terminal.
TRIM
1 in.
3. Slide the copper tube into the brass plug.
4. Insert cable into copper tube.
4. Place the local-remote switch in the “remote” position to allow output control at the LN-9 GMA.
SET SCREW
5. Set the meter polarity switch on the rear of the
Invertec to coincide with wire feeder polarity used.
The wire feeder will now display the welding voltage.
6. K608-1 adapter is required in LN-9 GMA for LN-9
type control. K608-1 is installed in line with P10
connection at the LN-9 GMA voltage board. See
diagram S20607 at the back of this manual.
7. K442-1 Pulse Power Filter Board is also required
for GMAW, but should be disconnected for FCAW.
BRASS PLUG
COPPER TUBE
5. Tighten set screw to collapse copper tube. Screw
must apply pressure against welding cable. The
top of the set screw will be well below the surface
of the brass plug after tightening.
6. Slide rubber boot over brass plug. The rubber
boot must be positioned to completely cover all
electrical surfaces after the plug is locked into the
receptacle.
8. If K596 is not available, see connection diagram
S20608 at the back of this manual for modification
of K196 LN-9 GMA input cable with K867 universal
adapter plug.
Output Cables
Select the output cable size based upon the following
chart.
Cable sizes for Combined Length of Electrode and
Work Cable (Copper) 75° rated:
Duty
Cycle
Current
Length Up
61m (200 ft.)
61-76m
(200-250 ft.)
100%
60%
250
300
1/0
1/0
1/0
2/0
Quick Disconnect Plugs
A quick disconnect system is used for the welding
cable connections. The welding plug included with the
machine is designed to accept a welding cable size of
1/0 to 2/0.
1. Remote 25mm (1 in.) of welding cable insulation.
– 10 –
OPERATING INSTRUCTIONS
Output Control - This controls the output voltage in
the CV modes and output current in the CC modes.
WARNING
Control is provided over the entire output range of the
power source with 1 turn of the control knob. This control may be adjusted while under load to change
power source output.
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 closed containers.
OUTPUT
Local/Remote Switch - Place in the “LOCAL” position to allow output adjustment at the machine. Place
in the “REMOTE” position to allow output adjustment
at the wire feeder or with a remote control option
package.
REMOTE
-----------------------------------------------------------------------ARC RAYS can burn eyes and skin.
• Wear eye, ear and body
protection.
-----------------------------------------------------------See additional warning information at
front of this operator’s manual.
----------------------------------------------------------DUTY CYCLE
Digital Meter Switch - Select either “A” for amps or
“V” for volts to display welding current or voltage on
the meter.
When welding current is not present, the meter will
display the set current for the CC modes or the set
voltage for the CV modes. This set reading is an indication of machine control setting. For a more precise
process reading, read meter during actual welding.
The Invertec is rated at 300 amps, 60% duty cycle for
3 phase inputs (based on a 10 minute cycle). It is also
rated at 250 amps, 100% duty cycle.
CONTROL FUNCTION / OPERATION
Power Switch - Place the lever in the “ON” position to
energize the machine. When the power is on, the digital meter will activate and the fan will operate.
Mode Switch
OFF
– 11 –
GTAW
Optimized for both scratch start and HiFreq kit use.
CC SOFT
Best for EXX18 thru EXX28 stick electrodes.
CC Crisp
Use this mode for stick welding with
EXX10 thru EXX14 electrodes. Nonwelding applications such as resistive
heating or output tests with resistive
loads should be done in this mode with
Arc Force Control set to minimum.
CV FCAW
CV GMAW
This setting has been optimized for
Innershield® and Outershield® flux-cored
electrodes.
Short circuit, glob and spray transfer
solid wire and gas welding are done in
this mode. Low end procedures, less
than 17V, may operate better in the
FCAW mode. Voltage in the GMAW
mode can become erratic when
welding is attempted using voltages
equal to or less than 17V DC+.
SMAW
CRISP
FCAW
SMAW
SOFT
GMAW
Arc Force / Inductance Control
This control functions in all modes except GTAW. For
CC modes, this control acts as an Arc Force adjustment. The arc is soft at the minimum settings and
more forceful or driving at the maximum settings.
Higher spatter levels may be present at the maximum
settings.
For CV modes, this control will set the degree of
“pinch effect” which predominantly affects short circuit
transfer. In FCAW, the maximum setting is generally
preferred. With GMAW, the upper half of the range is
preferred with CO2 or high content CO2 mixed. The
lower half is for inert gas mixes.
GTAW
Output Terminals Switch
For processes and equipment that require energized
machine terminals (stick, TIG, air-carbon arc cutting or
hot tip LN-25), set the Output Terminals Switch to
“ON” position.
Recommended Arc Force / Inductance Settings
For Selected Applications
Set to the REMOTE (OFF) position when using LN-25
with K431 and K432 options or LN-7 which will allow
the gun trigger to energize the welding terminals.
Full Range Is 1-10,
1 Is Very Soft, 10 Is Very Crisp
ON
OUTPUT
TERMINALS
Nominal
Setting
Recommended
Adjustment Range
EXX18 thru
EXX28 stick
5
1 (gentle, may stick) to 9
(forceful, more spatter)
EXX10 thru
EXX14 stick
6
3 to 10
Air Carbon Arc
Cutting
1
None
Innershield or
Outershield
10
None
Air Carbon Arc
Cutting
1
None
CO2 or 25% CO2
7.5
5 to 10
5
1 to 10
Mode
Process
CC SMAW 1
CC SMAW 2
REMOTE
CV FCAW
CV GMAW*
or similar
gas mixes
98% Ar-2% O2Ar,
90% He-7.5% Ar
2.5% CO2 and
other
predominantly
inert gases
* 1 = Lowest pinch, highest inductance and least spatter.
10 = Highest pinch, lowest inductance and most spatter.
– 12 –
–
Meter Polarity Switch
MAINTENANCE
The wire feeder polarity switch is located at the rear of
the machine. The switch provides a work connection
for wire feeder voltmeters. Place the switch in the
position of the electrode polarity indicated by the
decal. The switch does not change the welding
polarity.
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service
this equipment.
• Turn the input power off at the fuse
box before working on equipment.
• Do not touch electrically hot parts.
---------------------------------------------------------------------
EXPLODING PARTS can cause
injury.
T13086-84
• Failed parts can explode or cause other
parts to explode when power is applied.
• Always wear a face shield and long sleeves when servicing.
---------------------------------------------------------------------------------Capacitor Discharge Procedure
Auxiliary Power
1. Obtain a power resistor (25 ohms, 25 watts).
A 24 VAC @ 1 amp supply is included for use with the
LN-25 wire feeder (24 volts needed for K431 and
K432 options). This supply is protected by a selfresetting current limiter.
A 42 VAC @ 5.5 amp supply is included for use with
other wire feeders. This supply is protected by a 6
amp breaker located on the rear of the machine.
