Lincoln Electric Invertec V300-PRO Welding Power Source Service Manual
Below you will find brief information for Invertec V300-PRO. This 300-amp arc welding power source offers single or three-phase input for constant voltage or current outputs, optimized for GMAW, SMAW, TIG, and FCAW processes. It's compatible with LN-25 and LN-7 wire feeders and features versatile output controls for precise welding adjustments.
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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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And, most importantly, think before you act and be careful.
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INVERTEC V300-PRO
For use with machines having Code Number : 9825 THRU 10450
SVM105-B
April, 2007
SERVICE MANUAL
Copyright © 2007 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
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Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS may be dangerous
____________________________________________________
1.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.
____________________________________________________
1.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.
____________________________________________________
1.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.
___________________________________________________
1.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.
2.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
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.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.
___________________________________________________
1.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.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii
ELECTRIC SHOCK can kill.
3.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.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.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.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. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.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.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
SAFETY
ARC RAYS can burn.
4.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.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.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.
FUMES AND GASES can be dangerous.
5.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.
5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
5.c. 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.
5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the 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.
5.f. Also see item 1.b.
AUG 06 ii
iii
WELDING SPARKS can cause fire or explosion.
6.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.
6.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.
6.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.
6.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).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.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.
6.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.
6.h. Also see item 1.c.
SAFETY
CYLINDER may explode if damaged.
7.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.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.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.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.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.
iii
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
iv
PRÉCAUTIONS DE SÛRETÉ
SAFETY
zones où l’on pique le laitier.
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: iv
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.
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.
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.
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.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93
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MASTER TABLE OF CONTENTS FOR ALL SECTIONS
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V300-I
Section A-1 TABLE OF CONTENTS
- INSTALLATION SECTION -
Section A-1
Installation ..............................................................................................................Section A
V300-PRO
A-2 INSTALLATION A-2
TECHNICAL SPECIFICATIONS - V300-PRO (K1349-3, K1349-4)
INPUT
Standard
Voltage
208/230/460/575
50/60
THREE PHASE
Input Current at Rated Output
Code
Number
48/43/24/20 9825,9834,9965
10034,10035
10130,10131
Standard
Voltage
208/230/460
50/60
RATED OUTPUT
THREE PHASE
Duty Cycle
60% Duty Cycle
100% Duty Cycle
Amps
300
250
Volts at
Rated
Amperes
32
30
Duty Cycle
60% Duty Cycle
100% Duty Cycle
SINGLE PHASE
Input Current at Rated Output
69/62/38-
Code
Number
9825,9936,9965
10034, 10130,
SINGLE PHASE
Amps
200
165
Volts at
Rated
Amperes
28
26.5
OUTPUT
THREE PHASE SINGLE PHASE
Welding Constant Open
Current Range Circuit Voltage
5-300 Amps 60-70 VDC
Input
Voltage
Frequency (1)
Auxiliary
Power
42 VAC, 5.5 Amps
24 VAC, 1 Amp
*115 VAC, 2 Amps
*Not on all codes
Welding Constant Open
Current Range Circuit Voltage
5-200 Amps 60-70 VDC
Auxiliary
Power
42 VAC, 5.5 Amps
24 VAC, 1 Amp
*115 VAC, 2 Amps
*Not on all codes
RECOMMENDED INPUT WIRE AND FUSE SIZES
THREE PHASE SINGLE PHASE
Fuse Input
(Superlag) Ampere or
Breaker
Size
Rating on
Nameplate
Type 75°C
Copper
Wire in
Conduit
Type 75°C
Copper
Ground
Wire in
Conduit
AWG (IEC) AWG (IEC)
Sizes Sizes
Input
Voltage
Frequency (1)
Fuse Input
(Superlag) Ampere or
Breaker
Size
Rating on
Nameplate
Type 75°C
Copper
Wire in
Conduit
Type 75°C
Copper
Ground
Wire in
Conduit
AWG (IEC) AWG (IEC)
Sizes Sizes
208/60
230/60
460/60
575/60
60
60
40
30
48
39
25
25
6 (16mm 2 ) 10 (6mm 2 )
8 (10mm 2 ) 10 (6mm 2 )
10 (6mm 2 ) 10 (6mm 2 )
10 (6mm 2 ) 10 (6mm 2 )
208/60
230/60
460/60
85
80
50
69
62
38
6 (16mm 2 ) 10 (6mm 2 )
6 (16mm 2 ) 10 (6mm 2 )
8 (10mm 2 ) 10 (6mm 2 )
Height
18.7 in.
475 mm
PHYSICAL DIMENSIONS
Width
10.8 in.
Depth
22.2 in.
274 mm 564 mm
Weight
64 lbs.
29 Kg
V300-PRO
A-3
PRODUCT DESCRIPTION
INSTALLATION
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 50/60
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.
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.
----------------------------------------------------------------------
LOCATION
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.
• Keep machine dry. Shelter from rain and snow. Do not place on wet ground or in puddles.
ELECTRICAL INSTALLATION
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. When received from the factory, multiple voltage
(208/230/460) machines are internally connected for 460 volt input.
3. Single voltage, 575 VAC machines, can only be connected to 575 VAC. No internal reconnection for other input voltages is possible.
4. Initial 208 VAC and 230 VAC operation will require a voltage panel setup, as will later reconnection back to 460 VAC: a.
Open the access panel on the right side of the machine.
b.
For 208 or 230: Position the large switch to
200-230.
For 460: Position the large switch to 380-460.
c.
Move the “A” lead to the appropriate terminal.
CAUTION: DO NOT CHANGE SWITCH
POSITION WITH INPUT POWER
APPLIED. MAJOR DAMAGE WILL
RESULT.
INPUT VOLTAGE SETUP
A-3
RECONNECT PROCEDURE
1. BE SURE POWER SWITCH IS OFF.
2. CONNECT LEAD 'A' TO DESIRED
INPUT VOLTAGE RANGE.
440-460V
380-415V
220-230V
200-208V
'A'
.
.
.
.
Disconnect input power before inspecting or servicing machine.
Do not operate with wraparound removed.
Do not touch electrically live parts.
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: CHECK FUSE;
REPLACE WITH A 3 AMP SLOW BLOW ONLY.
3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.
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 are too high
(380v on 230v setting), the input circuits of this machine protecting the filter capacitors, FETS and other components from damage will not be energized.
VOLTAGE=380-460V
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
9-11-92
VOLTAGE=200-230V
S20324
V300-PRO
A-4
POWER INPUT CONNECTION
INSTALLATION
CONNECTION OF WIRE FEEDERS TO
THE INVERTEC
Connect terminal marked to earth ground per any existing local or national electrical codes.
LN-25 Connection Instructions
A-4
Single Phase Input
1. Turn the Invertec power switch “off”.
Connect the supply lines to the upper and lower terminals of the line switch. Torque to 27.5in.-lbs.(3.0 Nm).
Do not use center terminal of the line switch.
2. Connect the electrode cable to the output terminal of polarity required by electrode. Connect the work lead to the other terminal.
Three Phase Input
Connect the supply lines to the line switch. Torque to
27.5in.-lbs.(3.0 Nm).
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 in
Operator’s Mamual.
Install in accordance with all local and national electric codes.
The V300-PRO is supplied with one cord connector to provide strain relief for the input power cord. It is designed for a cord diameter of .310-1.070” (7.9 -
27.2mm). The jacketed portion of the cord must go through the connector before tightening the connector screws.
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).
LN-7 Connection Instructions (not applicable to
IEC machines with only 42V Aux.).
Recommended Fuse Sizes Based On The U.S.
National Electrical Code And Maximum Machine
Outputs
3 phase
50/60 Hz
Input Volts (1)
208
230
460
575
1 phase
50/60 Hz
208
230
460
Fuse Size in Amps
(Time Delay Fuses)
60
60
40
25
85
80
50
(1) Input voltage must be within ±10% of rated value.
1. Turn the Invertec power switch “off”.
2. Connect the K480 or K1818-10 control cable from the LN-7 to the Invertec control cable connector.
The control cable connector is located at the rear of the Invertec.
3. Connect the electrode cable to the output terminal of polarity required by electrode. Connect the work lead to the other terminal.
4. Place the local-remote switch in the “local” position to allow output control at the Invertec. (K864 remote control adapter and K857 remote control are required for remote output control. See connection diagram S19901.
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 a K480 or K1818-10 is not available, see connection diagram S19404 for modification of K291 or K404 LN-7 input cable with K867 universal adapter plug..
V300-PRO
A-5 INSTALLATION A-5
LN-9 GMA Connection Instructions (Not applicable to machines with only 42V Aux.)
1. Turn the Invertec power switch “off”.
2. Connect the K596 or K1820-10 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.
3. Connect the electrode cable to the output terminal of polarity required by electrode. Connect the work lead to the other terminal.
4. Place the local-remote switch in the “remote” position to allow output control at the LN-9 GMA.
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. See connection diagram S20607.
7. K442-1* Pulse Power Filter Board is also required for GMAW,but should beremoved for FCAW.
8. If K596 is not available, see connection diagram
S20608 for modification of K196 LN-9 GMA input cable with K867 universal adapter plug.
* These kits are no longer available.
GENERAL INSTRUCTIONS FOR CONNEC-
TION OF WIRE FEEDERS TO INVERTEC
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 for more information.
Remote Control of Invertec
Remote control K857, hand amptrol K963 and foot amptrol K870 require K864 remote control adapter.
See connection diagram S19309.
K954-1 MIG PULSER
The MIG Pulser is a hand-held “pendant” type GMAW
Pulsing option for the V300-PRO Power Source. See the Mig Pulser’s IM manual (IM555) for connection information.
V300-PRO
K900-1 DC TIG STARTER CONNECTION
This versatile new kit was made to mate with the
Invertec
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. See diagram S20405.
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, see the
K900-1 (IM465) manual.
PARALLEL OPERATION
The Invertec is 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.
To set machine outputs, start with output control pots and arc force/pinch pots in identical positions. If running in a CC mode, adjust output and arc force to maintain current sharing while establishing the proper output current. In CV modes, set the pots to identical positions. Then switch the machine meters to read 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.
A-6 INSTALLATION
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
100%
60%
Current
250
300
Length Up
61m (200 ft.)
1/0
1/0
61-76m
(200-250 ft.)
1/0
2/0
QUICK DISCONNECT PLUGS (K852-7)
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. Remove 1 inch (25mm) of welding cable insulation.
2. Slide rubber boot on to the 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.
3. Slide the copper tube into the brass plug.
4. Insert the cable into the copper tube.
5. Tighten set screw to collapse copper tube. The 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 the rubber boot over the brass plug. The rubber boot must be positioned to completely cover all electrical surfaces after the plug is locked into the receptacle.
WELDING CABLE
25 mm
1 in.
TRIM
reverse 25mm & 1in
COPPER TUBE
SET SCREW
A-6
BOOT
BRASS PLUG
V300-PRO
Section B-1 TABLE OF CONTENTS
- OPERATION SECTION -
Section B-1
Operation ................................................................................................................Section B
V300-PRO
B-2 OPERATION B-2
OPERATING INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrode with skin or wet clothing.
• Insulate yourself from work and ground.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes from breathing zone.
-------------------------------------------------------
-----------------
WELDING SPARKS can cause fire or explosion.
• Keep flammable material away.
• Do not weld on closed containers.
------------------------------------------------------------------------
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
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.
OUTPUT CONTROL - This controls the output voltage in the CV modes and output current in the CC modes.
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.
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
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.
OFF .
V300-PRO
B-3 OPERATION
MODE SWITCH
GTAW Optimized for both scratch start and Hi-
Freq 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 This setting has been optimized for
Innershield ® and Outershield ® flux-cored electrodes.
CV GMAW Short circuit, glob and spray transfer solid wire and gas welding are done in this mode. Low end procedures, less than 16V, may operate better in the
FCAW mode.
B-3
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 gas. The lower half is for inert gas mixes.
SMAW
CRISP
SMAW
SOFT
GTAW
FCAW
GMAW
RECOMMENDED SETTINGS FOR SELECTED
APPLICATIONS
Full Range Is 1-10,
1 Is Very Soft, 10 Is Very Crisp
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.
Set to the REMOTE (OFF) position when using LN-25 with K431/K432 or K624-1 options or other wirefeeders which allow the gun trigger to energize the welding terminals.
ON
OUTPUT
TERMINALS
REMOTE
Mode
CC SMAW 1
Process
EXX18 thru
EXX28 stick
CC SMAW 2 EXX10 thru
EXX14 stick
Air Carbon Arc
Cutting
CV FCAW Innershield or
Outershield
Air Carbon Arc
Cutting
Nominal
Setting
5
6
1
10
1
CV GMAW* CO2 or 25% CO2 or similar gas mixes
98% Ar-2% O2Ar,
90% He-7.5% Ar
2.5% CO2 and other predominantly inert gases
7.5
5
Recommended
Adjustment Range
1 (gentle, may stick) to 9
(forceful, more spatter)
* 1 = Lowest pinch, highest inductance and least spatter.
10 = Highest pinch, lowest inductance and most spatter.
3 to 10
None
None
None
5 to 10
1 to 10
V300-PRO
B-4 OPERATION
METER POLARITY SWITCH
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.
B-4
AUXILIARY POWER
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.
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.
All three supplies are not to be loaded simultaneously
LINCOLN
-
OUTPUT TERMINALS
V300-PRO
+
Section C-1 TABLE OF CONTENTS
- ACCESSORIES SECTION -
Section C-1
Accessories ............................................................................................................Section C
V300-PRO
C-2
OPTIONS / ACCESSORIES
CABLE PLUGS
ACCESSORIES
K876 REMOTE CONTROL
ADAPTER
Cable Plug Kit for 1/0-2/0 cable (K852-70) attaches to welding cable to provide quick disconnect from machine.
C-2
For operating an LN-25 wire feeder. The adapter connects to the 14-pin receptacle of Invertec power sources and to the 6-pin connector of the LN-25
K432 remote control cable.
Cable Plug Kit for 2.0-3/0 cable (K852-95).
NOTE: Two K852-70 plugs are included with the V300-I.
K900-1 DC TIG STARTER
Solid state GTAW starting unit. Rated 300 A, 60%.
K864 REMOTE CONTROL
ADAPTER
Plugs into the 14-pin receptacle on the rear panel of the
Invertec. Adapter splits remote control circuitry to a 6pin receptacle and to a 14-pin receptacle. Adapter permits remote output control of Invertec by means of
K857 Remote Control, K812 Hand Amptrol or K870
Foot Amptrol. Allows remote while using LN-7 K480-7 control cable.
K867 UNIVERSAL ADAPTER
PLUG
Consisting of a 14-pin plug connected to labeled wires, the adapter allows user connection of any suitable accessory or wire feeder to the remote control, contactor, and auxiliary power circuitry of the Invertec.
V300-PRO
Section D-1 TABLE OF CONTENTS
- MAINTENANCE SECTION -
Section D-1
Maintenance ...........................................................................................................Section D
V300-PRO
D-2 MAINTENANCE
WARNING
Failure to follow this capacitor discharge procedure can result in electric shock.