2. Hold resistor body with electrically insulated glove.
DO NOT TOUCH TERMINALS. Connect the resistor terminals across the two hex head cap screws
in the position shown. Hold in each position for 1
second. For 575 VAC only, repeat for second
capacitor. Repeat for the capacitor(s) on the other
side of the machine
A 110/115 VAC @ 2 amp supply is included for use
with the LN-7 or LN-9 GMA wire feeders. This supply
is protected by a 2.5 amp breaker located on the rear
of the machine. It is NOT available on IEC units.
RESISTOR
All three supplies are not to be loaded simultaneously.
CAPACITOR
TERMINALS
3. Use a DC voltmeter to check that voltage is not
present across either capacitor.
Routine Maintenance
1. Every 6 months or so the machine should be
cleaned with a low pressure airstream. Keeping
the machine clean will result in cooler operation
and higher reliability. Be sure to clean these areas:
• Power, switch, driver, protection and control printed
circuit boards.
• Power switch
• Main transformer
• Input rectifier (located in front of fan blade)
• Heat sink fins
2. Examine the sheet metal case for dents or breakage.
Repair the case as required. Keep the case in good condition to insure that high voltage parts are protected and
correct spacings are maintained. All external sheet
metal screws must be in place to insure case strength
and electrical ground continuity.
– 13 –
PERIODIC MAINTENANCE
TROUBLESHOOTING
WARNING
Overload Protection
ELECTRIC SHOCK can kill.
The machine is electrically protected from producing
high output currents. Should the output current
exceed 340-360A, an electronic protection circuit will
reduce the current to approximately 150A. The
machine will continue to produce this low current until
the protection circuit is reset. Reset occurs when the
output load is removed.
• Have an electrician install and service
this equipment.
• Turn the input power off at the fuse
box before working on equipment.
• Do not touch electrically hot parts.
---------------------------------------------------------------------
EXPLODING PARTS can cause
injury.
Thermal Protection
• Failed parts can explode or cause other
parts to explode when power is applied.
Thermostats protect the machine from excessive
operating temperatures. Excessive temperatures may
be caused by a lack of cooling air or operating the
machine beyond the duty cycle and output rating. If
excessive operating temperature should occur, the
thermostat will prevent output voltage or current. The
meter will remain energized during this time.
• Always wear a face shield and long sleeves when servicing.
---------------------------------------------------------------------------------Visual Inspection
Thermostats are self-resetting once the machine cools
sufficiently. If the thermostat shutdown was caused by
excessive output or duty cycle and the fan is operating
normally, the Power Switch may be left on and the
reset should occur within a 15 minute period. If the fan
is not turning or the air intake louvers were obstructed,
then the power must be switched off for 15 minutes in
order to reset. The fan problem or air obstruction must
also be corrected.
Clean interior of machine with a low pressure
airstream. Make a thorough inspection of all components. Look for signs of overheating, broken leads or
other obvious problems. Many problems can be
uncovered with a good visual inspection.
Open Circuit Voltage
The open circuit voltage of the Invertec V300-PRO is
60 to 75 VDC and cannot be adjusted by the output
control.
Test Conditions
Filter Capacitor Conditioning
A protection circuit is included to monitor the voltage
across filter capacitors C1 and C2 (also C14 and C15
on 575 VAC units). In the event that the capacitor voltage is too high, the protection circuit will prevent output. The protection circuit may prevent output providing all these circumstances are met:
1. Machine is internally connected for 380 VAC, or
higher input voltage.
2. Machine did not have power applied for many
months.
3. Machine did not produce output when power was
first switched on.
Perform all testing at the lowest input voltage available, except where a higher voltage is required by a
test step. Make ohmmeter checks only after power
has been disconnected from machine and after
capacitors have been discharged.
Certain high voltage connections have been insulated
with RTV sealant. It is necessary to break through the
sealant with a sharp probe in order to make voltage or
resistance checks.
Disconnect any control cables from remote control
receptacle.
If these circumstances apply, the proper action is to
switch the machine on and let it idle for up to 30 minutes. This is required to condition the filter capacitors
after an extended storage time. The protection circuit
will automatically reset once the capacitor conditioning
and resultant voltage levels are acceptable. It may be
necessary to turn the power switch off and back on
again after this period.
– 14 –
TROUBLESHOOTING GUIDE
Trouble
What To Do
Not output but fan operates and meter is on.
Perform test steps 1A and 1B.
Poor welding, weld settings drift, or output power is
low.
1.
2.
Main fuses open or Switch PC boards overheated.
Perform test steps 4 and 5 for both Switch PC Boards
and 7.
Output turns on momentarily then switches off and
repeats. Machine is connected for 380 VAC or higher
input voltage.
Perform test steps 3B, 4 and 5.
OCV is normal (approx. 65-75V) but output power is
low (less than 20V and 100A). Machine makes
squealing noise while under load. Machine is connected for 230 VAC, or lower, input voltage.
Perform test steps 4 and 5 for both Switch PC Boards.
Open circuit voltage is 1-2 volts.
Perform test step 6.
Output control not functioning on remote control. Local
control OK.
1.
2.
Check remote control assembly.
Check S3, Local/Remote switch.
Machine does not produce more than 250A output
when connected to 3 phase supply.
1.
2.
3.
4.
Replace main fuse if blown.
Replace Protection PC Board.
Replace Control PC Board.
Perform test step 7.
Machine does not produce more than 200 A output
while connected to 1 phase supply.
Normal operation.
Machine operates OK at 230 VAC or lower. No output
at 380 VAC or higher.
Perform test step 2.
Poor EXX10 stick electrode (5P) performance. Arc
“pops out”.
Check D6 and D12, L1 and L2.
No output or reduced output the first time power is
applied to the machine.
Check reconnect panel - connections and fuse.
Check front panel wiring and controls.
Replace Control PC Board.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
– 15 –
TEST PROCEDURES
Step
Test
1A
Output pilot circuit
(set S4 on)
1B
2
Check
223A to 210
302 (pos) to 275D (neg)
Protection PC
board output (set
S4 on)
313 (neg) to 311 (pos)
Test
Result
Conclusion
24 VAC
Fan thermostat, choke
thermostat, T1 transformer and S4 all OK.
0 VAC
Check above components.
15 VDC
T1 and 15V power supply OK.
0 VDC
Check T1 and Power PC
Board.
<1 VDC
Protection PC Board OK
Static capacitor
balance (set S4
off)
380 VAC input
and higher test
3B
Dynamic capacitor balance (set
S4 on)
380 VAC input
and higher test
Compare voltage across
terminals 9 & 12 of each
Switch PC Board.
575 VAC -- 407 VDC
460 VAC -- 325 VDC
440 VAC -- 311 VDC
415 VAC -- 293 VDC
380 VAC -- 269 VDC
575 VAC only - compare
voltage across 9A & 13
and 13 & 12A; then, 9B &
15 and 15 & 12B
Connect as in step 3A.
Same voltages as above.
<25 VDC
difference
between
readings
Repair Action
1B
2
Replace Power
and Control PC
Boards
3A
>5 VDC
3A
Next
Test
Step
C1, C2, R1, R9 - OK
(575 VAC machine C14,
C15 - OK)
3B
>25 VDC
difference
Check above components.
<25 VDC
OK
>25 VDC
Power PC Board or
Switch PC Boards are
damaged.
Replace
Protection PC
Board
4
and
5
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
– 16 –
–
Step
Test
4
Switch PC Board
resistance test.
No dynamic test
is possible.
Remove leads
401/403, 1/8, 9,
12, 4/5 and
402/404.
Check
Terminals on Switch
PC Board:
1/8 (pos) to
12 (neg)
1/8 (neg) to
12 (pos)
9 (pos) to
4/5 (neg)
9 (neg) to
4/5 (pos)
1/8 (pos) to
9 (neg)
1/8 (neg) to
9 (pos)
12 (pos) to
4/5 (neg)
12 (neg) to
4/5 (pos)
12 (pos) to
401/403 (neg)
12 (neg) to
401/403 (pos)
9 (pos) to
402/404 (neg)
9 (neg) to
402/404 (pos)
Test
Result
Conclusion
>1K ohms
OK
<100 ohms
Short
<100 ohms
OK
>1K ohms
Open
>1K ohms
OK
<100 ohms
Short
<100 ohms
OK
>1K ohms
Open
<100 ohms
OK
>1K ohms
Open
>1K ohms
OK
<100 ohms
Short
<100 ohms
OK
>1K ohms
Open
>1K ohms
OK
<100 ohms
Short
>1K ohms
OK
<100 ohms
Short
<100 ohms
OK
>1K ohms
Open
<100 ohms
OK
>1K ohms
Open
>1K ohms
OK
<100 ohms
Short
Next
Test
Step
Repair Action
cont
5
Replace Switch PC Board
cont
5
Replace Switch PC Board
cont
5
Replace Switch PC Board
cont
5
Replace Switch PC Board
cont
5
Replace Switch PC Board
cont
5
Replace Switch PC Board
cont
5
Replace Switch PC Board
cont
5
Replace Switch PC Board
cont
5
Replace Switch PC Board
cont
5
Replace Switch PC Board
cont
5
Replace Switch PC Board
cont
5
Replace Switch PC Board
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
– 17 –
Step
5
Test
Snubber
Resistors
Disconnect leads
401, 402, 403 and
404 from Switch
PC Board
Check
Lead 401 to terminal
12
Lead 402 to terminal
9
Lead 403 to terminal
12
Lead 404 to terminal
9
6
Test
Result
Repair Action
25 ohms
OK
>30 ohms
<20 ohms
R4 open
R4 shorted
25 ohms
OK
>30 ohms
<20 ohms
R5 open
R5 shorted
25 ohms
OK
>30 ohms
<20 ohms
R6 open
R6 shorted
25 ohms
OK
>30 ohms
<20 ohms
R7 open
R7 shorted
Replace R7
<100 ohms
Shorted output
diode D1 thru
D12
Test individually
>200 ohms
Output diodes OK
Output diodes
+ output plug (pos)
to
- output plug (neg)
Conclusion
Next
Test
Step
cont
Replace R4
cont
Replace R5
cont
Replace R6
cont
Remove output
load
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
– 18 –
Step
7
Test
D13 Input
Rectifier
Check
9 (pos) to H1 (neg)
9 (pos) to A (neg)
9 (pos) to H5 (neg)
12 (neg) to H1 (pos)
12 (neg) to A (pos)
12 (neg) to H5 (pos)
9 (neg) to H1 (pos)
9 (neg) to A (pos)
9 (neg) to H5 (pos)
12 (pos) to H1 (neg)
12 (pos) to A (neg)
12 ( pos) to H5 (neg)
Test
Result
Conclusion
Next
Test
Step
>1K ohms
OK
cont
<100 ohms
Shorted
4-5
>1K ohms
OK
cont
<100 ohms
Shorted
4-5
>1K ohms
OK
cont
<100 ohms
Shorted
4-5
>1K ohms
OK
cont
<100 ohms
Shorted
4-5
>1K ohms
OK
cont
<100 ohms
Shorted
4-5
>1K ohms
OK
cont
<100 ohms
Shorted
4-5
<100 ohms
OK
cont
>1K ohms
Open
4-5
<100 ohms
OK
cont
>1K ohms
Open
4-5
<100 ohms
OK
cont
>1K ohms
Open
4-5
<100 ohms
OK
cont
>1K ohms
Open
4-5
<100 ohms
OK
cont
>1K ohms
Open
4-5
<100 ohms
OK
cont
>1K ohms
Open
4-5
– 19 –
Repair Action
Replace D13, inspect S1,
test C1 and C2
Replace D13, inspect S1,
test C1 and C2
Replace D13, inspect S1,
test C1 and C2
Replace D13, inspect S1,
test C1 and C2
Replace D13, inspect S1,
test C1 and C2
Replace D13, inspect S1,
test C1 and C2
Replace D13, inspect S1,
test C1 and C2
Replace D13, inspect S1,
test C1 and C2
Replace D13, inspect S1,
test C1 and C2
Replace D13, inspect S1,
test C1 and C2
Replace D13, inspect S1,
test C1 and C2
Replace D13, inspect S1,
test C1 and C2
Matched Parts
5. Thoroughly clean the heat sink surface.
Certain parts must be replaced in matched sets.
Matched sets are required in the following areas:
6. Apply a thin layer (ideally .005-.010”) of Dow 340
Heat Sink Compound to the module mounting surfaces of the new Switch PC Board and a thinner
layer (.002”) to the capacitor terminals. Keep the
heat sink compound away from the screw threads
since this compound will affect the torque specifications.
Output diodes: D1, D2, D3, D4 and D5
Output diodes: D7, D8, D9, D10 and D11
Capacitor bleeder resistors: R1 and D9
Capacitors: C1 and C2
Capacitors: C1, C2, C14 and C15 (575 VAC only)
Switch PC Board Repairs
7. Carefully place the Switch PC Board onto the heat
sink. Be sure the mounting holes are lined up
before making full contact with the heat sink.
If a test indicates that a Switch PC Board is defective,
both Switch PC Boards must be replaced.
Replacement boards must have completely identical
part numbers. A defective module is likely to damage
other devices in the power circuitry. The defect may
be subtle and not detectable by an ohmmeter measurement. Unknown defective parts may cause newly
replaced parts to fail.
8. Caution: The heat sink and the capacitor terminals
are relatively soft material and it is very easy to
cross-thread the mounting screws. Holding the
Switch PC Board, install the 4 socket head cap
screws, finger tight only. Then install the hex head
cap screws into the capacitor, finger tight only.