D-2
5. Locate the two capacitor terminals (large hex head capscrews)shown in Figure D.1.
INPUT FILTER CAPACITOR
DISCHARGE PROCEDURE
6. Use electrically insulated gloves and insulated pliers. Hold body of the resistor and connect resistor leads across the two capacitor terminals. Hold resistor in place for 10 seconds. DO NOT TOUCH
CAPACITOR TERMINALS WITH YOUR BARE
HANDS.
1. Turn off input power or disconnect input power lines.
2. Remove 14 5/16” hex head screws from side and top of machine (6 screws on each side and 2 screws on top) and remove wrap-around machine cover.
7. Repeat discharge procedure for capacitor on other side of machine. If you are working on a
575 VAC machine, repeat discharge procedure for second capacitor on each side of machine.
3. Be careful not to make contact with the capacitor terminals that are located in the center of the
Switch Boards.
8. Check voltage across terminals of all capacitors with a DC voltmeter. Polarity of capacitor terminals is marked on PC board above terminals.
Voltage should be zero. If any voltage remains, repeat this capacitor discharge procedure.
4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This resistor is not supplied with machine. NEVER
USE A SHORTING STRAP FOR THIS PROCE-
DURE. .
FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS.
V300-PRO
D-3 MAINTENANCE
PREVENTIVE MAINTENANCE
1. Perform the following preventive maintenance procedures at least once every six months. It is good practice to keep a preventive maintenance record; a record tag attached to the machine works best.
2. Remove the machine wrap-around cover and perform the input filter capacitor discharge procedure
(detail at the beginning of this chapter).
3. Clean the inside of the machine with a low pressure airstream. Be sure to clean the following
components thoroughly. See Figure D.2 for loca-
tion of these components.
• Power Switch, Driver, Protection, and Control printed circuit boards
• Power Switch
• Main Transformer
• Input Rectifier
• Heat Sink Fins
• Input Filter Capacitors
• Output Terminals
4. Examine capacitors for leakage or oozing.
Replace if needed.
5. Examine wrap-around cover for dents or breakage. Repair as needed. Cover must be kept in good condition to assure high voltage parts are protected and correct spacings are maintained.
6. Check electrical ground continuity. Using an ohmmeter, measure resistance between either output stud and an unpainted surface of the machine
case. (See Figure D.2 for locations.) Meter read-
ing should be 500,000 ohms or more. If meter reading is less than 500,000 ohms, check for electrical components that are not properly insulated from the case. Correct insulation if needed.
7. Replace machine cover and screws.
D-3
OVERLOAD PROTECTION
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 (“Fold Back”) 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.
THERMAL PROTECTION
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.
PC BOARD REPLACEMENT
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.
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.
V300-PRO
D-4 MAINTENANCE
FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS.
D-4
1
2
3
10
6
COMPONENT
PC BOARDS
CONTROL
DRIVER
PROTECTION
SWITCH
POWER
INPUT RECTIFIER
POWER SWITCH
HEAT SINK FINS
MAIN TRANSFORMER
OUTPUT STUDS
INPUT FILTER CAPACITORS
QTY,
1
2
1
1
1
2
1
1
1
1
2
ITEM
NO.
10
4
5
6
3
7
1
2
8
9
11
9
V300-PRO
4
5
8
7
11
Section E-1 TABLE OF CONTENTS
- THEORY OF OPERATION SECTION -
Section E-1
Theory of Operation ...............................................................................................Section E
FIGURE E.1 – V300-PRO BLOCK LOGIC DIAGRAM
1
2
3
FAN
POWER SWITCH
SECTIONS
20KHZ
LEFT SWITCH BOARD
FET MODULES
CAP
FET MODULES
LINE
SWITCH
AUXILIARY
TRANSFORMER
INPUT
1ø OR 3ø DETETCTION (H5)
RECTIFIER
3A
AC1
AC2
AC3
A-LEAD
24VDC
PRE-CHARGE
DRIVER
BOARD
CR1
PULSE
TRAIN
CR2
PRE-CHARGE
18VAC
2ND STEP PWM
POWERBOARD
24VAC
<1 VDC
TO
WIREFEEDER
PROTECTION
BOARD
RIGHT SWITCH BOARD
FET MODULES
CAP
FET MODULES
LOCAL
REMOTE
METER MODE POT
1ST STEP PWM VOLTAGE
15VDC-CONTROL BOARD FUNCTION VOLTAGE
24VAC-THERMOSTATS-GUN TRIGGERING
POT
CURRENT
TRANSFORMER
CONTROL
BOARD
Y-Y FEEDBACK
MAIN
TRANSFORMER
CHOKE
TOP
BOTTOM
TOP
RECTIFIER
HEATSINK
1 DIODE
5 DIODES
5 DIODES
1 DIODE
CHOKE
VOLTAGE FEEDBACK
CURRENT FEEDBACK-PROTECTION
CHOKE
SHUNT
V300-PRO
E-2 THEORY OF OPERATION
FIGURE E-2 --- INPUT CIRCUITS
1
2
3
FAN
POWER SWITCH
SECTIONS
20KHZ
LEFT SWITCH BOARD
FET MODULES
CAP
FET MODULES
LINE
SWITCH
AUXILIARY
TRANSFORMER
INPUT
RECTIFIER
3A
AC1
AC2
AC3
A-LEAD
24VDC
1ø OR 3ø DETETCTION (H5)
PRE-CHARGE
DRIVER
BOARD
CR1
PULSE
TRAIN
CR2
PRE-CHARGE
2ND STEP PWM
18VAC
POWERBOARD
24VAC
<1 VDC
TO
WIREFEEDER
PROTECTION
BOARD
RIGHT SWITCH BOARD
FET MODULES
CAP
FET MODULES
LOCAL
REMOTE
METER MODE POT
1ST STEP PWM VOLTAGE
15VDC-CONTROL BOARD FUNCTION VOLTAGE
24VAC-THERMOSTATS-GUN TRIGGERING
POT
CURRENT
TRANSFORMER
CONTROL
BOARD
Y-Y FEEDBACK
MAIN
TRANSFORMER
CHOKE
TOP
BOTTOM
TOP
RECTIFIER
HEATSINK
1 DIODE
5 DIODES
5 DIODES
1 DIODE
CHOKE
VOLTAGE FEEDBACK
CURRENT FEEDBACK-PROTECTION
CHOKE
SHUNT
E-2
INPUT LINE VOLTAGE & AUXILIARY
TRANSFORMER
The V300-PRO can be connected for a variety of three phase or single phase input voltages. Power is applied through the Line Switch to the Input Rectifier and the
Auxiliary Transformer.
The Reconnect Panel has switches to select high or low operating voltage. The “A” lead must then be set for the proper input voltage. It is important to set the switches and “A” lead to the proper positions before applying input power. Changing the switch position with the power applied will result in major damage to the machine
The auxiliary transformer provides 18v.a.c. and
24v.a.c. supplies to the Control and Power Boards. It also provides 115v.a.c., 42v.a.c. and 24v.a.c. supplies to the wirefeeder amphenol. (CE machines do not have
115v.a.c. supply)
The Power Board provides a 15v.d.c. supply to the
Control Board and a 24v.d.c.supply to the Driver Board to operate the Pre-charge Relays.
NOTE: Unshaded areas of block logic diagram are the subject of discussion
V300-PRO
E-3 THEORY OF OPERATION
FIGURE E-3 ---PRECHARGE & PROTECTION CIRCUITS
1
2
3
FAN
POWER SWITCH
SECTIONS
20KHZ
LEFT SWITCH BOARD
FET MODULES
CAP
FET MODULES
LINE
SWITCH
AUXILIARY
TRANSFORMER
INPUT
RECTIFIER
3A
AC1
AC2
AC3
A-LEAD
24VDC
1ø OR 3ø DETETCTION (H5)
PRE-CHARGE
DRIVER
BOARD
CR1
PULSE
TRAIN
CR2
PRE-CHARGE
2ND STEP PWM
18VAC
POWERBOARD
24VAC
<1 VDC
TO
WIREFEEDER
PROTECTION
BOARD
RIGHT SWITCH BOARD
FET MODULES
CAP
FET MODULES
LOCAL
REMOTE
METER MODE
POT
1ST STEP PWM VOLTAGE
15VDC-CONTROL BOARD FUNCTION VOLTAGE
24VAC-THERMOSTATS-GUN TRIGGERING
POT
CURRENT
TRANSFORMER
CONTROL
BOARD
Y-Y FEEDBACK
MAIN
TRANSFORMER
TOP
BOTTOM
TOP
CHOKE
RECTIFIER
HEATSINK
1 DIODE
5 DIODES
5 DIODES
1 DIODE
CHOKE
VOLTAGE FEEDBACK
CURRENT FEEDBACK-PROTECTION
CHOKE
SHUNT
E-3
PRECHARGE & PROTECTION CIRCUITS
The DC voltage from the Input Rectifier is applied to the
Driver Board to begin charging the Switch Board capacitors at a slow rate. When the pre-charge level is achieved, the input relays close, applying the full DC voltage to the capacitors. Depending on the Code
Number of the machine, there will be either two or four relays and they may or may not be mounted on the
Driver Board.
The Driver Board is also responsible for gating the
Field Effect Transistors (FETs) on the Switch Boards, as directed by the pulse width modulated (PWM) signal from the Control Board.
Another function of the Protection Board is to detect whether the input voltage is single phase or three phase and pass that information to the Control Board.
The maximum output of the machine will be limited to approximately 250 amps with single phase input and
360 amps with 3 phase input.
The Protection Board monitors the capacitors for proper balance and voltage level. If an imbalance or overvoltage condition is detected, the Protection Circuit will de-energize the relays, removing the power from the switch circuits. The machine output will also be disabled.
NOTE: Unshaded areas of block logic diagram are the subject of discussion
V300-PRO
E-4 THEORY OF OPERATION
FIGURE E-4 ---SWITCH CIRCUITS & TRANSFORMER
1
2
3
FAN
POWER SWITCH
SECTIONS
20KHZ
LEFT SWITCH BOARD
FET MODULES
CAP
FET MODULES
LINE
SWITCH
AUXILIARY
TRANSFORMER
3A
1ø OR 3ø DETETCTION (H5)
INPUT
RECTIFIER
AC1
AC2
AC3
A-LEAD
24VDC
PRE-CHARGE
DRIVER
BOARD
CR1
PULSE
TRAIN
CR2
PRE-CHARGE
2ND STEP PWM
18VAC
POWERBOARD
24VAC
<1 VDC
TO
WIREFEEDER
PROTECTION
BOARD
RIGHT SWITCH BOARD
FET MODULES
CAP
FET MODULES
LOCAL
REMOTE
METER MODE
POT
1ST STEP PWM VOLTAGE
15VDC-CONTROL BOARD FUNCTION VOLTAGE
24VAC-THERMOSTATS-GUN TRIGGERING
POT
CURRENT
TRANSFORMER
CONTROL
BOARD
Y-Y FEEDBACK
MAIN
TRANSFORMER
TOP
BOTTOM
TOP
CHOKE
RECTIFIER
HEATSINK
1 DIODE
5 DIODES
5 DIODES
1 DIODE
CHOKE
VOLTAGE FEEDBACK
CURRENT FEEDBACK-PROTECTION
CHOKE
SHUNT
E-4
SWITCH BOARDS
The Switch Boards contain the the Field Effect
Transistors (FETs) which, when switched ON, supply power to the primary windings of the main transformer.
Each Switch Board powers a separate, oppositely wound primary winding. The opposite direction of current flow in those windings and a slight offset in of the
FET switching produces a square wave AC signal in the secondary of the transformer.
The DC current of the primaries is clamped back to the respective capacitors through diodes on the board when the FETs turn off. This protects against inductive voltage spikes due to the inductance of the windings and also helps maintain capacitor balance.
Along with ease of control, the 20Khz operating frequency allows for a much smaller and lighter transformer
Signals from the Current Transformer insure that one switch circuit is turned off before the other is gated on.
Field Effect Transistor operation and Pulse Width
Modulation are discussed in more detail later in this section.
The boards are fired during a 50 microsecond interval with respect to a Pulse Width Modulated (PWM) signal from the Control Board through the Driver Board. This creates a constant 20Khz output in the secondary.
NOTE: Unshaded areas of block logic diagram are the subject of discussion
V300-PRO
E-5 THEORY OF OPERATION
FIGURE E-5 --OUTPUT & CONTROL CIRCUITS
POWER SWITCH
SECTIONS
20KHZ
LEFT SWITCH BOARD
FET MODULES
CAP
FET MODULES
1
2
3
FAN
LINE
SWITCH
AUXILIARY
TRANSFORMER
INPUT
RECTIFIER
3A
AC1
AC2
AC3
A-LEAD
24VDC
1˘ OR 3˘ DETETCTION (H5)
PRE-CHARGE
DRIVER
BOARD
CR1
PULSE
TRAIN
CR2
PRE-CHARGE
2ND STEP PWM
18VAC
POWERBOARD
24VAC
<1 VDC
TO
WIREFEEDER
PROTECTION
BOARD
RIGHT SWITCH BOARD
FET MODULES
CAP
FET MODULES
LOCAL
REMOTE
METER MODE POT
1ST STEP PWM VOLTAGE
15VDC-CONTROL BOARD FUNCTION VOLTAGE
24VAC-THERMOSTATS-GUN TRIGGERING
POT
CURRENT
TRANSFORMER
CONTROL
BOARD
Y-Y FEEDBACK
MAIN
TRANSFORMER
CHOKE
RECTIFIER
HEATSINK
TOP
BOTTOM
TOP
1 DIODE
5 DIODES
5 DIODES
1 DIODE
CHOKE
VOLTAGE FEEDBACK
CURRENT FEEDBACK-PROTECTION
CHOKE
SHUNT
E-5
OUTPUT AND CONTROL CIRCUITS
The AC output of the transformer is changed to DC by the Output Rectifier. The Output Choke between the negative side of the rectifier and the negative output stud provides the necessary filtering for DC welding.
The two smaller chokes and their series diodes are the
OCV boost circuit used to help provide good weld starts.
Current feedback to the Control Board is provided by the shunt in the negative output circuit. It is used for weld control, overcurrent protection and actual ammeter readings. The Voltage feedback lead at the positive output stud also provides information for weld control and actual voltmeter readings.
When weld output is requested, the Control Board compares the input information to the feedback signals and provides the correct PWM signals to the Switch
Boards for optimum welding. The Mode Switch setting determines which feedback signal (voltage or current) will have the most relevance. However, both signals are used in all modes.
The Control Board also monitors signals from the thermostats and the Protection Board and if necessary, shuts off the weld output. The protection circuit information is discussed in more detail later in this section.
The Control Board monitors input from the front panel controls (output, arc control, mode switch, etc..). The software on the board processes these inputs, sets up the proper weld information and sends the “set” parameter information to the meter.
NOTE: Unshaded areas of block logic diagram are the subject of discussion
V300-PRO
E-6 THEORY OF OPERATION
FIELD EFFECT TRANSISTOR OPERATION
SOURCE
TERMINAL
GATE
TERMINAL
(0 VOLTS)
DRAIN
TERMINAL
DRAIN (N)
SOURCE (N)
SUBSTRATE (P)
A. PASSIVE
N CHANNEL
GATE
TERMINAL
(+ 6 VOLTS)
SOURCE (N) DRAIN (N)
E-6
B. ACTIVE
ELECTRONS
An FET is a type of transistor. FETs are semiconductors well suited for high-frequency switching because they are capable of going from full off to full on much more quicklfy than other types of semi-conductors.
Drawing A above shows an FET in a passive mode.
There is no gate signal, zero volts relative to the source and, therefore, no current flow. The drain terminal of the FET may be connected to a voltage supply; but since there is no conduction, the circuit will not supply current to downstream components connected to the source. The circuit is turned off like a light switch in the
OFF position.
Drawing B above shows the FET in an active mode.
When the gate signal, a positive DC voltage relative to the source, is applied to the gate terminal of the FET, it is capable of conducting current. A voltage supply connected to the drain terminal will allow the FET to conduct and henceforth supply current to downstream components. Current will flow through the conducting
FET to downstream components as long as the gate signal is present. This is similar to turning on a light switch
V300-PRO
E-7 sec
THEORY OF OPERATION
PULSE WIDTH MODULATION
FIGURE E.6 — TYPICAL FET OUTPUTS.
48
50 sec sec
MINIMUM OUTPUT sec
E-7
24 sec
2 sec
50 sec
MAXIMUM OUTPUT
The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the positive and negative portions of the cycle.
Changing the pulse width is known as MODULA-
TION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine.
MINIMUM OUTPUT
By controlling the duration of the gate signal, the FET is turned on and off for different durations during a cycle. The top drawing above shows the minimum output signal possible over a 50-microsecond time period.
The positive portion of the signal represents one FET group1 conducting for 1 microsecond. The negative portion is the other FET group1. The dwell time (off time) is 48 microseconds (both FET groups off).
1 An FET group consists of the sets of FET modules grouped onto one switch board.
24 sec
Since only 2 microseconds of the 50-microsecond time period is devoted to conducting, the output power is minimized.
MAXIMUM OUTPUT
By holding the gate signals on for 24 microseconds each and allowing only 2 microseconds of dwell time
(off time) during the 50-microsecond cycle, the output is maximized. The darkened area under the top curve can be compared to the area under the bottom curve. The more dark area under the curve, the more power is present.
V300-PRO
E-8
PROTECTIVE CIRCUITS
THEORY OF OPERATION
THERMAL PROTECTION
Protective circuits are designed into the Invertec machine to sense trouble and shut down the machine before the trouble damages the internal machine components. Both overload and thermal protection circuits are included.
E-8
Thermostats protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of cooling air or by operating the machine beyond it’s duty cycle or output rating. If excessive operating temperature should occur, the thermostat will open and prevent output. The meter will remain on during this time. Thermostats will normally self-reset once the machine cools sufficiently.
OVERLOAD PROTECTION
The machine is electronically protected from producing excessive output current. Should the output current exceed 340 to 360 amps, an electronic protection circuit will reduce the current to approximately
150 amps. Lincoln Electric refers to this current reduction as “Fold Back.” The machine will continue to produce this low current until the protection circuit is reset by removing the load.
If the thermal 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.
Another protection circuit is included to monitor the voltage across input filter capacitors. In the event that the capacitor voltage is too high, the protection circuit will signal the Control Board to prevent output.
The protection circuit may prevent output, if any of these circumstances occur:
1. Capacitor conditioning is required
(Required if machine has been off for prolonged periods of time.)
2. Line surges over 500 VAC
3. Internal Component damage
4. Improper connections
V300-PRO
Section F-1 TABLE OF CONTENTS
- TROUBLESHOOTING & REPAIR SECTION -
Section F-1
Troubleshooting & Repair Section ........................................................................Section F
PC Board Troubleshooting Procedures and Replacement...........................................F-3
Test Procedures
Replacement Procedures
Test After Switch Board or Capacitor Replacement .............................................F-57
V300-PRO
F-2 TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
CAUTION
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.
F-2
This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into categories of typical problems.
Step 3. PERFORM COMPONENT TESTS. The last column, labeled “Recommended Course of
Action” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.
Step 2. PERFORM EXTERNAL TESTS.
cover.
The second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap-around
All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the referred to test points, components, terminal strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
V300-PRO
F-3 TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
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.
CAUTION
Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure:
1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.
2. Check for loose connections at the PC board to assure that the PC board is properly connected.
3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:
PC board can be damaged by static electricity.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
- Remove your body’s static charge before opening the staticshielding bag. Wear an anti-static wrist strap. For safety, use a 1
Meg ohm resistive cord connected to a grounded part of the equipment frame.
- If you don’t have a wrist strap, touch an un-painted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.
F-3
- Remove the PC board from the static-shielding bag and place it directly into the equipment. Don’t set the PC board on or near paper, plastic or cloth which could have a static charge. If the PC board can’t be installed immediately, put it back in the static-shielding bag.
- If the PC board uses protective shorting jumpers, don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the staticshielding bag. This will prevent further damage and allow proper failure analysis.
4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
(Some “test” boards are available to Service
Facilities through the Parts Department).
NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.
5. Remove the replacement PC board and substitute it with the original PC board to recreate the original problem.
a. If the original problem does not reappear by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.
b. If the original problem is recreated by the substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.
6. Always indicate that this procedure was followed when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.
- Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.
V300-PRO
F-4 TROUBLESHOOTING & REPAIR
ADDITIONAL INFORMATION
OSCILLOSCOPE WARNING
F-4
Do not use oscilloscopes and other pieces of test equipment that are powered by 115 VAC. This equipment should not be used with inverter-type machines, such as Invertec V300-PRO. There are high voltages present, which are “floating” off case ground (floating ground). Connecting the ground lead of a test probe (which may be connected to the case of the test equipment) to a high voltage potential presents a shock hazard as well as the possibility of damage to the equipment in question.
INPUT FILTER CAPACITOR CONDITION-
ING
Capacitor conditioning may be required if the machine will not produce output after power is applied and the following two conditions exist:
The machine is connected to a supply of 380 v.a.c. or higher and
Power has not been applied to the machine for an extended period of time (months).
To condition the input filter capacitors:
1. Turn the Power Switch OFF
2. Remove any load and do not load the machine until the capacitor conditioning is completed.
3. Turn the Power Switch ON and leave the machine energized for at least 30 minutes.
4. Cycle the Power Switch OFF and on again .
The machine should now work normally. If not,continue with the Troubleshooting Section of this manual.
MATCHED PARTS
The following parts must be replaced in matched sets:
Output Diodes D1, D2, D3, D4, and D5.
Output Diodes D7, D8, D9, D10, and D11.
Note: On newer codes where Diode Modules are used in place of individual diodes, both modules on a heat sink assembly should be replaced if one fails.
Capacitor Bleeder Resistors: R1 & R9
Capacitors: C1 & C2
Capacitors C1, C2, C14 & C15 on 575 v.a.c. units.
Switch Boards proir to L10598-[ ]
V300-PRO
F-5 TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-5
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
Major physical or electrical damage is observed when cover wraparound is removed.
Machine is dead — no output — no fan — no display.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FEEDING PROBLEMS
Contact Lincoln Electric Service
Department (1-888-935-3877)
RECOMMENDED
COURSE OF ACTION
Power Switch must be in ON position.
Check input voltage.
Check continuity of 3-amp slow blow fuse located on reconnect panel.
1.
Check Power Switch (S1).
If machine is set for single-phase operation, inspect to assure that
WHITE and BLACK leads of the
Power Cord are connected properly and RED lead is not connected and is insulated.
2.
Look for loose or broken wires between Power Switch and
Input Rectifier (component
D13).
3.
Check for broken leads to pri mary of Auxiliary Transformer
T1.
Check that input voltage set-up switch and jumper A (the reconnect, auxiliary jumper) are in proper position for input voltage being used.
4.
Possible open primary coil of
Auxiliary Transformer T1.
No output but fan operates and the meter display is on.
Output Terminal Switch or Remote
Trigger MUST be in ON position.
1.
See Output Pilot Circuit test.
Local/Remote Switch must be in
LOCAL position unless remote control device is attached to remote receptacle.
2.
3.
If machine has not been used for a long time and is connected for 380
VAC or higher, Capacitors may
need “conditioning.” See Input
in this section
4.
5.
7.
Look for broken or loose connections on high current-carrying parts of machine (i.e., choke, output bridges, output studs, main transformer.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
V300-PRO
F-6 TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-6
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
No output or reduced output the first time power is applied to machine.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FEEDING PROBLEMS
Check input voltages, fuses, and input voltage reconnect procedures.
See Installation section.
RECOMMENDED
COURSE OF ACTION
Check continuity of 3-amp slow blow fuse located on reconnect panel.
Output turns on momentarily, then switches off and repeats cycle.
If high input (380 VAC or higher) voltage is applied. Capacitors may need conditioning.
Check input voltages and reconnection procedures. See Installation section.
See
1.
2.
Check output terminal switch S4 and/or Remote Trigger Options
(i.e., wire feeders, guns, cables, etc.).
3.
NOTE: This test is necessary only if machine is connected for 380 VAC or higher.
4.
5.
Remote output control not functioning. Machine performs well on
LOCAL control.
Test or replace Output Remote
Control Device
1.
Test Local/Remote Switch S3 with ohmmeter. See Wiring
2.
Check continuity of local/remote circuit. See schematic drawing
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
V300-PRO
F-7 TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-7
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
No ouput. Main fuses open, indicating excessive current draw.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FEEDING PROBLEMS
Inspect input leads for possible shorts or grounds or misconnections.
RECOMMENDED
COURSE OF ACTION
Inspect interior of machine for physical signs of electrical and heat damage. Replace any damaged components after conducting the tests below: Install new fuses and reapply power.
If fuses open again, go to next column of this Guide.
1.
2.
3.
4.
Machine does not produce more than 250 amps on meter (while welding) when connected to
3-phase supply.
Check input voltages, fuses, and input voltage reconnect procedures.
See Installation section of this man-
ual.
1.
2.
See Control Board test.
Machine does not produce more than 250 amps on meter (while welding) while connected to singlephase supply
Normal operation.
Nothing is wrong.
3.
See Input Rectifier test (com-
ponent D13).
No test necessary. The singlephase operation is detected by the
Protection Board and the output current is limited accordingly.
Machine operates okay at 230 VAC or lower. No output at 380 VAC or higher
Check input voltage and input voltage reconnect procedures. See
Installation section of this manual.
1.
Check Re-connect Switches
2.
test.
3.
4.
5.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
V300-PRO
F-8 TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-8
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
Meter reads low voltage (1-2 VDC), and output is extremely low or no output.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FEEDING PROBLEMS
Local/Remote Switch must be in
LOCAL position unless Remote
Control device is attached to remote receptacle.
RECOMMENDED
COURSE OF ACTION
1.
2.
3.
4.
5.
See Control Board test.
Poor welding, weld settings drift, or output power is low.
Check welding procedures and weld cable connections.
Check with machine on local control.
1.
Check Mode Switch S2 for damage and continuity.
Check input voltages and input voltage reconnect procedures. See
Installation section of this manual.
2.
Check for continuity between
Mode Switch S2 and Control
Board. See Wiring Diagram in
Section G.
3.
Check for loose or faulty connections in heavy current-carrying leads (i.e., choke, shunt, output bridge, and output studs). See wiring diagram in
Section G.
4.
Current Trigger Circuit tests.
5. See Control Board test
Welding “too hot”. Actual weld current is considerably higher than display indicates.
Check condition of the shunt and leads to the Control Board.
Protection Current Trigger test
If shunt and leads check OK, possible defective Control Board
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
V300-PRO
F-9 TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
F-9
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
Poor stick electrode performance.
Arc pops out.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FEEDING PROBLEMS
Check output welding cables.
RECOMMENDED
COURSE OF ACTION
Is electrode DRY? Try welding with another electrode from a different container.
1.
Check for loose or burned connections at choke, shunt, and output studs. See wiring dia-
Make sure you have the correct electrode for your application.
2.
Test and inspect D6, D12, L1 and L2. See Wiring Daigram in
Machine makes “squealing” noise while under load when welding.
Output power is low (less than 20
VDC on meter @ 100 amps). Input voltage 230 VAC or lower.
Check input lines and connections.
Check input voltage and reconnection procedures
1.
2.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
V300-PRO
F-10 NOTES F-10
V300-PRO
F-11 TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will drain off any charge stored in the capacitors that are part of the
Switch Board Assemblies. This procedure MUST be performed as a safety precaution before conducting any test or repair that requires you to touch internal components of the machine
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Insulated Gloves
Insulated Pliers
High Wattage Resistor (25-1000 ohms/25watt)
Misc. Hand Tools
F-11
V300-PRO
F-12 TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (cont.)
F-12
WARNING
Failure to follow this capacitor discharge procedure can result in electric shock.
INPUT FILTER CAPACITOR
DISCHARGE PROCEDURE
5. Locate the two capacitor terminals (large hex head capscrews)shown in Figure F.1.
1. Turn off input power or disconnect input power lines.
6. Use electrically insulated gloves and insulated pliers. Hold body of the resistor and connect resistor leads across the two capacitor terminals. Hold resistor in place for 10 seconds. DO NOT TOUCH
CAPACITOR TERMINALS WITH YOUR BARE
HANDS.
2. Remove 14 5/16” hex head screws from side and top of machine (6 screws on each side and 2 screws on top) and remove wrap-around machine cover.
3. Be careful not to make contact with the capacitor terminals that are located in the center of the Switch
Boards.
7. Repeat discharge procedure for capacitor on other side of machine. If you are working on a 575 VAC machine, repeat discharge procedure for second capacitor on each side of machine.
4. Obtain a high resistance and high wattage resistor
(25-1000 ohms and 25 watts minimum). This resistor is not supplied with machine. NEVER USE A
SHORTING STRAP FOR THIS PROCEDURE.
8. Check voltage across terminals of all capacitors with a DC voltmeter. Polarity of capacitor terminals is marked on PC board above terminals. Voltage should be zero. If any voltage remains, repeat this capacitor discharge procedure.
FIGURE F.I - LOCATION OF INPUT FILTER CAPACITOR TERMINALS
V300-PRO
F-13 TROUBLESHOOTING & REPAIR
OUTPUT PILOT CIRCUIT TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the Thermostats, the Auxiliary Transformer (T1) and the
Output Terminal Switch (S4) are functioning properly.
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
Wiring Diagram (Section G)
F-13
V300-PRO
F-14 TROUBLESHOOTING & REPAIR F-14
OUTPUT PILOT CIRCUIT TEST(cont.)
TEST PROCEDURE
1. Turn Input Power Switch OFF 5. Set the Output Terminals Switch to the ON position.
2. Perform Input Capacitor Discharge test as
described in the Maintenance Section.
6. Turn the Input Power Switch ON.
3. Remove the four screws that hold the Control Panel to the frame.
4. Move the Control Panel forward and to the left so that there is access to the Control PC Board. Be careful not to stress any of the connections to the
Control Panel.
FIGURE F.2 - REMOVING CONTROL PANEL
V300-PRO
F-15 TROUBLESHOOTING & REPAIR
OUTPUT PILOT CIRCUIT TEST (cont.)