In addition to replacing the Switch PC Boards, replace
C1 and C2 (also C14 and C15 of the 575 VAC V300PRO) if the following conditions are met:
9. Torque the 4 socket head cap screws to 44 inchlbs force (5 N - m). Then torque the capacitor hex
head cap screws to 55 inch-lbs force (6 N - m).
10. Reconnect all the leads to the board.
1. Machine was operating from 380 VAC or higher
supply when failure occurred.
2. Switch PC Boards have burned areas.
Before applying input power to the machine, check all
electrical connections. An incorrect connection will result
in machine damage when the power is switched on.
Switch PC Board Replacement Procedure
Test After Repair
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service
this equipment.
• Turn the input power off at the fuse
box before working on equipment.
• Do not touch electrically hot parts.
---------------------------------------------------------------------
EXPLODING PARTS can cause
injury.
• Failed parts can explode or cause other
parts to explode when power is applied.
• Always wear a face shield and long sleeves when servicing.
---------------------------------------------------------------------------------1. Carefully disconnect the leads at the top of the
Switch PC Board.
2. Remove the four socket head cap screws with a
3/16” hex key wrench.
3. While holding the Switch PC Board, remove the
hex head cap screws from the center area of the
board.
1. Short terminals 14 and 53 of the Protection PC
Board. Connect an ohmmeter, set for X1000
range, to terminals 9 (+) and 12 (-) of the Switch
PC Board. The meter will show the capacitors
charging up. The meter may take a minute or so to
stabilize. The value must not exceed 8600 ohms.
Test both boards. For 575V only units - measure
across each power capacitor, 2 per switch board;
All four readings should be approximately 5,000
ohms.
2. If OK, remove the short and proceed with the
power test.
3. Fuse input supply with 5 amp fuses.
4. Check output open circuit voltages. Do not apply
output load.
5. Connect machine for 460 (V300-PRO), or 575
(V300-PRO, 575V), or 380, 415 or 440 (V300-I)
VAC input.
6. Check output open circuit voltages. Do not apply
output load.
4. Remove the board.
7. Fuse for 20 amps and test under load.
– 20 –
–
Replacement of Power Modules and Output
Diodes
The compound should be applied to the heat sink in a
very thin layer, less than 0.001 in. DO NOT apply on
diode stud and mounting nut threads.
Input rectifier, D13, is a power module. When mounting power modules, the heat sink and module mounting surface should be clean and free of burrs and foreign material. Apply heatsink compound (Dow 340) as
a uniform layer ideally .010” thick, to eliminate all air
pockets. This may be verified by mounting and then
removing the module. When removed, the compound
on both surfaces will appear textured as if a vacuum
had created veinlike ridges when the parts were separated. If the compound does not have this appearance, apply more heatsink compound and recheck.
Components must have proper torque applied to
mounting screws and to electrical terminals. Torque
the modules according to the following:
Replacement of output diodes D1 thru D12 is similar.
Clean and brighten mounting surface with fine steel
wool. Compound should be used on surface between
diode and heat sink when mounting individual diodes.
Component to Heat Sink
Torque ±10%
Terminal
Torque ±10%
Module
44 Inch - Lbs.(1)
(5N - m)
N.A.
Capacitor
N.A.
55 Inch - Lbs.
(6.3 N - m)
Input Rectifier
(M15454-1)
6 Inch - Lbs.(2)
(0.7 N - m)
26 Inch - Lbs.
3 (N - m)
Output Diode
(M15482-2)
25 Inch - Lbs.
(3 N - m)
N.A.
Component
Switch Board
(1)
(2)
Retorque after 3 hours to allow for spread of compound.
Tighten in staggered fashion one quarter turn at a time.
Environment Protection
Printed Circuit Board Replacement
High voltage connections are covered with an RTV
sealant to prevent malfunction in severe environments. Sealant must be applied to connections which
have been opened or otherwise lost their protection. A
noncorrosive electronic grade sealant such as Dow
Corning 3140, 3145, 738, Columbus Adhesives 0172
or GE RTV-162 is recommended. Sealant may also
be purchased from Lincoln Electric (order E2519
Silicone Rubber RTV Coating). Apply sealant after
machine is repaired and tested.
1. Handle PC Boards by edges only.
2. Store PC Boards only in the bags that disperse
static charges.
3. Inspect PC Board for burned conductors or components. If damage is visible, inspect the machine
wiring for grounds or shorts to avoid damaging a
new PC Board.
High voltage areas which require sealant are as listed:
- Input rectifier D13, all 5 terminals.
4. If there is no visible damage to the PC Board,
install a new PC Board and see if the problem is
fixed. If the problem is fixed by the new board,
reinstall the old board and see if the problem reoccurs. If the problem does not reoccur, check the
wiring harness and plugs for loose connections.
– 21 –
– 22 –
K876
TO POWER SOURCE
STRAIGHT PLUG (14 PIN)
K864
STRAIGHT PLUG (14 PIN)
TO POWER SOURCE
3) K870 FOOT AMPTROL
1) K857 REMOTE CONTROL
2) K963 HAND AMPTROL
1) LN-7 WIRE FEEDERS
TO:
1) LN-25 WIRE FEEDERS
CABLE RECEPTACLE (6 SOCKET)
TO:
CABLE RECEPTACLE (14 SOCKET)
TO:
CABLE RECEPTACLE (6 SOCKET)
OR WHEN CONNECTING OR DISCONNECTING PLUGS TO
WELDING POWER SOURCE.
TURN THE POWER SWITCH OF THE WELDING POWER
SOURCE "OFF" BEFORE INSTALLING PLUGS ON CABLES
REMOTE CONTROL ADAPTERS
S19309
4-19-96D
– 23 –
IT IS DESIGNED TO ALLOW THE USER TO MAKE CONNECTIONS
115V AC (31, 32),
42V AC
WELDING MODE CONTROL
82
81
SPARE
L
M
N
WELDING MODE CONTROL
115V AC
31
42V AC
41
I
42
WORK
21
H
K
OUTPUT CONTROL
J
OUTPUT CONTROL
77
E
76
OUTPUT CONTROL
4
D
75
TRIGGER CIRCUIT
2
F
CHASSIS CONNECTION
TRIGGER CIRCUIT
GND
B
C
G
115V AC
32
A
STANDARD FUNCTION
LEAD
PIN
AND TRIGGER
CIRCUIT (2, 4)
E=77
M=81
K=42
AND 14-PIN CABLE PLUG,
14-PIN BOX RECEPTACLE,
D=4
C=2
L=82
B=GND
A=32
REAR VIEW
FRONT VIEW
F=76
G=75
N=SPARE
H=21
I=41
J=31
F=76
M=81
K=42
AND 14-PIN CABLE PLUG,
14-PIN BOX RECEPTACLE,
G=75
H=21
N=SPARE
I=41
J=31
THE INSULATING METHOD MUST BE RATED FOR 120V AC OR GREATER.