FIGURE F.3 – CONTROL BOARD TEST POINTS
F-15
302
210 223A
J5
G2527
CONTROL J1 J2 J4 J3
275D
7. Measure voltage from Lead #210 (J2/Pin 4) to
Lead # 223A (J4/Pin 11).
a. If voltage is 24v.a.c., thermostats, transfor mer T1 and switch (S4) are OK. Go on to
Step 8.
b. If voltage is 0v.a.c. test the following com ponents individually:
Auxiliary Transformer T1
Fan Thermostat
Choke Thermostat
Output Terminal Switch (S4)
8. Measure voltage from lead 302 (J1/Pin 6) to Lead
275D (J1 /Pin1).
a. If voltage is 15v.d.c, Transformer T1 and 15
volt supply are OK. Go to Protection Board
b. If voltage is 0v.d.c. check Transformer T1
and then go to Power Board test
V300-PRO
F-16 NOTES F-16
V300-PRO
F-17 TROUBLESHOOTING & REPAIR
PROTECTION BOARD OUTPUT TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the Protection PC Board is defective , or responding to external signals causing it to prevent the Input Filter Capacitors from charging.
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Misc Hand Tools
Wiring Diagram (Section G)
F-17
V300-PRO
F-18
TROUBLESHOOTING & REPAIR
PROTECTION BOARD OUTPUT TEST(cont.)
F-18
TEST PROCEDURE
1. TURN POWER SWITCH OFF
2. Remove sheetmetal wraparound.
3. Perform Input Filter Capacitor Discharge procedure detailed in Maintenance section
4. Remove the two through bolts that attach the
Power/Driver Board bracket to Protection/Input
Rectifier bracket. Each through bolt also supports a resistor.
5. Slide the through bolts toward the Control Panel until the brackets are disconnected and resistors are loose. Be careful when loosening these through bolts, as they secure the two resistors. As the through bolts are removed, carefully place the resistors and the connected wires to the side
FIGURE F.4 — REMOVING THROUGH BOLTS & MOUNTING SCREWS
6. Remove the two screws attaching the Protection
Board/Input Rectifier bracket to main assembly bracket.
7. Tilt the top of the Protection Board bracket toward the Power Panel to gain access to test points on the
Protection Board.
V300-PRO
F-19 TROUBLESHOOTING & REPAIR
PROTECTION BOARD OUTPUT TEST(cont.)
F-19
TEST PROCEDURE
8.
With power OFF, disconnect J8 and attach voltage probes into back of wire harness lead junction block (J8). See Figure F.5.
Insert probes into back of the connection cavities for leads 313 (-) and 311 (+) of Protection Board.
Make sure contact is made with conductor material.
NOTE: Right-angle, thin-gauge probes are best for this test.
With probes attached, plug the (J8) block into the
PC board.
9.
Turn main power ON.
10. Move Output Terminal Switch S4 to ON position on
Control Panel.
11. Test for less than 1 VDC between leads 313 (-) and
311 (+).
a. If less than 1 VDC is measured, test is OK and
Protection Board is functioning properly.
b. If more than 5 VDC is measured, go to Static
Capacitor Balance Test.
NOTE:. During voltage test, be cautious when positioning loose components to avoid shorts and damage to equipment.
FIGURE F.5 - INSERTING PROBES
L7915
PROTECTION
306
275F
J8
313
311
V300-PRO
J15
F-20 TROUBLESHOOTING & REPAIR
PROTECTION BOARD OUTPUT TEST(cont.)
FIGURE F.6 - INSERTING PROBES
L7915
PROTECTION
F-20
313
306
J8
275F
311
TEST PROCEDURE
12. Open S4 and Turn Power OFF
13. Move probes to test between leads 306 (+) and
275 (-). (See Figure F.6)
14. Turn Power ON and close S4. If voltage is less than 1 VDC, Protection Board is OK. If voltage is greater than 14 VDC, Protection Board may be
defective.See Overvoltage Protection DC
V300-PRO
J15
F-21 TROUBLESHOOTING & REPAIR
CAPACITOR BALANCE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine the condition of the capacitors,bleeder resistors and
Switch Boards.
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
Wiring Diagram (Section G)
NOTE: This procedure should only be done with the reconnect
switches and jumper set for “380-460” Volt operation and the proper input voltage applied.
F-21
V300-PRO
F-22 TROUBLESHOOTING & REPAIR
CAPACITOR BALANCE TEST (cont.)
F-22
STATIC CAPACITOR TEST
TEST PROCEDURE:
1. With Output Terminal Switch S4 in REMOTE (OFF) position, turn Power Switch ON.
2. Test VDC across terminals 9 and 12 of one Switch
Board (see Fig F.7). Repeat the test for the other
Switch Board. See Table F.1 in this procedure for expected voltage readings.
NOTE: For 575 VAC only machines, compare voltage across 9A and 13 and 13 and 12A; then 9B and
15 and 15 and 12B.
b. If more than 25 VDC difference is measured between the Switch Boards, test each of the following components:
• Capacitors C1 and C2 and Resistors R1 and
R9.
• (575 VAC only machines —Capacitors C1,
C2, C14, and C15; and Resistors R1 and
R9.)
DYNAMIC CAPACITOR TEST
TEST PROCEDURE:
3. Record VDC measured for each Switch Board and determine the difference in VDC.
NOTE: The following measurements should result based on VAC input.
TABLE F.1 — EXPECTED VOLTAGE READINGS.
VDC at Switch
Board Terminals should be
If VAC Input is: approximately:
575VAC
460 VAC
440 VAC
415 VAC
380 VAC
407 VDC
325 VDC
311 VDC
293 VDC
269 VDC a. If less than 25 VDC difference is measured between the Switch Boards, then capacior balance is OK.
• This indicates that Capacitors C1 and C2,
Resistors R1 and R9 are OK.
• (575 VAC only machines — Capacitors C1,
C2, C14, and C15; Resistors R1 and R9 are
OK.)
Go to Dynamic Capacitor Balance Test.
1. Move Output Terminal Switch S4 to ON position.
Adjust the output control to the minimum setting.
Place the mode control at the SMAW (soft) position.
2. Test VDC across terminals 9 and 12 of one Switch
Board (see Fig. F.7). Repeat the test for the other
Switch Board. See Table F.1 for expected voltages
NOTE: For 575 VAC ONLY, compare voltage across 9A and 13 and 13 and 12A; then 9B and 15 and 15 and 12B.
3. Record VDC measured for each Switch Board and determine the difference in VDC. (See Table F1).
a.
If less than 15 VDC difference is measured between the Switch Boards, test is OK.
b.
If more than 15 VDC difference is measured between the Switch Boards, the Power Board
or Switch Board is damaged. See SWITCH
BOARD test and POWER BOARD test.
V300-PRO
F-23 TROUBLESHOOTING & REPAIR
CAPACITOR BALANCE TEST (cont.)
FIGURE F.7 - SWITCH BOARD TEST POINTS
9 12
F-23
WR 401/
403
1/
8
4/
5
402/
404
L8604-1
SWITCH
V300-PRO
F-24 NOTES F-24
V300-PRO
F-25 TROUBLESHOOTING & REPAIR
SWITCH 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the Switch Boards are working properly. This resistance test is preferable to a voltage test with the machine energized because these boards are easily damaged. Also, it is more dangerous to work on these boards when power is applied.
MATERIALS NEEDED
ANALOG
Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
Wiring Diagram (Section G)
NOTE: Most digital meters will not supply enough current in the
“ohms” mode to do this test effectively
.
F-25
V300-PRO
F-26 TROUBLESHOOTING & REPAIR
SWITCH BOARD TEST (cont.)
F-26
TEST PROCEDURE
1. Disconnect power to the machine and perform
Input Filter Capacitor Discharge Procedure as
described in Section F.
2. Disconnect all wiring harness leads (401/403, 1/8,
9, 12, 4/5, 402/404) from the Switch Boards.
3. Fold the leads up so they do not interfere with the exposed PC board terminals. See Figure F.8.
4. Using an ohmmeter, perform the Resistance Tests
detailed in Table F.2 and Table F.3. If any test fails,
replace both Switch Boards. See Switch Board
5. If the Switch Boards appear to be burned or overheated, or if the machine was supplied by a 380
VAC or higher voltage supply when the failure occurred, replace the Capacitors and the Switch
Boards.
FIGURE F.8 - SWITCH BOARD RESISTANCE TEST
V300-IPRO
F-27 TROUBLESHOOTING & REPAIR
SWITCH BOARD TEST (CONT.)
TABLE F.2
SWITCH BOARD RESISTANCE CHECKS
Apply Positive Apply Negative
Test Probe to Test Probe to
Terminal Terminal
1/8 12
Test Result Conclusion Repair Action Next Procedure Notes
Greater than
1K ohm
OK None Continue
Less than
100 ohms
Shorted Replace both Snubber Test
Switch Boards
12 1/8 None Continue
9
4/5
4/5
9
Less than
100 ohms
OK
Greater than Open
1K ohm
Greater than OK
1K ohm
Less than
100 ohms
Shorted
Replace both
Switch Boards
None
Replace both
Switch Boards
None
Snubber Test
Continue
Snubber Test
Continue
1/8
9
12
9
1/8
4/5
Less than
100 ohms
OK
Greater than Open
1K ohm
Less than
100 ohms
OK
Greater than Open
1K ohm
Greater than OK
1K ohm
Less than
100 ohms
Shorted
Replace both
Switch Boards
None
Replace both
Switch Boards
None
Replace both
Switch Boards
None
Snubber Test
Continue
Snubber Test
Continue
Snubber Test
Continue
4/5 12
Less than
100 ohms
OK
Greater than Open
1K ohm
Greater than OK
1K ohm
Less than
100 ohms
Shorted
Replace both
Switch Boards
None
Replace both
Switch Boards
Snubber Test
Continue
Snubber Test
F-27
NOTE: K ohm = ohm reading multiplied by 1000.
NOTE: Always make sure that Switch Boards are changed in matched pairs. Never mix an old style (different part number) Switch Board with a newer style.
V300-PRO
F-28 TROUBLESHOOTING & REPAIR
SWITCH BOARD TEST (CONT.)
TABLE F.3
SWITCH BOARD RESISTANCE CHECKS
Apply Positive Apply Negative
Test Prove to Test Probe to
Terminal Terminal
12 401/403
Test Result Conclusion Repair Action Next Procedure Notes
Greater than
1K ohm
OK None Continue
Less than
100 ohms
Shorted Replace both Snubber Test
Switch Boards
401/403 12 None Continue
9
402/404
402/404
9
Less than
100 ohms
OK
Greater than Open
1K ohm
Less than
100 ohms
OK
Greater than Open
1K ohm
Greater than OK
1K ohm
Less than
100 ohms
Shorted
Replace both Snubber Test
Switch Boards
None Continue
Replace both Snubber Test
Switch Boards
None Continue
Replace both Snubber Test
Switch Boards
F-28
V300-PRO
F-29 TROUBLESHOOTING & REPAIR
SNUBBER RESISTOR TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the Snubber Resistors are defective.
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
Wiring Diagram (Section G)
F-29
V300-PRO
F-30 TROUBLESHOOTING & REPAIR
SNUBBER RESISTOR TEST (cont.)
FIGURE F.9 - SNUBBER RESISTOR TEST POINTS
WR 401/
403
1/
8 5
402/
404
W
F-30
1. Turn main Power off.
2. Perform Input Filter Capacitor Discharge proce-
dure.
3. Remove leads 401,402 403 & 404 from theSwitch
Boards.
4. Test for 25 ohms resistance from lead 401 to terminal 12 on Switch Board.
a. If 25 ohms is measured, Resistor R4 is OK.
b. If 30 ohms or more is measured, Resistor R4 is faulty and must be replaced.
c. If 20 ohms or less is measured, Resistor R4 is faulty and must be replaced.
5. Repeat same procedures to test R5, R6, and R7 per
Table F.4.
Check
Lead 401 to
Terminal 12
Lead 402 to
Terminal 9
Lead 403 to
Terminal 12
Lead 404 to
Terminal 9
Test Result
25 ohms
>30 ohms
<20 ohms
25 ohms
>30 ohms
<20 ohms
25 ohms
>30 ohms
<20 ohms
25 ohms
>30 ohms
<20 ohms
TABLE F.4 SNUBBER RESISTORS TEST
Conclusion
OK
R4 open
R4 faulty
OK
R5 open
R5 faulty
OK
R6 open
R6 faulty
OK
R7 open
R7 faulty
Next Test Step
Continue
Continue
Continue
Continue
Repair Action
Replace R4
Replace R5
Replace R6
Replace R7
V300-PRO
F-31 TROUBLESHOOTING & REPAIR
OUTPUT DIODE TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
F-31
TEST DESCRIPTION
This procedure will determine if the Output Diodes are defective.
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Wiring Diagram (Section G)
V300-PRO
F-32 TROUBLESHOOTING & REPAIR
OUTPUT DIODE TEST (cont.)
F-32
TEST PROCEDURE
1. Locate the Output Terminals on front panel.
2. Remove any cables from Output Terminals.
3. Test for more than 200 ohms resistance between positive and negative Output Terminals: positive meter lead to the positive terminal, negative meter lead to the negative terminal.
NOTE: Polarity of test leads is important.
a.
If reading is more than 200 ohms, Output
Diodes are OK.
b.
If reading is less than 100 ohms, one or more
Output Diode is shorted. Test all Output Diodes
(D-1 thru D-12) or diode modules individually.
NOTE: On codes prior to 10200 the diodes should also be tested individually to check for “Open” diodes. An open diode may cause an imbalance condition when output is activated. Be sure to per-
form the Input Filter Capicitor Discharge
Procedure as detailed in this section.
FIGURE F.10 — TESTING OUTPUT DIODES.
LINCOLN
+
V300-PRO
F-33 TROUBLESHOOTING & REPAIR
INPUT RECTIFIER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
F-33
TEST DESCRIPTION
This procedure will determine if the Input Rectifier is defective.
MATERIALS NEEDED
ANALOG
Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
Wiring Diagram (Section G)
V300-PRO
F-34 TROUBLESHOOTING & REPAIR
INPUT RECTIFIER TEST
FIGURE F.11 - INPUT RECTIFIER LOCATION
F-34
TEST PROCEDURE
1. Perform
Input Filter Capacitor Discharge
Procedure as detailed in this section.
6. Inspect Main Power Switch S1 and replace if faulty.
Go to step 7.
2. Locate Input Rectifier (Component D-13).
7. Test Capacitors C1 and C2 and replace both
Capacitors if either is faulty.
3. Locate leads needed to perform tests shown in
Figure F.11.
NOTE: Faulty Capacitors could be the reason for a defective Input Rectifier.
4. Use ohmmeter to perform tests shown in Table F.5.
Replace the Inpit Rectiferif readings are not as indicated
Visually inspect Capacitors for leakage, damage, etc., and use appropriate test equipment to determine component integrity (also check/test Switch Boards for damage).
NOTE: When installing a new Input Rectifier, torque mounting nuts (in a cross tightening pattern) to 6 inch-pounds (.7 Nm). Torque terminals to 26 inchpounds (3 Nm). ALWAYS GO TO STEP 6 TO
CHECK RELATED COMPONENTS.
TABLE F.5
Steps
E
F
G
H
C
D
A
B
K
L
I
J
Test Points
+ Probe – Probe
A
H5
12
12
9
9
9
H1
12
H1
A
H5
9
9
H1
A
H1
A
H5
9
H5
12
12
12
V300-PRO
Acceptable Meter Reading
Greater than 1K ohms
Greater than 1K ohms
Greater than 1K ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
Greater than 1K ohms
Greater than 1K ohms
Greater than 1K ohms
F-35 TROUBLESHOOTING & REPAIR
OVERCURRENT PROTECTION CURRENT TRIGGER TEST
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
F-35
TEST DESCRIPTION
This procedure will determine if the overcurrent trigger circuit is working correctly and also if the current limiting portion of the Control Board is working correctly.
MATERIALS NEEDED
Digital
Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
Wiring Diagram (Section G)
V300-PRO
F-36 TROUBLESHOOTING & REPAIR
OVERCURRENT PROTECTION CURRENT TRIGGER TEST (cont.)
F-36
FIGURE F.12 - GETTING ACCESS TO CONTROL BOARD
TEST PROCEDURE
1. Perform Input Filter Capacitor Discharge
Procedure detailed in this section.
2. Remove front panel from machine to access Control
Board.
3. Arrange wires so there is ample room to work on the board.
4. Turn main power ON.
5. Test for 15 VDC between leads 302 and 275D.
a.
If 15 VDC is present, test is OK. Go to step 6.
b.
If 15 VDC is not present, check Power Board and leads 302 and 275D for continuity and wire breakage.
FIGURE F.13 - CONTROL BOARD TEST POINTS
J5
302
G2527
CONTROL
J1 J2 J4
275D
V300-PRO
J3
F-37 TROUBLESHOOTING & REPAIR
OVERCURRENT PROTECTION CURRENT TRIGGER TEST (cont.)
F-37
FIGURE F.14 - CONTROL BOARD TEST POINTS
J2 J4
2J3 (White)
J3 J5
G2527
CONTROL
J1
1J3 (Black)
6. Turn main power OFF.
7. Perform
Input Filter Capacitor Discharge
Procedure detailed in this section.
Test resistance of the Black and White leads from
1J3 and 2J3 to the shunt. See Figure F.14.
a.
If zero ohms resistance (continuity) is shown, test is OK. b.
If resistance of any value is shown, check wire and connections.
NOTE: On earlier codes the terminals on the shunt leads were crimped but not soldered. Corrosion may cause inaccurate current readings. Cleaning and soldering the terminals to the leads may eliminate that problem.
If tests for steps 5, 7, are OK and the machine continues to experience the problem, the Control Board should be replaced.
FIGURE F.15 - OVERCURRENT PROTECTION CURRENT TRIGGER CIRCUIT.
302
6J1 1J1
CONTROL
BOARD
275D
1J3 2J3
BLACK WHITE
L3
CHOKE
400 AMP
SHUNT
V300-PRO
(-) OUTPUT
TERMINAL
F-38 TROUBLESHOOTING & REPAIR
OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST
F-38
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the overvoltage protection and related portions of the
Protection Board and Power Board are functioning properly.
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
Wiring Diagram (Section G)
NOTE: Fig. F.19 shows the Overvoltage Protection DC trigger Circuit.
V300-PRO
F-39 TROUBLESHOOTING & REPAIR
OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST (cont.)
F-39
FIGURE F.16 - PC BOARDS REMOVED
TEST PROCEDURE
1. Turn main power OFF.
2. Perform Input Filter Capacitor Discharge proce-
dure detailed in Maintenance section.
3. Detach the following PC boards so you can gain access to and have ample room to perform the tests: (Do not disconnect from wiring harness.)
• Control Board
• Protection Board
• Power Board
NOTE: Do not disconnect any wires. The machine must be functional to perform tests.
4. Arrange the PC boards and wiring so you can easily perform the tests.
NOTE: Do not allow live connections to touch each other.
5. Turn main power ON.
6. Move the Output Terminal Switch S4 to the ON position (closed).
V300-PRO
F-40 TROUBLESHOOTING & REPAIR
OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST (cont.)
F-40
FIGURE F.17 — PROTECTION BOARD TEST POINT
L7915
PROTECTION
313
306
J8
275F
311
7. Test for 0 VDC between leads 311 and 313 on
Protection Board.
a. If 0-1 VDC is present, the Protection Board is
OK. Go to step 8.
b. If 15 VDC is present, go to step 11.
J15
V300-PRO
F-41 TROUBLESHOOTING & REPAIR
OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST (cont.)
F-41
FIGURE F.18 - POWER BOARD TEST POINTS
309 310
L8033
POWER BOARD
212A
301 302
501
504
J7
313
J14
311 211A
J6
305
275D
8. Test for 15 VDC supply voltage between leads 302 and 275D on Power Board.
a.
If 15 VDC is present, test is OK. Go to step 9.
b.
If 15 VDC is not present, the Power Board may be faulty. Check for 18 VAC input voltage at lead 501 and 504 (J7).
If 18 VAC is present the Power Board is faulty and must be replaced.
9. Test for 0-1 VDC (DC trigger circuit) between leads
305 and 275D on Power Board.
a.
If 0-1 VDC is present, DC trigger circuit is operating properly.
b.
If 15 VDC is present, go to step 10.
10. Test for 0-1 VDC between leads 301 and 275D on
Power Board.
a.
If 0-1 VDC is present, AC trigger, Control
Board, and Power Board are operating properly.
b.
If 15 VDC is present, go to Thermal Protection
AC Trigger Circuit Test .
V300-PRO
F-42 TROUBLESHOOTING & REPAIR
OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST (cont.)
F-42
FIG. F.19 - OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT
THESE LEADS
ARE USED FOR
MONITORING
CAPACITOR
VOLTAGES
SEE TABLE 1
BELOW
52
14
53
51
1J8
3J8
PROTECTION
BOARD
#311
#313
1J14
2J14
POWER
BOARD
6J6
#302
1J6
#275D
OPTOCOUPLER
DEPENDENT ON
PROTECTION BOARD
#301
TABLE 1:INPUT VOLTS FOR
460 VOLTS AC
LEADS
52-53
51-53
14-53
14-52
NORMAL
325 VDC
325 VDC
14-15 VDC
315 VDC
IF AC TRIGGER
CIRCUIT IS GOOD,
#301 LEAD
IS TAKEN TO
CIRCUIT COMMON
#275D
5J1
#305
CONTROL
BOARD
4J1
+15 VDC
(+)
(-)
11. If 15 VDC is present at step 7, test Capacitor voltages using leads shown in Figure F.19.
If voltage does not match table, check reconnect switches for proper operation and proper position
for voltage applied. Perform Capacitor Balance
V300-PRO
F-43 TROUBLESHOOTING & REPAIR
THERMAL PROTECTION AC TRIGGER CIRCUIT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
F-43
TEST DESCRIPTION
This procedure will check the two thermostats and associated circuity through the
Auxiliary Transformer, Power Board and Control Board.
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
Wiring Diagram (Section G)
V300-PRO
F-44 TROUBLESHOOTING & REPAIR
THERMAL PROTECTION AC TRIGGER CIRCUIT (cont.)
FIGURE F.20 - PC BOARDS MOVED FOR ACCESS
F-44
TEST PROCEDURE
1. Turn main power OFF.
2. Perform Input Filter Capacitor Discharge proce-
dure detailed in this section.
3. Detach the following PC boards so you can gain access to and have ample room to perform the tests. (Do not disconnect from wiring harness.)
• Power Board
• Control Board
NOTE: Do not disconnect any wires. The machine must be functional to perform test.
V300-PRO
F-45 TROUBLESHOOTING & REPAIR
THERMAL PROTECTION AC TRIGGER CIRCUIT (cont.)
FIGURE F.21 - THERMAL PROTECTION AC TRIGGER CIRCUIT
F-45
#503 #503A
CHOKE
THERMOSTAT
#224
T1
24
VOLTS
AC
#212D
10J6
EXTERNAL
TRIGGER
2 C
4D
#212C #212A
#223B
#212B
9J6
S4 OUTPUT
TERMINAL
SWITCH
#223A
POWER
BOARD
PART OF 14 PIN
AMPHENOL
11J4
CONTROL
BOARD
4J2
NORMALLY CLOSED
NOTE:
WHEN THERMOSTATS
TRIP, THE CIRCUIT
WILL BE OPENED
#210
FAN
THERMOSTAT
4. Locate the Auxiliary Transformer T1 and leads used for test. See Figure F.21.
5. Turn main power ON.
6. Test Auxiliary Transformer voltage for 24 VAC between leads 503 and 212D. See Figure F.21.
a. If 24 VAC is present, transformer is OK. Go to step 7.
b. If 0 VAC is present, test input voltage to Auxiliary
Transformer.
c. If input voltage to Auxiliary Transfor-mer is correct, replace Auxiliary Transformer.
d. If input voltage to Auxiliary Transfor-mer is not correct, check Line Switch S12 and connecting leads.
7. Check that Output Terminal Switch S4 is in the ON position (closed).
8. Test for 24 VAC between leads 223A and 210.
a. If 24 VAC is present, then AC Trigger Circuit is functioning normally.
b. If 0 VAC is present, check Choke Thermostat and Fan Thermostat.
V300-PRO
F-46 NOTES F-46
V300-PRO
F-47 TROUBLESHOOTING & REPAIR
POWER 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.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will help to determine if the Power Board or associated circuitry is defective.
MATERIALS NEEDED
Volt/ohm Meter (multimeter)
Misc. Hand Tools
Wiring Diagram (Section G)
F-47
V300-PRO
F-48 TROUBLESHOOTING & REPAIR
POWER BOARD TEST (cont.)
.
TEST PROCEDURE
NOTE: Perform Test A before disassembling the unit
Test A
1.
Turn main power OFF.
2.
Position yourself at Switch Board area of the machine (near Case Back) so as to hear the operation of the control relays.
3.
Turn main power ON.
F-48
4.
Listen for control relays to operate (audible click of contacts closing) after about a 5-second delay.
a. If audible click of control relay contacts closing is heard, Power Board is probably OK.
b. If audible click of control relay contacts closing is not heard, Power Board could be faulty. Go to Test B.
NOTE: If the relays energize but there is still a suspicion that the Power Board is faulty, go on to
Test B.
FIGURE F.22 - REMOVING CONTROLPANEL
Test B
1.
Turn main power OFF.
4.
Detach Control Panel by removing the four mounting screws. Move the panel to the left to gain access to the Power Board.
2.
Remove wrap-around cover.
3.
Perform Input Filter Capacitor Discharge proce-
dure.
5.
Turn main power ON.
V300-PRO
F-49
309 310
TROUBLESHOOTING & REPAIR
POWER BOARD TEST (cont.)
FIGURE F.23 - POWER BOARD TEST POINTS
F-49
POWER BOARD
212A
301 302
L8033
501
504
J7
313
J14
311 211A
J6
305
275D
6.
Test for 18 VAC input from Auxiliary Transformer between leads 504 and 501 (J7-pin 5 & pin 6) on
Power Board.
If 18 VAC is not correct, check the 3 amp fuse, the
Auxiliary Transformer and associated wires.
7.
Test for 15 VDC output between leads 275D (-) and
302 (+) (J6-pin1 & pin 6) on Power Board.
If 15 VDC output is not present, replace Power
Board.
NOTE: If relays energized in Step 4a, skip to Step 10.
8. Test for 24 VAC from lead 211A to lead 212A (J6pin 4 & pin 9).
If 24VAC is not present, test the Auxiliary trans former and associated wires. The Control Board or thermostats may also be defective. (See Fig. F.24).
9.
Test for 24VDCfrom lead 309 (+) to lead 313 (-)
(J7pin 2 to J14 pin 2).
If 24VDC is not present but 24VAC (step 8) is cor rect, the Power Board is defective.
10. Test for 24VDC from lead 309(+) to lead 310(-) (J7 pin 2 to J7 pin 4).
If 24 VDC is not present, check the voltage from lead 311(+) to lead 313(-).
If the voltage is greater than 1VDC, perform the
If the voltage is approximately 1vdc and the 24vdc is not present between leads 309 & 310, the
Power Board is defective
V300-PRO
F-50 TROUBLESHOOTING & REPAIR
POWER BOARD TEST (cont.)
FIGURE F.24 - SIMPLIFIED TRIGGER CICUIT
F-50
SIMPLIFIED TRIGGER CIRCUIT
FROM PROTECTION
BOARD OVERVOLTAGE
POWER BOARD
7J6
#301
11J4
2J6
#305
3J4
PWM
OUTPUTS
TO POWER
BOARD
STT II Only
CONTROL BOARD
P
W
M
T1 AUXILIARY
TRANSFORMER
2
4
V
A
C
3J31
#503A
2J31
#212
6J22
#224
TO
POWER
BOARD
#379
#210
6J4
5J4
12J4 6J34
REMOTE
PROTECTION
BOARD (STT ONLY)
9J4
#223
8J33
3.5 ohms
14 AMPHENOL
13J36
#413
C
3.5 ohms
5J36
#405
D
#212C
V300-PRO
F-51 TROUBLESHOOTING & REPAIR
CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid in the relpacement of the Input Filter Capacitors.
MATERIALS NEEDED
MIsc. Hand Tools
Torque Wrench (60 in./lb.)
Wiring Diagram (Section G)
NOTE: CAPACITORS MUST ALL BE CHANGED AS A SET IF ANY ARE
DEFECTIVE.
F-51
V300-PRO
F-52 TROUBLESHOOTING & REPAIR
CAPACITOR REMOVAL AND REPLACEMENT (cont.)
PROCEDURE
NOTE: When replacing capacitors, remove the entire FET Heat Sink Assembly as a unit.
Remove and reassemble one side at a time, using the other side as a model to insure that all parts are reinstalled prop erly
1. Perform the Input Filter Capacitor Discharge
2. Remove the two 3/8” hex nuts from the top of the through bolts. The hex nuts are located on top of the fan shroud See Figure F.25.
FIGURE F.25 - REMOVING HEX NUTS
F-52
3. Turn the machine on it’s side as shown in Figure
F.26. Slide the plastic insulators that go through the base to one side and pull out the through bolts, being careful to save all of the insulation and standoff material. Set aside and save for reassembly.
FIGURE F26 - REMOVING THROUGH BOLTS
V300-PRO
F-53 TROUBLESHOOTING & REPAIR
CAPACITOR REMOVAL AND REPLACEMENT (cont.)
FIGURE F.27 -- REMOVING CAPACITOR NUTS
F-53
4.
Remove the two 1/4-28 hex head bolts that hold the Capacitor to the PC board. See Figure F.27.
5.
Loosen the set screw of the Capacitor clamp ring and remove the Capacitor from the clamp ring.
See Figure F.28.
FIGURE F.28 — LOOSENING THE CLAMP RING SET SCREW.
V300-PRO
F-54 TROUBLESHOOTING & REPAIR
CAPACITOR REMOVAL AND REPLACEMENT (cont.)
FIGURE F.29 -- COMPLETE SWITCH BOARD ASSEMBLY READY FOR INSTALLATION
F-54
NOTE: Proper capacitor polarity must be noted when attaching the capacitor to the Switch Board assembly.
6.
Install the new Capacitor and tighten the two bolts to a torque of 55 inch-pounds (6 Nm). Hand tighten first, then tighten the bolts in increments of 10 inch-pounds, alternating between the two. See
7. Tighten the set screw of the clamping ring
8.
Perform the Test After Repair of Switch Boards
V300-PRO
F-55 TROUBLESHOOTING & REPAIR
SWITCH BOARD REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid in the relpacement of the Switch Boards.