CRIMP SPLICE OR SOLDER CONNECTIONS AS REQUIRED AND INSULATE EACH USED AND UNUSED LEAD
MAY NOT BE PRESENT IN YOUR EQUIPMENT.
REFERENCE ONLY AND EACH MAY OR
24V AC (SPARE)
INDEPENDENT CIRCUITS INSIDE THE WELDER.
42V AC (41, 42),
MAY OR MAY NOT BE ISOLATED,
IN THE UNIVERSAL ADAPTER.
USE LUG,
NOTE:
THE STANDARD CONNECTOR PIN DESIGNATIONS AND FUNCTIONS ARE SHOWN BELOW.
CONSULT THE APPROPRIATE EQUIPMENT WIRING DIAGRAMS FOR THE CONNECTIONS TO UNIVERSAL ADAPTER.
THESE FUNCTIONS ARE LISTED FOR
24V AC
NOR ARE THEY REQUIRED FOR PROPER WIRE FEEDER OPERATION.
TURN THE POWER SWITCH OF THE WELDING POWER SOURCE OFF BEFORE INSTALLING
THIS ADAPTER TO WIRE FEEDER CABLE.
(SEE APPROPRIATE WIRING DIAGRAM)
3.
2.
1.
NOT ALL CIRCUITS ARE PRESENT IN EVERY POWER SOURCE,
CONSULT THE WIRING DIAGRAM OF THE POWER SOURCE AND WIRE FEEDER THIS ADAPTER WILL BE USED WITH.
TO ANY OF THE 14 CIRCUITS PRESENT IN THE WIRE FEEDER RECEPTACLE.
WIRE FEEDER RECEPTACLE.
THIS CONNECTOR IS MEANT TO BE USED WITH LINCOLN POWER SOURCES WHICH HAVE A 14-PIN
INSTALLATION INSTRUCTIONS
K867 UNIVERSAL ADAPTER FOR 14-PIN WIRE FEEDER RECEPTACLE
S19386
3-16-90
FRONT VIEW
REAR VIEW
E=77
D=4
L=82
C=2
B=GND
A=32
N.D.
N.C.
N.B.
SPLICE LEADS AND INSULATE.
INSULATE EACH UNUSED LEAD INDIVIDUALLY.
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
DIAGRAM SHOWS ELECTRODE POSITIVE.
+
INVERTEC
POWER SOURCE
WITH 115VAC
AUXILIARY POWER
LN-7
CONTROL
BOX
-
K291 OR K404
INPUT CABLE
WORK
TO CHANGE POLARITY, TURN POWER "OFF",
77
76
75
N.D.
77
76
GREEN
75
GND
GND
4
21
21
K867 UNIVERSAL
ADAPTER PLUG
2
4
81
42
41
31
32
2
75
14 PIN
AMPHENOL
76
K775 OPTIONAL
REMOTE CONTROL
TO
N.C.
WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
service this machine.
Only qualified persons should install, use or
CAN KILL
SHOCK
ELECTRIC
82
SPARE
service this machine.
Only qualified persons should install, use or
Before connecting the wire feeder.
using the disconnect switch at the fuse box
32
31
N.C.
Turn off input power to the Welding Power Source
K867 PLUG TO LN-7 - CONNECTION DIAGRAM
WARNING
REMOTE CONTROL
K775 OPTIONAL
LN-7
CONTROL
BOX
K291 OR K404
INPUT CABLE
SPLICE LEADS AND INSULATE.
INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.A.
Before connecting the wire feeder.
using the disconnect switch at the fuse box
Turn off input power to the Welding Power Source
K867 PLUG TO LN-7 - CONNECTION DIAGRAM
WARNING
SHOCK
ELECTRIC
CAN KILL
82
SPARE
81
42
41
31
4
75
2
2
21
14 PIN
AMPHENOL
31
32
4
32
21
GND
76
77
GREEN
GND
K867 UNIVERSAL
ADAPTER PLUG
77
WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
ELECTRODE CABLE
TO LN-7
ELECTRODE CABLE
TO LN-7
TO
WORK
+
INVERTEC
POWER SOURCE
WITH 115VAC
N.D.
N.A.
DIAGRAM SHOWS ELECTRODE POSITIVE.
TO CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
AUXILIARY POWER
N.B.
N.D.
N.C.
S19404
12-10-93A
– 24 –
S19404
12-10-93A
– 25 –
A
B
75
76
N.E.
D
N.E.
REMOVE 6 PIN PLUG FROM
N.D.
SPLICE LEADS AND INSULATE.
LABEL EACH LEAD (A THRU F) AS THEY ARE REMOVED FROM 6 PIN PLUG.
K432 CABLE IN ORDER TO CONNECT K867 PLUG.
INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.C.
DIAGRAM SHOWS ELECTRODE POSITIVE.
TO CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
N.B.
N.D.
C
F
SPARE
77
E
2
4
32
31
GND
N.C.
WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
K867 ADAPTER
AMPHENOL
14 PIN
41
42
81
82
21
service this machine.
Only qualified persons should install, use or
Before connecting the wire feeder.
using the disconnect switch at the fuse box
Turn off input power to the Welding Power Source
N.A.
INVERTEC
POWER SOURCE
+
-
TO
WORK
ELECTRODE CABLE
TO LN-25
CAN KILL
SHOCK
ELECTRIC
WARNING
K867 PLUG TO LN-25 - CONNECTION DIAGRAM
K432 REMOTE
CONTROL CABLE
S19405
1-25-91
LN-25 WITH
K431 OPTION
– 26 –
/
VAC
VAC
/
REMOTE
OUTPUT
N.D.
N.C.
TO CHANGE POLARITY, TURN POWER "OFF",
K867
4
WIRE FEEDER
FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION
2
RELAY TO CLOSE LEADS 2 & 4.
TO
TO
INSULATE EACH UNUSED LEAD INDIVIDUALLY.
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
N.C.
N.D.
CONTROL
VOLTMETER CONNECTION
(WORK TERMINAL) OF INVERTEC
CONNECTION
AMP
AMP
FOR
DIAGRAM SHOWS ELECTRODE POSITIVE.
MIN.
10K
2
5.5
FRAME
/
WIRE FEEDER
CONNECTS TO
INVERTEC
115
42
AMP
INVERTEC
TOGETHER
OUTPUT
1
ON
N.B.
75
76
77
21
GND
32
VAC
USED
CONNECT
WELDING
24
NOT
WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
K867 UNIVERSAL
ADAPTER PLUG
42
AMPHENOL
31
41
14 PIN
4
2
SPARE
82
81
service this machine.
Only qualified persons should install, use or
Before connecting the wire feeder.
using the disconnect switch at the fuse box
Turn off input power to the Welding Power Source
N.A.
AUXILIARY POWER
POWER SOURCE
WITH 115VAC
INVERTEC
+
-
WORK
TO
ELECTRODE CABLE
CAN KILL
SHOCK
ELECTRIC
WARNING
K867 UNIVERSAL ADAPTER / INVERTEC - CONNECTION DIAGRAM
S19406
12-10-93A
– 27 –
DIAGRAM SHOWS ELECTRODE POSITIVE.
TO CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
FOR INVERTECS WITH 6 PIN AMPHENOL, K432 CABLE CAN BE CONNECTED DIRECTLY.
N.B.
N.C.
AMPHENOL
6 PIN
WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
K876 ADAPTER
AMPHENOL
14 PIN
service this machine.
Only qualified persons should install, use or
Before connecting the wire feeder.
using the disconnect switch at the fuse box
Turn off input power to the Welding Power Source
N.A.
INVERTEC
POWER SOURCE
+
-
TO
WORK
ELECTRODE CABLE
TO LN-25
CAN KILL
SHOCK
ELECTRIC
WARNING
K876 ADAPTER TO LN-25 - CONNECTION DIAGRAM
CONTROL CABLE
K432 REMOTE
K431 OPTION
LN-25 WITH
S19899
1-25-91
– 28 –
DIAGRAM SHOWS ELECTRODE POSITIVE.
K480-7 INPUT CABLE CAN BE CONNECTED DIRECTLY IF REMOTE CONTROL IS NOT REQUIRED.
K864 ADAPTER CANNOT BE USED WITH AN LN-25.
N.C.
N.D.
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
TO CHANGE POLARITY, TURN POWER "OFF",
WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B.
OR
K870
FOOT AMPTROL
HAND AMPTROL
K963
K857
REMOTE CONTROL
6 PIN
AMPHENOL
K480-7 INPUT CABLE
ADAPTER
OR
AMPHENOL
14 PIN
CONTROL
BOX
LN-7
K864
AMPHENOL
14 PIN
service this machine.
Only qualified persons should install, use or
Before connecting the wire feeder.
using the disconnect switch at the fuse box
Turn off input power to the Welding Power Source
N.A.
AUXILIARY POWER
WITH 115VAC
POWER SOURCE
INVERTEC
+
-
WORK
TO
TO LN-7
ELECTRODE CABLE
CAN KILL
SHOCK
ELECTRIC
WARNING
K864 ADAPTER TO LN-7 & REMOTE CONTROL - CONNECTION DIAGRAM
S19901
4-19-96D
– 29 –
AMPHENOL
TOP 14 PIN
AMPHENOL
SET UP SHOWN IS FOR DC NEGATIVE TIG WELDING.
N.C.
THE OUTPUT CONNECTIONS ON THE INVERTEC AND SETTING THE INVERTEC’S ELECTRODE POLARITY
SWITCH TO POSITIVE.
K814
FOOT AMPTROL
K870
HAND AMPTROL
K963
ARC START SWITCH
DC POSITIVE WELDING IS OBTAINED BY REVERSING
A WIRE FEEDER CAN BE PLUGGED INTO THE DC TIG STARTER TO REDUCE PROCESS CONVERSION TIME.
TO
WORK
OR
OR
N.B.
+
N.C.
TO TIG
TORCH
WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
AUXILIARY POWER
-
IN
OUT
WITH 5.5 AMP 42 VOLT
POWER SOURCE
INVERTEC
DC TIG STARTER
K900-1
APPROPRIATE WIRE FEEDERS AMD CONNECTORS.
CONSULT INVERTEC INSTRUCTION MANUAL FOR
Only qualified persons should install, use or service this machine.
Starter to the power source, or the Amptrol or Wire Feeder
to the DC Tig Starter.
Turn off input power to the Welding Power Source using the
disconnect switch at the fuse box before connecting the DC Tig
N.A.
BOTTOM 14 PIN
N.B.
WIRE FEEDER
ELECTRIC
SHOCK
CAN KILL
WARNING
K900-1 DC TIG STARTER - CONNECTION DIAGRAM
S20405
4-19-96D
– 30 –
CONTROL CABLE
ASSEMBLY
K596 REMOTE
LN-9 GMA WITH
K608-1 AND
K442-1 KITS.
FOR GMAW WELDING, INSTALL PULSE POWER FILTER KIT K442-1 IN LN-9 GMA.
INSTALL K608-1 ADAPTER IN LINE WITH P10 TO LN-9 GMA VOLTAGE BOARD
PER INSTRUCTIONS IN V300 MANUAL.
N.C.
N.D.
DIAGRAM SHOWS ELECTRODE POSITIVE.
TO CHANGE POLARITY, TURN POWER "OFF", REVERSE
ELECTRODE AND WORK CABLE AT POWER SOURCE. SET METER POLARITY SWITCH ON REAR
OF INVERTEC TO COINCIDE WITH POLARITY USED. SET LN-9 GMA POLARITY SWITCH ALSO.
WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
14 PIN
AMPHENOL
service this machine.
Only qualified persons should install, use or
Before connecting the wire feeder.
using the disconnect switch at the fuse box
Turn off input power to the Welding Power Source
N.B.
N.A.
INVERTEC
POWER SOURCE
WITH 110/115V AUX.
+
-
TO
WORK
ELECTRODE CABLE
TO LN-9 GMA
CAN KILL
SHOCK
ELECTRIC
WARNING
LN-9 GMA WITH K596 CABLE TO INVERTEC - CONNECTION DIAGRAM
C
7
B
533
11
12
3.9K
524
6
10
500
500
4
5
521
530A
3
2
P10,J10’
DETAIL
S20607
9-29-95C
12
7
11
6
5
4
3
2
P10’,J10
CONNECTION
K608-1
– 31 –
4
21
4
21
N.D.
2
2
A
B
C
75
76
77
GND
32
32
GND
31
31
41
42
N.C.
K196
INPUT CABLE
N.F.
SPLICE LEADS AND INSULATE.
INSTALL K608-1 ADAPTER IN LINE WITH P10 TO LN-9 GMA VOLTAGE BOARD AND SECURE TO
FOR GMAW WELDING, INSTALL PULSE POWER FILTER KIT K442-1 IN LN-9 GMA.
ADJACENT HARNESS WITH WIRE TIE PROVIDED. TURN "START" TRIMMER ON VOLTAGE BOARD FULLY ’CCW’.
INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.D.
N.E.
DIAGRAM SHOWS ELECTRODE POSITIVE.
TO CHANGE POLARITY, TURN POWER "OFF", REVERSE
ELECTRODE AND WORK CABLE AT POWER SOURCE. SET METER POLARITY SWITCH ON REAR
OF INVERTEC TO COINCIDE WITH POLARITY USED. SET LN-9 GMA POLARITY SWITCH ALSO.
WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
K867 UNIVERSAL
ADAPTER PLUG
14 PIN
AMPHENOL
81
82
SPARE
service this machine.