MATERIALS NEEDED
Misc. Hand Tools
Torque Wrench (60 in./lb.)
Wiring Diagram (Section G)
NOTE: BOTH SWITCH BOARDS IN A MACHINE MUST HAVE IDENTICAL
PART NUMBERS. THEY SHOULD ALWAYS BE CHANGED IN PAIRS
EXCEPT FOR L10958-[ ] BOARDS WHICH MAY BE REPLACED
INDIVIDUALLY
F-55
V300-PRO
F-56 TROUBLESHOOTING & REPAIR
SWITCH BOARD REPLACEMENT (cont.)
F-56
NOTE: If a test indicates that a Switch Board is defective, unless their part number is L10958-[ ] both Switch
Boards must be replaced at the same time. In addition to replacing the Switch Boards, Capacitors C1 and C2
(plus C14 and C15 on 575 VAC models) must also be replaced if the following conditions exist: a. The part number of the Switch Boards is something other than L10985-[ ] b.
The machine was operating from 380 VAC or higher when the failure occurred.
c.
Burned areas are visible on the Switch Boards.
PROCEDURE
1. Perform the Input Filter Capacitor Discharge
2. Remove the Switch Board assembly from the
machine as directed in the CAPACITOR
3. Remove the four socket head screws that hold the
Switch Board to the heat sink.
4. Remove the 1/4”-28 hex head capacitor mounting screws.
5. Remove the Switch Board from the heat sink.
6.
Clean the heat sink surfaces thoroughly to remove all the heat sink compound. During machine operation, this compound helps conduct heat from the
PC board to the heat sinks.
7.
Apply a thin layer (.002”) of Dow 340 or Penetrox
A13 Heat Sink Compound to the mounting surfaces of the new PC board and to the Capacitor terminals. DO NOT allow the compound to enter the mounting screw holes because it can distort the torque values.
8.
Prepare to mount the new PC board on the heat sink by first lining up the mounting holes. Then press the PC board into place.
9.
Insert each of the four socket head screws into the mounting holes and thread finger tight. The threads are soft — be careful not to cross thread the screws.
10. Loosen the capacitor mounting bracket tightening
11. Torque both sets of screws in 10 inch-pound increments using a diagonal tightening sequence.
Torque the four socket head screws to 44 inchpounds (5 Nm). Torque the two hex head capacitor screws to 55 inch-pounds (6 Nm).
12. Tighten the capacitor mounting bracket mounting screw
13. Remount the assembly into the machine
14. Reconnect all the leads to the PC board. Double check that each lead is connected to the correct terminal. Failure to reconnect the leads correctly can result in machine damage when the power is applied.
15. Perform the Test After Repair of Switch Boards
V300-PRO
F-57 TROUBLESHOOTING & REPAIR
TEST AFTER SWITCH BOARD OR CAPACITOR REPLACEMENT
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This test MUST be performed after replacement of either the Switch Boards or Input
Filter Capacitors.
MATERIALS NEEDED
Misc. Hand Tools
Small jumper or clip lead
Wiring Diagram (Section G)
NOTE: BOTH SWITCH BOARDS IN A MACHINE MUST HAVE IDENTICAL
PART NUMBERS. THEY SHOULD ALWAYS BE CHANGED IN PAIRS
EXCEPT FOR L10958-[ ] BOARDS WHICH MAY BE REPLACED
INDIVIDUALLY
F-57
V300-PRO
F-58 TROUBLESHOOTING & REPAIR
TEST AFTER SWITCH BOARD OR CAPACITOR REPLACEMENT (cont.)
F-58
TEST PROCEDURE
1. Turn main power OFF.
2. Perform Input Filter Capacitor Dis-charge proce-
dure detailed in Mainten-ance section..
3. Connect a shorting conductor across terminals 14 and 53 of Protection Board.
4. Set an ohmmeter to X1000 range and place probes on terminals 9 (+) and 12 (-) of one Switch Board.
The meter will show the Capacitors charging up and may take a minute or so to stabilize. The final meter reading should not exceed 8600 ohms (8.6
on the scale).
5. Test the other Switch Board the same way.
NOTE: Repeat the Input Filter Capacitor Dis-charge
procedure.
6.
Remove the shorting conductor set up in step 3.
7.
Install 5-amp fuses in the input supply fuse holders.
NOTE: These fuses should be installed to protect against excessive current flow caused by a short circuit during the procedure.
8.
Turn on the machine.
9.
With the output free of a load, check the open circuit voltages of the output.
10. Connect the machine for 440- or 575-volt operation.
11. With the output free of a load, check open circuit voltages of the output. Voltage should be 70 VDC.
12. Remove the 5-amp fuse from the input supply fuse holders.
13. Install 20-amp fuses and test under load.
NOTE: A resistive-type grid load bank is recommended.
14. Perform Retest After Repair.
FIGURE F.30 - PLACEMENT OF SHORTING JUMPER
B300-PRO
F-59 TROUBLESHOOTING & REPAIR
OUTPUT DIODE REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid in the relpacement of the Output Diodes.
MATERIALS NEEDED
Misc. Hand Tools
Torque Wrench (60 in./lb.)
Wiring Diagram (Section G)
NOTE: Most Output Rectifier Assemblies are made with two sets of five individual diodes connected in parallel. If one or more diodes in a set fails, all five must be replaced.
Some Output Rectifier Assemblies are made with Diode Modules. It is only necessary to replace the Defective part on these units
F-59
V300-PRO
F-60 TROUBLESHOOTING & REPAIR
OUTPUT DIODE REPLACEMENT PROCEDURE (cont.)
FIGURE F.31 - RECTIFIER ASSEMBLY WITH PARALLELED DIODES
F-60
PROCEDURE (Paralleled IndividualDiodes)
1. Turn main power OFF.
2. Perform Input Filter Capacitor Discharge proce-
dure detailed in Maintenance section..
3. Detach and remove both Switch Board assemblies
and attached capacitors. See Switch Board
Removal and Replacement procedure
4. Detach the fan shroud to gain access to the diode heat sink and mounting bracket. When the fan shroud is lifted, the tabs securing the heat sink mounting bracket will release.
5. Move the diode heat sink and mounting bracket away from the Case Back.
6. Unsolder the leads from each of the diodes to be replaced.
7. Remove the nut that secures each diode to the heat sink and mounting bracket.
8. Mount the replacement diodes to the heat sink.
IMPORTANT: The replacement diodes will come with an instruction sheet that addresses surface preparation and torque values. Failure to follow these instructions may result in subsequent break down.
9. Carefully resolder the leads to the new diodes.
10. Reassemble the unit being careful to use all of the insulating materials. Also make certain to replace all disconnected leads in their proper location.
Failure to do so may result in machine damage when the power is applied.
11. Perform the Test After Switch Board or
V300-PRO
F-61 TROUBLESHOOTING & REPAIR
OUTPUT DIODE REPLACEMENT PROCEDURE (cont.)
FIGURE F.32 - RECTIFIER ASSEMBLY WITH DIODE MODULES
F-61
PROCEDURE (Diode Modules)
1. Turn main power OFF.
2. Perform Input Filter Capacitor Discharge proce-
dure detailed in Maintenance section..
3. Detach and remove both Switch Board assemblies
and attached capacitors. See Switch Board
Removal and Replacement procedure
4. Detach the fan shroud to gain access to the diode heat sink and mounting bracket. When the fan shroud is lifted, the tabs securing the heat sink mounting bracket will release.
5. Move the diode heat sink and mounting bracket away from the Case Back.
6. Disconnect the leads from the defective Module and remove the module from the heat sink.
7. Mount the new module and re-connect the leads.
IMPORTANT: The replacement module will come with an instruction sheet that addresses surface preparation, torque values and hardware changes.
Failure to follow these instructions may result in subsequent breakdown.
8. Reassemble the unit being careful to use all of the.
insulating materials. Also make certain to replace all disconnected leads in their proper location.
Failure to do so may result in machine damage when the power is applied.
9. Perform the Test After Switch Board or Capacitor
V300-PRO
F-62 TROUBLESHOOTING & REPAIR F-62
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.
NOTE: 50 Hz machines may be tested using 60 Hz power.
INPUT IDLE AMPS AND IDLE WATTS
Input
Volts/Hertz
220/50 or 60
230/60
440/50 or 60
460/60
380/50 or 60
575/60
2.75
3.00
1.38
1.50
1.67
—
Single Phase
Max. Amps
OCV at rated INPUT: V300-PRO, V300-I
Max. Watts
425
450
425
450
425
—
Three Phase
Max. Amps Max. Watts
2.75
3.00
425
450
60-75V
MAXIMUM ACCEPTABLE OUTPUT AMPS (AT MINIMUM OUTPUT SETTINGS)
Output
Min. (Max. acceptable), all machines:
CC modes
CV modes
12A @ 10V.
20A @ 19V.
(GTAW, SOFT, CRISP)
(FCAW, GMAW)
OUTPUT MINIMUM ACCEPTABLE VOLTS (AT MAXIMUM OUTPUT SETTINGS,
WITH FULL LOAD)
Min. Acceptable,
Max. — All Modes
1 phase @ 200A
3 phase @ 300A
380V
—
32V
V300-I
220/440V
38V
36V
208V
—
34V
V300-PRO
230/460V
38V
38V
575V
36V
36V
AUXILIARY TRANSFORMER — 50 Hz or 60 Hz
TEST POINTS
18 VAC winding to Power Board J7 pins 5 and 6 Welding terminals sw. remote
24 VAC winding to Control Board J2 pin 4 to lead 212
STANDARD CODES: (Test at Amphenol)
24 VAC without load, measure across pins C and D
42 VAC without load, measure across pins I and K
115 VAC without load, measure across pins A and J
RANGE
17-20 VAC
23-26.5 VAC
22-25 VAC
39-44 VAC
109-120 VAC
V300-PRO
Section G-1 TABLE OF CONTENTS
-
ELECTRICAL DIAGRAMS
SECTION -
Section G-1
Electrical Diagrams ...............................................................................................Section G
* NOTE: Many PC Board Assemblies are now totally encapsulated and are therefore considered to be unserviceable. The Assembly drawings are provided for reference only.
V300-PRO
G-2
WIRING DIAGRAM - ENTIRE MACHINE - CODE 9825 & 9965 (L8657)
ELECTRICAL DIAGRAMS
311
275F
313
306
1 2 3 4
J8
PROTECTION
BOARD
J15
52
14
53
51
H5
1
2
3
4
5
6
52
14
53
51
H5
314
316
315
317
N.F.
52
7500
25W
14
53
N.G.
9A
9A
R7
25
25W
25
25W
R6
2200 F
450V
C2 +
12A
12A
9
-
402, 404
+
SWITCH
BOARD
(LEFT)
401, 403
12
R W R W
4, 5
1, 8
4
1
INPUT
PER
N.A.
R
B
S1
POWER
OFF ON
W
U
INPUT
RECTIFIER
D13
H1
H1
AC1
TP1
9C 9D
+
V
W
AC2
TP3
AC3
TP2
-
G
H5
A
12C 12D
3 AMP
SLOW
BLOW
REMOTE
OUTPUT
CONTROL
MIN
75
77
31
110/115
VAC
42
VAC
32
{
41
42
2
TRIGGER
76
4
G
A
I
K
C
F
E
J
D
A
A
75
76
77B
212
32
212
42
212C
223B
S7
RECONNECT
9B
9C 9B
12C
12A
12A
9B 12A
9D
9A
12B
12D
CR1(N0)
CR2(N0)
CR3(N0)
CR4(N0)
J16
1 2 3 4 5 6
63 2 5 1
DRIVER
BOARD
J9
3 6 2 5 4
J10
1
4
314 315
317 316
51
N.H.
N.F.
H1 H3
FAN
MOTOR
CB2
2AMP
7500
25W
32A
CB1
6AMP
42A
N.D.
A
N.G.
9B
9B
R5
25
25W
25
25W
R4
2200 F
450V
C1 +
12B
12B
H1
J13
1
200-
208V
H3
220-
230V
H2
H3
4
2
9
-
W R
4, 5
+
W R
402, 404
401, 403
SWITCH
BOARD
(RIGHT)
12
H1
H2
H3
18V
110V
4
6
1
J12
504
501
32A
1, 8
H4
H4 3
380-
415V
440-
460V
H6 6
H5
42V
5
24V
3
0V
2
42A
503
212D
J11
1 3 2 4
309
308 310
5
8
T3
CURRENT
TRANSFORMER
I
YY
I
FAN
THERMOSTAT
N.C.
81
82
21
GND
SPARE
M
L
H
B
N
21
GND
211B
+
S6
-
285
229
WIRE FEEDER
WELDING
POLARITY
SWITCH
T1
AUXILIARY
TRANSFORMER
224
212C
212A
150 5W
210
WIRE
FEEDER
REMOTE
CONTROL
RECEPTACLE
T2
MAIN
TRANSFORMER
S
L2
RIGHT
F
10
2W 4
F
TOP
OUTSIDE
S
S
BOTTOM
INSIDE
1
F
F
BOTTOM
AUX
S
F
BOTTOM
S
10
2W
307
308
309
310
501
504
5
BOTTOM
F
OUTSIDE
S
S
TOP
INSIDE
8
F
311
313
S
TOP
F
S
TOP
AUX
F
S
L1
LEFT
F
10
2W
10
2W
N.E.
1
3
5
6
2
4
7
8
POWER
BOARD
J7
1
2
3
4
J14
J6
2
7
6
3
8
1
4
5
9
10
D12
C7
R13
.001/400
.001/400
R3
C4
D11
D10
D9
D8
D7
N.E.
D1
D2
D3
D4
D5
C3
R2
.001/400
.001/400
R10
C8
D6
305
301
302
303
304
275D
211A
211B
212B
212D
CHOKE
THERMOSTAT
224 503A
220
204A
76
203
206
211A
223A
227
213
214
225
226
275F
275D
301
302
305
303
304
400A
SHUNT
L3
CHOKE
229
TP5
250
25W
286
B W
2
3
1
5
6
4
7
8
1
10
5
3
4
12
11
2
9
6
8
7
J4
J5
J3
6
14
4
11
10
5
9
1
2
8
13
12
7
3
J1
J2
2
1
4
2
1
3
CONTROL
BOARD
TP4
W
B
C5
TP6
229
229
C6
502
229
228
207
208
276
218
75
77A
215
306
Y
Y
210
275A
285
204C
220
203
215
206
204A
204B
213
218
77B
77A
276
275C
275B
275A
228
204B
204C
207
208
214
275B
225
226
227
275C
+5
GND
DPC
DP1
IN(+)
IN(-)
212A
212B
223B
223A
502
503
503A
Y
1
2
5
4
3
V
A
CW (MAX)
10K
2W
LOCAL
REMOTE
CW (MAX)
10K
2W
+ ARC
- ARC
CC GTAW
CC SOFT
CC CRISP
CV FCAW
CV GMAW
ON
REMOTE
S5
METER
FUNCTION
SWITCH
S2
MODE
SWITCH
R11
OUTPUT
CONTROL
S3
LOCAL/REMOTE
SWITCH
R12
ARC FORCE
/INDUCTANCE
CONTROL
S4
OUTPUT
TERMINAL
SWITCH
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
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.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
N.E. D1 THRU D5 OUTPUT DIODES ARE A MATCHED SET.