Only qualified persons should install, use or
Before connecting the wire feeder.
using the disconnect switch at the fuse box
Turn off input power to the Welding Power Source
N.C.
N.B.
N.A.
POWER SOURCE
WITH 110/115V AUX.
INVERTEC
+
-
TO
WORK
ELECTRODE CABLE
TO LN-9 GMA
CAN KILL
SHOCK
ELECTRIC
WARNING
LN-9 GMA WITH K196 CABLE AND K867 PLUG TO INVERTEC - CONNECTION DIAGRAM
533
B
3.9K
K608-1 AND
K442-1 KITS.
LN-9 GMA WITH
12
11
10
C
524
6
7
500
5
500
521
3
4
530A
2
P10,J10’
DETAIL
S20608
9-11-92
12
7
11
6
5
4
3
2
P10’,J10
CONNECTION
K608-1
– 32 –
MAR97
W
V
U
3 AMP
SLOW
BLOW
ON
N.C.
J15
4
REMOTE
CONTROL
RECEPTACLE
GND
211B
21
N
H
B
L
21
GND
M
81
82
223B
212C
212
42
212
32
SPARE
D
2
4
I
K
C
41
42
A
32
212
77B
E
77
J
76
F
75
76
31
9D
12D
F -
12C
TP2
G
A
A
C
D +
TP3
TP1
B
9C
51
H5
314
51
H5
1
2
3
4
5
6
51
42A
C R1
H1
A
285
229
-
+
3 10
25
25W
S6
460V
440-
415V
380-
230V
220-
H3
208V
200-
R4
3 09
H6
H4
H3
H2
H1
9B
6
3
2
4
1
J13
12B
12B
+
9B
C1
2200 F
450V
C R2
310
12
H1
H5
H4
H3
H2
12B
7
0V
24V
42V
110V
18V
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
2
3
5
6
4
1
4
W
212D
503
42A
32A
501
504
J12
4,5
1
4
212A
FAN
5
T3
8
COLOR
B =
G =
R =
W =
Y =
150 5W
Y
CODE:
BLACK
GREEN
RED
WHITE
YELLOW
210
Y
CURRENT
TRANSFORMER
THERMOSTAT
1
L5
212C
224
6 2 5 4
J9
1,8
3
3 4
308
J11
1 2
307
1,8
R
SWITCH
BOARD
(RIGHT)
R
317
316
12D
12 13 14
J10
W
4,5
I
I
T2
4
307
313
311
504
501
310
309
308
S
8
F
INSIDE
TOP
F
F
S
S
F
S
OUTSIDE
BOTTOM
5
1
INSIDE
BOTTOM
OUTSIDE
TOP
MAIN
TRANSFORMER
J6
J11, J14
J2, J8
10
9
5
4
1
8
3
6
7
2
J4
J9, J10, J12
J13, J15
212D
212B
211B
211A
275D
304
303
302
301
305
D1B
224
1
10
6
ELECTRICAL SYMBOLS PER E1537
J5, J16
J1, J7
304
303
305
302
301
275D
275F
226
8
7
6
4
5
3
1
2
7
8
9
275B
213
2
502
R
W
6
218
75
275A
210
Y
Y
306
215
77A
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
R11
OUTPUT CONTROL
S3
LOCAL/REMOTE
SWITCH
S4
OUTPUT TERMINAL
SWITCH
2
4
3
1
9
5
10
11
4
276
207
208
228
7
3
14
C6
229
C9
C5
12
13
2
8
1
1
2
TP4
L4
J3
J2
J1
J5
J4
R W
286
TP5
229
250
25W
CONTROL
BOARD
11
12
4
5
3
214
227
211A
223A
206
203
76
220
204A
503A
CHOKE
L3
400A
SHUNT
CHOKE
THERMOSTAT
CONNECTOR CAVITY NUMBERING SEQUENCE
J6
J3
J14
J7
POWER
BOARD
F
D3
D2
D1A
(VIEWED FROM COMPONENT SIDE OF BOARD)
2
3
4
1
3
1
6
5
4
2
7
8
L1
LEFT
S
F
AUX
S
TOP
F
TOP
S
S
F
BOTTOM
AUX
S
F
L2
RIGHT
F
BOTTOM
S
R8
229
215
503A
503
502
223A
223B
212B
212A
208
207
204C
204B
228
275A
275B
275C
276
77A
77B
218
213
204B
204A
206
Y
275C
227
226
214
220
204C
203
285
TP6
229
5
4
REMOTE
LAYOUT
CONTROL PANEL
10K
2W
CW (MAX)
REMOTE
LOCAL
10K
2W
ON
CV GMAW
CV FCAW
CC CRISP
CC SOFT
CC GTAW
CW (MAX)
3
2
1
A
V
S5
METER
FUNCTION
SWITCH
- ARC
+ ARC
3
4
5
6
3
4
5
6
L10189
B
R12
ARC FORCE/INDUCTANCE
CONTROL
S5
METER FUNCTION
SWITCH
S2
MODE SWITCH
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
S4
OUTPUT
TERMINAL
SWITCH
R12
ARC FORCE
/INDUCTANCE
CONTROL
S3
LOCAL/REMOTE
SWITCH
R11
OUTPUT
CONTROL
S2
MODE
SWITCH
1
2
1
2
PANEL
METER
NOTE: This diagram is for reference only. It may not be accurate for all machines covered 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, write to the Service Department for a replacement. Give the equipment code number..
CONNECTION SHOWN IS FOR 380-460V OPERATION.
N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
N.G. C1, C2 CAPACITORS ARE A MATCHED SET.
N.F. R1, R9 BLEEDER RESISTORS ARE A MATCHED SET.
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "I".
9D
8
401, 403
12
T1
-
52
3
R
3 2 5 1
W
W
402, 404
9
315
2
+
314
1
J16
6
R
401, 403
SWITCH
BOARD
(LEFT)
402, 404
DRIVER
BOARD
-
+
9
AUXILIARY
TRANSFORMER
12A
12A
+
9A
9A
C2
2200 F
450V
N.G.
12D
R5
25
25W
12A
12A
12A
9B
9B
12B
R6
25
25W
R7
25
25W
N.G.
WIRE FEEDER
WELDING
POLARITY
SWITCH
N.D.
H3
7500
25W
N.F.
N.H.
9B
12C
9C
RECONNECT
S7
9D
9A
30 9
53
14
7500
25W
52
N.F.
CB1
6AMP
32A
CB2
2AMP
FAN
MOTOR
12D
9D
317
316
315
52
14
53
52
14
53
75
MIN
A
H5
H1
H1
A
INPUT
RECTIFIER
D13
WIRE
FEEDER
TRIGGER
42
VAC
110/115
VAC
G
B
R
J8
3
306
NOTES:
N.A.
1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO)
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I)
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.
REMOTE
OUTPUT
CONTROL
INPUT
PER
N.A.
S1
POWER
OFF
W
2
313
PROTECTION
BOARD
1
275F
R1
R9
311
WIRING DIAGRAM V300-PRO Code 10256, V300-I Code 10258
R11
R12
– 33 –
MAR97
J8
3
W
V
N.C.
TRIGGER
REMOTE
CONTROL
RECEPTACLE
WIRE
FEEDER
21
GND
211B
H
21
N
L
B
M
81
82
223B
212C
212
42
212
32
F -
GND
D
C
2
4
K
J
A
31
32
42
E
212
76
77B
F
75
12B
77
I
D +
TP2
76
41
9D
TP3
G
C
B
TP1
75
MIN
H6
H5
H1
H1
A
INPUT
RECTIFIER
D13
51
H5
314
51
H5
1
2
3
4
5
6
H1
53
14
42A
H3
51
285
229
-
+
9D
9A
10K
25W
10K
25W
52
CB1
6AMP
32A
CB2
2AMP
FAN
MOTOR
9D
317
316
315
52
14
53
52
14
53
SPARE
42
VAC
110/115
VAC
REMOTE
OUTPUT
CONTROL
G
B
R
U
ON
POWER
OFF
W
S1
J15
4
306
R1
309
H6
575V
220230V
H3
H1
12B
12B
+
+
T1
0V
24V
42V
110V
18V
12
AUXILIARY
TRANSFORMER
H5
H3
52
317
2
3
5
6
4
1
4
W
3
W
212D
503
42A
32A
501
504
J12
1
COLOR
B =
G =
R =
W =
Y =
212A
1
4
FAN
5
8
150 5W
CODE:
BLACK
GREEN
RED
WHITE
YELLOW
T3
Y
210
Y
CURRENT
TRANSFORMER
THERMOSTAT
L5
212C
224
1, 8
R
4,5
6 2 5 4
J9
3 4
308
J11
1 2
307
1, 8
SWITCH
BOARD
(RIGHT)
R
316
12 13 14
J10
401, 403
13,15
R
3 2 5 1
W
W
402, 404
9
9D
8
J16
7
+
-
3
H1
315
2
6
R
401, 403
12
4, 5
I
I
T2
4
J6
F
J11, J14
J2, J8
J14
J7
POWER
BOARD
L1
LEFT
S
F
AUX
S
TOP
F
TOP
S
S
F
BOTTOM
F
J4
J9, J10, J12
J13, J15
212D
212B
9
10
211B
211A
4
5
275D
304
303
302
301
305
1
8
3
6
7
2
D1B
D3
D2
D1A
(VIEWED FROM COMPONENT SIDE OF BOARD)
CONNECTOR CAVITY NUMBERING SEQUENCE
J6
2
3
4
1
3
S
AUX
S
F
BOTTOM
L2
RIGHT
1
10
5
6
304
303
305
302
301
275D
275F
226
8
7
6
4
5
3
1
J2
J1
J5
J3
R W
J4
229
208
77A
4
275A
210
Y
Y
306
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
R11
OUTPUT CONTROL
S3
LOCAL/REMOTE
SWITCH
S4
OUTPUT TERMINAL
SWITCH
2
4
3
1
9
5
10
215
75
14
11
218
6
276
207
7
3
228
229
502
R
W
C9
C6
TP6
C5
12
13
2
8
1
1
2
L4
TP4
286
TP5
250
25W
CONTROL
BOARD
2
7
8
9
275B
213
2
11
12
4
3
214
227
211A
223A
206
203
76
220
204A
J1, J7
224
503A
CHOKE
L3
400A
SHUNT
CHOKE
THERMOSTAT
J5, J16
ELECTRICAL SYMBOLS PER E1537
313
311
5
1
4
6
2
7
8
504
F
501
J3
8
310
309
308
307
S
INSIDE
TOP
F
F
S
S
F
S
OUTSIDE
BOTTOM
5
1
INSIDE
BOTTOM
OUTSIDE
TOP
MAIN
TRANSFORMER
R8
229
285
229
503A
503
502
223A
223B
212B
212A
208
207
204C
204B
228
275A
275B
275C
276
77A
77B
218
213
204B
204A
206
215
203
275C
227
226
214
220
204C
10K
2W
CW (MAX)
REMOTE
LOCAL
10K
2W
CW (MAX)
REMOTE
ON
CV GMAW
CV FCAW
CC CRISP
CC SOFT
CC GTAW
CONTROL PANEL
LAYOUT
Y
5
4
3
2
1
A
V
- ARC
S5
METER
FUNCTION
SWITCH
+ ARC
3
4
5
6
3
4
5
6
B
L10191
CONTROL
R12
ARC FORCE/INDUCTANCE
SWITCH
S5
METER FUNCTION
S2
MODE SWITCH
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
S4
OUTPUT
TERMINAL
SWITCH
R12
ARC FORCE
/INDUCTANCE
CONTROL
S3
LOCAL/REMOTE
SWITCH
R11
OUTPUT
CONTROL
1
2
2
S2
MODE
SWITCH
PANEL
METER
1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered 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, write to the Service Department for a replacement. Give the equipment code number..
6
2
1
J13
C15
314
1
9B
C1
-
SWITCH
BOARD
(LEFT)
402, 404
13,15
+
9
V300-PRO CODE 10257 (575V)
DRIVER
BOARD
912
912
+
+
9A
9A
12A
15
WIRE FEEDER
WELDING
POLARITY
SWITCH
S6
R4
25
25W
C2
C14
N.F.
310
13
R5
25
25W
CR1
R6
25
25W
R7
25
25W
N.F.
NOTES:
N.A.
1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO)
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I)
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "I".
N.F. C1, C2, C14, C15 CAPACITORS ARE A MATCHED SET.
INPUT
PER
N.A.
2
313
PROTECTION
BOARD
1
275F
R9
311
WIRING DIAGRAM
R11
R12
NOTES
INVERTEC V300-PRO & V300-I
NOTES
INVERTEC V300-PRO & V300-I
NOTES
INVERTEC V300-PRO & V300-I
Now Available...12th Edition
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New Lessons in Arc Welding
This printing will go fast so don’t delay. Place your
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● Do not touch electrically live parts or
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
● Keep flammable materials away.
● Wear eye, ear and body protection.
● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.
fuera del área de trabajo.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
cuerpo.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Mantenha inflamáveis bem guarda-
dos.
● Use proteção para a vista, ouvido e
corpo.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
– 38 –
● Keep your head out of fumes.
● Use ventilation or exhaust to
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
remove fumes from breathing zone.
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-
tien.
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
guardas quitadas.
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von
● No operar con panel abierto o
● Strom vor Wartungsarbeiten
● Anlage nie ohne Schutzgehäuse
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
oder Innenschutzverkleidung in
Betrieb setzen!
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
● Mantenha-se afastado das partes
serviço.
● Não toque as partes elétricas nuas.
● Não opere com os paineis abertos
moventes.
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
– 39 –
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–