D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET.
N.F. R1, R9 BLEEDER RESISTORS ARE A MATCHED SET.
N.G. C1, C2 CAPACITORS ARE A MATCHED SET.
N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
CONNECTION SHOWN I S F OR 380-460V OPERATION.
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
Y = YELLOW
J3
J6
J2, J8
J11, J14
J9, J10, J12
J13, J15, J16
J4
S4
OUTPUT TERMINAL SWITCH
J1, J7
S3
LOCAL/REMOTE SWITCH
R11
OUTPUT CONTROL
J5
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
ELECTRICAL SYMBOLS PER E1537 CONTROL PANEL
LAYOUT
S5
METER FUNCTION SWITCH
R12
ARC FORCE/INDUCTANCE CONTROL
9-11-92
L8657
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
G-2
V300 PRO
G-3
WIRING DIAGRAM - ENTIRE MACHINE CODE 9934 (L8841)
ELECTRICAL DIAGRAMS
311
275F
313
306
N.F.
1 2 3 4
J8
PROTECTION
BOARD
J15
52
14
53
51
H5
1
2
3
4
5
6
52
14
53
51
H5
314
316
315
317
14
52
10K
25W
53
R7
25
25W
25
25W
R6
13
C2
C3
9A
9A
+
+
12A
912
-
9
+
402, 404
13,15
SWITCH
BOARD
(LEFT)
401, 403
W
12
R R W
4, 5
1, 8
4
1
T2
MAIN
TRANSFORMER
4
F
TOP
OUTSIDE
S
S
BOTTOM
INSIDE
1
F
S
L2
RIGHT
F
BOTTOM
AUX
S
F
BOTTOM
S
F
10
2W
10
2W
D12
R13
.001/400
.001/400
R3
C7
C4
D11
D10
D9
D8
D7
400A
SHUNT
L3
CHOKE
229
250
TP5
25W
B W
286
TP4
C5
TP6
C6
INPUT
PER
N.A.
POWER
OFF ON
W
U
R
V
S1
INPUT
RECTIFIER
D13
H1
H1
H5
AC1
TP1
9D
AC2
TP3
+
9D
9A
12B
12D
CR1(N0)
CR2(N0)
CR3(N0)
CR4(N0)
J16
1 2 3 4 5 6
63 2 5 1
DRIVER
BOARD
J9
3 6 2 5 4
J10
1
4
1
J11
3 2 4
B
G
W
H6
AC3
TP2
-
314 315
317 316
307
308
309
310
T3
CURRENT
TRANSFORMER
I
12D
10K
25W
N.F.
R5
25
25W
15
C1
912
9B
+
9
+
W R
402, 404
13,15
W R
4, 5
SWITCH
BOARD
(RIGHT)
5
YY
I
C4
+
51
-
1, 8 8
25
25W
R4 401, 403
REMOTE
OUTPUT
CONTROL
76
77
31
110/115
VAC
42
VAC
32
{
41
42
2
TRIGGER
MIN
75
4
81
82
21
GND
SPARE
G
F
E
J
K
C
A
I
D
75
76
77B
212
32
212
42
212C
223B
FAN
H1
MOTOR
CB2
2AMP
32A
CB1
6AMP
42A
+
-
H3
H1
12B
12B
J13
H3
220-
230V
575V
H6
1
2
6
H1
H3
H5
12
18V
110V
42V
24V
0V
1
4
6
5
3
2
T1
AUXILIARY
TRANSFORMER
J12
504
501
32A
42A
503
212D
212C
212A
FAN
THERMOSTAT
307
308
309
310
501
504
311
313
N.C.
M
L
H
B
N
21
GND
211B 285
229
S6
WIRE FEEDER
WELDING
POLARITY
SWITCH
224
150 5W 210
NOTES:
N.A.
WIRE
FEEDER
REMOTE
CONTROL
RECEPTACLE
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.E. D1 THRU D5 OUTPUT DIODES ARE A MATCHED SET.
D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET.
COLOR CODE:
B = BLACK
G = GREEN
R = RED
N.F. C1, C2, C3, C4 CAPACITORS ARE A MATCHED SET.
W = WHITE
Y = YELLOW
5
BOTTOM
F
OUTSIDE
S
S
TOP
INSIDE
8
F
3
4
2
1
1
3
4
5
6
7
8
2
S
TOP
F
S
TOP
AUX
F
S
L1
LEFT
F
POWER
BOARD
J7
J14
J3
J6
J6
10
2W
10
2W
4
5
8
1
2
7
6
3
9
10
N.E.
N.E.
D1
D2
D3
D4
D5
C3
R2
.001/400
.001/400
R10
C8
J2, J8
J11, J14
D6
305
301
302
303
304
275D
211A
211B
212B
212D
J4
CHOKE
THERMOSTAT
224
J9, J10, J12
J13, J15, J16
220
204A
76
203
206
211A
223A
227
213
214
225
226
275F
275D
301
302
305
303
304
503A
12
11
2
9
6
8
5
3
4
1
10
7
2
7
8
6
4
3
1
5
J4
J5
J3
J1
J2
CONTROL
BOARD
1
2
8
13
12
7
3
6
14
4
11
10
5
9
4
2
1
3
2
1
502
229
228
207
208
276
218
75
77A
215
Y
Y
210
275A
S4
OUTPUT TERMINAL SWITCH
J1, J7
S3
LOCAL/REMOTE SWITCH
J5
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
ELECTRICAL SYMBOLS PER E1537
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
W
B
306
R11
OUTPUT CONTROL
229
229
285
204C
220
214
275B
225
226
227
275C
203
215
206
204A
204B
213
218
77B
77A
276
275C
275B
275A
228
204B
204C
207
208
212A
212B
223B
223A
502
503
503A
Y
1
2
5
4
3
V
A
+5
GND
DPC
DP1
IN(+)
IN(-)
CW (MAX)
10K
2W
LOCAL
CC GTAW
CC SOFT
CC CRISP
CV FCAW
CV GMAW
REMOTE
CW (MAX)
10K
2W
+ ARC
- ARC
ON
REMOTE
CONTROL PANEL
LAYOUT
S5
METER
FUNCTION
SWITCH
S2
MODE
SWITCH
R11
OUTPUT
CONTROL
S3
LOCAL/REMOTE
SWITCH
R12
ARC FORCE
/INDUCTANCE
CONTROL
S4
OUTPUT
TERMINAL
SWITCH
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
MODE SWITCH
S5
METER FUNCTION
SWITCH
R12
ARC FORCE/INDUCTANCE
CONTROL
9-11-92
L8841
CLEVELAND, OHIO U.S.A.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
G-3
V300 PRO
G-4
WIRING DIAGRAM - ENTIRE MACHINE CODE 10034 (L9299)
ELECTRICAL DIAGRAMS
311
275F
313
306
1 2 3 4
J8
PROTECTION
BOARD
J15
52
14
53
5
6
3
4
51
H5
1
2
52
14
53
51
H5
314
316
315
317
N.F.
52
7500
25W
14
53
N.G.
9A
9A
R7
25
25W C2 +
25
25W
R6
2200 F
450V
12A
12A
9
-
402, 404
+
SWITCH
BOARD
(LEFT)
401, 403
12
R W R W
4, 5
1, 8
4
1
INPUT
PER
N.A.
REMOTE
OUTPUT
CONTROL
S1
POWER
OFF ON
W
U
INPUT
RECTIFIER
D13
H1
H1
A
9C
TP1
D +
9D
9D
R
V
H5
B
G
W
A
C
B
TP3
TP2
F -
12C
12D
12D
76
77
31 110/115
VAC
42
VAC
{
32
41
42
2
TRIGGER
N.C.
3 AMP
SLOW
BLOW
MIN
75
4
81
82
21
GND
SPARE
A
A
G
A
I
K
C
F
E
J
D
M
L
H
B
N
75
76
77B
212
32
212
42
212
212C
223B
21
GND
211B
51
309 310 309 310
307 308
9A
CR1 CR2
9D
12B
12D
S7
RECONNECT
9C
12C
9B
9B
9B
12A
12A
12A
N.H.
N.F.
7500
25W
N.G.
9B
9B
R5
25
25W
25
25W
R4
2200 F
450V
C1 +
12B
12B
DRIVER
BOARD
J16
1 2 3 7
314
315
52
12B
9D
12D
317
316
9
63 25 1
8 12 13 14
+
W
402, 404
-
J10
R W
4
3
J9
1 2 3 4
J11
6 2 5 4
R
4,5
401, 403
SWITCH
BOARD
(RIGHT)
1, 8
12
1
H1 H3
H1
J13
1
H1
1
J12
504
200-
208V
FAN
MOTOR
CB2
2AMP
H3
220-
230V
H2
H3
4
2
H2
H3
18V
110V
4
6
501
32A
32A
CB1
6AMP
42A
N.D.
A
380-
415V
440-
460V
H4
H6
+
-
285
229
S6
WIRE FEEDER
WELDING
POLARITY
SWITCH
3
6
H4
H5
42V
5
24V
3
0V
2
T1
AUXILIARY
TRANSFORMER
42A
224
212C
212A
5
8
T3
CURRENT
TRANSFORMER
FAN
THERMOSTAT
150 5W
YY
210
WIRE
FEEDER
REMOTE
CONTROL
RECEPTACLE
503
212D
I
I
T2
MAIN
TRANSFORMER
S
L2
RIGHT
F
4
F
TOP
OUTSIDE
S
S
BOTTOM
INSIDE
1
F
F
BOTTOM
AUX
S
F
BOTTOM
S
10
2W
10
2W
307
308
309
310
501
504
311
313
5
F
BOTTOM
OUTSIDE
S
S
TOP
INSIDE
8
F
S
TOP
F
S
TOP
AUX
F
S
L1
LEFT
F
10
2W
10
2W
7
8
1
3
5
6
2
4
POWER
BOARD
J7
J6
2
8
1
4
7
6
3
5
9
10
1
2
3
4
J14
N.E.
N.E.
D1
D2
D3
D4
D5
C3
R2
.001/400
.001/400
R10
C8
D6
D12
C7
R13
.001/400
.001/400
R3
C4
D11
D10
D9
D8
D7
305
301
302
303
304
275D
211A
211B
212B
212D
275F
275D
301
302
305
303
304
220
204A
76
203
206
211A
223A
227
213
214
225
226
400A
SHUNT
L3
CHOKE
B W
229
250
25W
286
CHOKE
THERMOSTAT
224 503A
7
8
6
4
2
3
1
5
6
8
7
11
2
9
1
10
5
3
4
12
J4
J5
J3
2
1
1
2
8
13
12
7
3
6
14
4
11
10
5
9
J1
J2
1
4
3
2
CONTROL
BOARD
TP4
W
B
502
229
228
207
208
276
218
75
77A
215
306
Y
Y
210
275A
C5
TP6
229
229
C6
285
+ ARC
- ARC
204C
220
V
A
214
275B
225
226
227
275C
+5
GND
DPC
DP1
IN(+)
IN(-)
S5
METER
FUNCTION
SWITCH
203
215
206
204A
204B
213
218
77B
77A
276
275C
275B
275A
1
2
5
4
3
CW (MAX)
10K
2W
CC GTAW
CC SOFT
CC CRISP
CV FCAW
CV GMAW
LOCAL
REMOTE
228
204B
204C
207
208
CW (MAX)
10K
2W
S2
MODE
SWITCH
R11
OUTPUT
CONTROL
S3
LOCAL/REMOTE
SWITCH
R12
ARC FORCE
/INDUCTANCE
CONTROL
212A
212B
223B
223A
502
ON
REMOTE
S4
OUTPUT
TERMINAL
SWITCH
503
503A
Y
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
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.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
N.E. D1 THRU D5 OUTPUT DIODES ARE A MATCHED SET.
D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET.
N.F. R1, R9 BLEEDER RESISTORS ARE A MATCHED SET.
N.G. C1, C2 CAPACITORS ARE A MATCHED SET.
N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 380-460V OPERATION.
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
Y = YELLOW
J3
J6
J2, J8
J11, J14
J9, J10, J12
J13, J15
J4
J1, J7
J5, J16
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
ELECTRICAL SYMBOLS PER E1537
S4
OUTPUT TERMINAL
SWITCH
S3
LOCAL/REMOTE
SWITCH
R11
OUTPUT CONTROL
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
CONTROL PANEL
LAYOUT
S2
MODE SWITCH
S5
METER FUNCTION
SWITCH
R12
ARC FORCE/INDUCTANCE
CONTROL
12-2-93L
CLEVELAND, OHIO U.S.A.
L9299
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
G-4
V300 PRO
G-5
WIRING DIAGRAM - ENTIRE MACHINE CODE 10035 (L9301)
ELECTRICAL DIAGRAMS
311
275F
313
306
N.F.
1 2 3 4
J8
PROTECTION
BOARD
J15
52
14
53
5
6
3
4
51
H5
1
2
52
14
53
51
H5
314
316
315
317
52
14
10K
25W
53
R7
25
25W
25
25W
R6
9A
9A
C2
+
13
C14
+
12A
912
9
4, 5
+
402, 404
13,15
-
401, 403
W
12
R
SWITCH
BOARD
(LEFT)
R W
1, 8
4
1
INPUT
PER
N.A.
S1
POWER
OFF ON
W
U
INPUT
RECTIFIER
D13
H1
H1
A
TP1
9D
D +
R
V
B
G
W
H5
H6
B
TP3
C
TP2
F -
9D
12B
9A
309 310
9D
CR1
63 25 1
DRIVER
BOARD
J16
J10
1 2 3 7 8 12 13 14
4
3
J9
1 2 3 4
J11
6 2 5 4 1
314
315
9D
52
317
316
307 308
T3
CURRENT
TRANSFORMER
N.F.
R5
25
25W
912
9B
C1
+
9
W
+
402, 404
13,15
R W
SWITCH
BOARD
(RIGHT)
R
4,5
10K
25W
15
C15
+
REMOTE
OUTPUT
CONTROL
MIN
75
76
77
31
110/115
VAC
42
VAC
{
32
41
42
2
TRIGGER
4
G
F
E
J
75
76
77B
212
A
I
K
C
32
212
42
D
212C
223B
FAN
MOTOR
CB2
2AMP
51
H1 H3
32A
CB1
6AMP
42A
25
25W
R4
12B
12B
H1
J13
1
H1
-
401, 403
12
1
J12
504
H3
220-
230V
2
H3
575V
H6 6
H5
18V
110V
4
6
42V
5
24V
3
0V
2
N.C.
81
82
21
GND
SPARE
M
L
H
B
N
21
GND
211B
+
-
285
229
S6
WIRE FEEDER
WELDING
POLARITY
SWITCH
T1
AUXILIARY
TRANSFORMER
WIRE
FEEDER
REMOTE
CONTROL
RECEPTACLE
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.E. D1 THRU D5 OUTPUT DIODES ARE A MATCHED SET.
D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET.
N.F. C1, C2, C14, C15 CAPACITORS ARE A MATCHED SET.
501
32A
42A
503
212D
1, 8
224
5
8
212C
212A 150 5W
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
Y = YELLOW
YY
I
FAN
THERMOSTAT
210
I
T2
MAIN
TRANSFORMER
4
F
TOP
OUTSIDE
S
S
BOTTOM
INSIDE
1
F
L2
RIGHT
S
F
BOTTOM
AUX
S
F
F
BOTTOM
S
10
2W
10
2W
307
308
309
310
501
504
311
313
5
F
BOTTOM
OUTSIDE
S
S
TOP
INSIDE
8
F
J3
J6
S
TOP
F
S
TOP
AUX
F
S
L1
LEFT
10
2W
F
10
2W
1
3
5
6
2
4
7
8
3
4
1
2
J14
POWER
BOARD
J7
J6
9
10
4
5
8
1
2
7
6
3
J4
D12
C7
R13
.001/400
.001/400
R3
C4
D11
D10
D9
D8
D7
N.E.
N.E.
D1
D2
D3
D4
D5
C3
R2
.001/400
.001/400
R10
C8
D6
305
301
302
303
304
275D
211A
211B
212B
212D
J2, J8
J11, J14
J9, J10, J12
J13, J15
275F
275D
301
302
305
303
304
220
204A
76
203
206
211A
223A
227
213
214
225
226
J1, J7
J5, J16
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
ELECTRICAL SYMBOLS PER E1537
400A
SHUNT
L3
CHOKE
CHOKE
THERMOSTAT
224 503A
229
250
TP5
25W
286
B W
7
8
6
4
2
3
1
5
6
8
7
11
2
9
1
10
5
3
4
12
J4
J5
J3
14
4
11
10
7
3
6
1
2
8
13
12
5
9
J1
J2
2
1
1
4
3
2
CONTROL
BOARD
TP4
W
B
C5
TP6
C6
502
229
228
207
208
276
218
75
77A
215
306
Y
Y
210
275A
S4
OUTPUT TERMINAL
SWITCH
S3
LOCAL/REMOTE
SWITCH
R11
OUTPUT CONTROL
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
229
229
285
204C
220
203
215
206
204A
204B
213
218
77B
77A
276
275C
275B
275A
212A
212B
223B
223A
502
228
204B
204C
207
208
214
275B
225
226
227
275C
+5
GND
DP1
IN(+)
IN(-)
503
503A
Y
1
2
5
4
3
V
A
CW (MAX)
10K
2W
LOCAL
REMOTE
CW (MAX)
10K
2W
+ ARC
- ARC
CC GTAW
CC SOFT
CC CRISP
CV FCAW
CV GMAW
ON
REMOTE
CONTROL PANEL
LAYOUT
S5
METER
FUNCTION
SWITCH
S2
MODE
SWITCH
R11
OUTPUT
CONTROL
S3
LOCAL/REMOTE
SWITCH
R12
ARC FORCE
/INDUCTANCE
CONTROL
S4
OUTPUT
TERMINAL
SWITCH
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
S2
MODE SWITCH
S5
METER FUNCTION
SWITCH
R12
ARC FORCE/INDUCTANCE
CONTROL
12-2-93L
CLEVELAND, OHIO U.S.A.
L9301
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
G-5
V300 PRO
G-6
WIRING DIAGRAM - ENTIRE MACHINE CODE 10130 (L9567)
ELECTRICAL DIAGRAMS
G-6
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
V300 PRO
G-7
WIRING DIAGRAM - ENTIRE MACHINE CODE 10131 (L9569)
ELECTRICAL DIAGRAMS
G-7
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
V300 PRO
G-8
WIRING DIAGRAM - ENTIRE MACHINE CODE 10256 (L10189)
ELECTRICAL DIAGRAMS
G-8
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
V300 PRO
G-9
WIRING DIAGRAM - ENTIRE MACHINE - CODE 10257 (L10191)
ELECTRICAL DIAGRAMS
G-9
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
V300 PRO
G-10 G-10
ELECTRICAL DIAGRAMS
SCHEMATIC - ENTIRE MACHINE
SCHEMATIC DIAGRAM FOR TROUBLESHOOTING INVERTEC V300-PRO
208 207
10K
2W
R12
CW (MAX)
R12
ARC FORCE
/INDUCTANCE
CONTROL
INPUT
}
B
G
S1
POWER
W
OFF ON
R
FAN
MOTOR
H1
H1
H5
H3
212A 212B 223B 223A
ON REMOTE
S4
OUTPUT
TERMINAL
SWITCH
A
AC1
TP1
H1
TP3
AC2
H5
A
A
TP2
AC3
D13
INPUT
RECTIFIER
-
+
12D
12C
3 AMP
SLOW
BLOW
S7
RECONNECT
SWITCH
9C
12C
9B
9C
9D
9B
9B
12A
12A
12A
H5
51
53
14
52
BH5 B51 B53 B14 B52
PROTECTION
BOARD
J8
J15
5
6
3
4
1
2
3
4
1
2
275A 275B 275C
10K
2W
276 77A 77B
1
R11
CW (MAX)
R11
OUTPUT
CONTROL
306
52
7500
25W
14
53
R7
9A
9A
25
25W
C2 +
25
25W
R6
2200 F
450V
12A
12A
9
402, 404
4, 5
+
-
401, 403
R W
12
SWITCH
BOARD
(LEFT)
1, 8
RW
15
4
1
T2
MAIN
TRANSFORMER
4
F
TOP
OUTSIDE
BOTTOM
INSIDE
1
F
S
S
S
L2
RIGHT
S
F
BOTTOM
AUX
S
F
10
2W
10
2W
R13
R3
D12
C7
C4
D11
D10
D9
D8
D7
J3
J6
J2, J8
J11, J14
J9, J10, J12
J13, J15, J16
J4
J1, J7
J5
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
ELECTRICAL SYMBOLS PER E1537
B = BLACK
G = GREEN
COLOR CODE:
R = RED
W = WHITE
Y = YELLOW
SOLDERED CONNECTION
QUICK CONNECTION
5
9
311
275F
313
306
314
316
315
317
7
7500
25W
51
9A
9D
12D
12B
+
-
9
W R
402, 404
401, 403
W R
4, 5
SWITCH
BOARD
(RIGHT)
12
1, 8
307 308 309 310 T3
CURRENT
TRANSFORMER
I
8
5
YY
I
A
H1
J13
1
200-
208V
H2 4
2
H3
220-
230V
H3
380-
415V
H4 3
H4
H1
H2
H3
440-
460V
H6
6
H6
18V
110V
4
6
1
J12
504
501
32A
42V
5
24V
3
0V
2
42A
503
212D
T1
AUXILIARY
TRANSFORMER
4
J5
1 2
208 207 276 77A
314 317 315 316
13 6
214 275B 225 226 227 275C
+5 GND DPC DP1 IN(+) IN(-)
63 25 1 4
J9
J10
3 6 2 5 4 1
11
CONTROL BOARD
14 8
3
11 7
LOCAL REMOTE
3 CC SOFT
SINGLE LINE CR2(N0)
CR1(N0)
CR4(N0)
CR3(N0)
J16
1 2 3 4 5 6
9B
9B
R5
25
25W
25
25W
R4
2200 F
450V
C1 +
12B
12B
METER
228 204B 204C
S3
LOCAL/REMOTE
SWITCH
1
DRIVER
BOARD
J11
3 2
16
4
8
D1
D2
D3
D4
5
BOTTOM
F
OUTSIDE
S
TOP
INSIDE
S
8
F
S
D5
L1 S
LEFT
TOP
F
S
TOP
F
AUX
F
10
2W
10
2W
C3
R2
.001/400
.001/400
R10
C8
D6
6
8
2
307
308
309
310
504
501
311
313
7
8
2
4
6
1
3
5
}
J7
13
10
12
2
3
4
1
}
J14 10 9
POWER
BOARD
2
14
7
11
J6
6 3 8 1 4 5
9
J4
4
212D
212B
275F
3
2
10
3
305
1
4
301 302 303 304 275D
5
5 6
12
J1
7 8
45
2 4
1
J2
J3
}
211B
211A
1
2
2
7
1
6
3
B
W
502 228 218 215 75 229 223A 226 225 214 227 213 206 203 204A 220 76 211A
213
5
218 204B 204A
215
206 1
CV GMAW
4
2
CC GTAW
203
CV FCAW
CC CRISP
S2
MODE
SWITCH
275A 210
204C 220
V
A
S5
METER
FUNCTION
SWITCH
Y
L3
CHOKE
400A
SHUNT
B W
285
229
229
229
250
25W TP5
286
TP4
285 21 229
-
S6
WIRE FEEDER
WELDING
POLARITY
SWITCH
210
C5
C6
FAN
THERMOSTAT
CHOKE
THERMOSTAT
224
150 5W 503A
502
Y
212C 212A
503
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
TP6
503A
+ ARC
REMOTE
CONTROL
RECEPTACLE
MULTI LINES
- ARC
TEST
POINT
1
LOCATION
R11
2
3
4
5
1J3 & 2J3
8J5 & 2J1
7J1 & 1J1
8J1 & 1J1
WIRE
NUMBERS
175/176
B/W
229/275F
303/275D
304/275D
Y/Y
210/223A
214/275D
311/313
501/504
VOLTAGE
0 - 4.5 V DC
0 V AT 0 AMP
50 mV AT 400 AMP
LINEAR FEEDBACK
OUTPUT FEEDBACK
13 V DC
NO LOAD
8 V DC
FULL LOAD
13 V DC
NO LOAD
8 V DC
FULL LOAD
5 V AC
24 V AC
5 V DC
1 V DC
18 V AC 10
11
6
7
8
9
1J2 & 3J2
4J2 & 11J4
6J4 & 1J1
1J8 & 3J8
5J7 & 6J7
6J6 & 1J6
12
13
14
15
7J7 & 1J6
8J7 & 1J6
307/275D
308/275D
2J6 & 7J6
SW BOARDS
305/301
R/W
.75 V DC
NO LOAD
6 V DC
FULL LOAD
.75 V DC
NO LOAD
6 V DC
FULL LOAD
1 V DC
.75 V DC
NO LOAD
24 V DC 16 2J11 & 4J11
32A
42A
CB2
2AMP
CB1
6AMP
309/310
32
212
42
212
223B
212
212C
21
GND
211B
75
M
L
H
B
N
G
A
J
I
K
D
C
76
77B
F
E
32
31
42
41
4
2
81
82
21
GND
SPARE
75
MIN
76
77
{
{
{
110/115
VAC
42
VAC
TRIGGER
WIRE
FEEDER
} REMOTE
OUTPUT
CONTROL
DAD 5 2 09 4
V300 PRO SCH
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
V300 PRO
G-11
SCHEMATIC - DRIVER PC BOARD - (S20216)
ELECTRICAL DIAGRAMS
G-11
FROM (-) RIGHT SWITCH BOARD
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
TO (-) INPUT RECTIFIER
V300 PRO
G-12
PC BOARD ASSEMBLY - DRIVER - (L8660-[])
R13
R14
ELECTRICAL DIAGRAMS
DZ1
Q1
DZ2
Q2
J16
G-12
Item
CR1, CR2, CR3, CR4
D1
DZ1, DZ2
J9, J10, J16
J11
Identification
RELAY, SPNO 24VDC 6000 ohms
AG-CDO
DIODE, AXLDS 1A 400V
DIODE, Zener 1W 12V 5%
1N4742A
CONNECTOR, Molex mini PCB
6 pin
CONNECTOR, Molex mini PCB
4 pin
PLUG, Molex mini 6 pin P9, P10, P16 (plugs into
J9, J10, J16)
P11 (plugs into J11)
Q1, Q2
R1, R2, R13, R14
R3, R4, R5, R6, R8, R9,
R7, R12
T1
PLUG, Molex mini 4 pin
TRANSISTOR, NMFT247 4A 900V
RESISTOR, WW 20W 5% 250K
RESISTOR, MF .25W 1% 150K
RESISTOR, MF .25W 1% 100K
TRANSFORMER, PCB
NOTE: Individual parts listed are not available from Lincoln Electric.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
V300 PRO
G-13
SCHEMATIC - DRIVER PC BOARD (S20799)
ELECTRICAL DIAGRAMS
G-13
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
V300 PRO
G-14
PC BOARD ASSEMBLY - DRIVER - (9134-[ ])
XXXX XXXX
ELECTRICAL DIAGRAMS
XXXX XXXX
DRIVER L9134
XXXX
XXXX XXXX XXXX XXXX
Item
J11
J9,J10
T1
J16
R1,R2,R13,R14
DZ1,DZ2
Q1,Q2
R7,R12
R3,R4,R5,R6,R8,R9,
R10,R11
Description
HEADER
HEADER
TRANSFORMER
HEADER
20 WATT 250 OHM RESISTOR
1N4742A
FET (SS)
100 1/4W
150K 1/4W
XXXX
G-14
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
V300 PRO
G-15
SCHEMATIC - SWITCH PC BOARD (L8440)
ELECTRICAL DIAGRAMS
W
D2
1N4936
C1
D4
1N4936
100
22.1K
R16
1.00K
DZ5
3.3V
1W
D5
1N4936
1.00K
221
Q2
1A
100V
IRFD110
Q7
600m A
40V
2N4403
6.2V
DZ6
1W
Q3
1A
100V
IRFD110
20
Q4
600m A
40V
2N4401
DZ3
10V 1W
1
1/2W
1
1/2W
D3
1N4936
D9
1N4936
DZ1
10V
1W
15.0K
C2
2700p
50V
100
1.50K
47.5
Q5
600m A
40V
2N4403
Q6
600mA
40V
2N4403
B
DZ4
15V
1W
475 475
C7
R8
10.0
R17
10.0
R6
10.0
R9
10.0
R33
10.0
R
W
D6
1N4936
C5
D1
1N4936
100
22.1K
R23
1.00K
DZ8
3.3V
1W
D8
1N4936
1.00K
221
Q1
1A
100V
IRFD110
Q11
600m A
40V
2N4403
6.2V
DZ9
1W
Q10
1A
100V
IRFD110
20
Q12
600mA
40V
2N4401
DZ12
10V 1W
1
1/2W
1
1/2W
D7
1N4936
D10
1N4936
DZ2
10V
1W
15.0K
C8
2700p
50V
100
1.50K
47.5
Q8
600mA
40V
2N4403
Q9
600m A
40V
2N4403
A
DZ7
15V
1W
475 475
C6
R19
10.0
R26
10.0
R25
10.0
R27
10.0
R34
10.0
R
G1
D1 D2 D3 D4 D5
G2
G3
G4
G5
S1 S2 S3 S4 S5
A2
IRFP460
C2
A2
A2
BYT30P600
A1
A2
BYT12P600
C1
9
POSITIVE
INPUT
SNUBBER
RESISTOR
402
---
404
C3
.047
1200V
4
-
5
TRANSFORMER
PRIMARY
R38
39.2K
R41
39.2K
R39
39.2K
R40
39.2K
INP UT
FILTER
CAPACITOR
C2
A2
A1
BYT30P600
G1
D1 D2 D3 D4 D5
G2
G3
G4
G5
S1 S2 S3 S4 S5
A1
IRFP460
1
-
8
TRANSFORMER
PRI M ARY
C4
.047
1200V
401
---
403
A1
C1
A1
BYT12P600
SNUBBER
RESISTOR
12
NEGATIVE
INPUT
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-15
V300 PRO
G-16
PC BOARD ASSEMBLY - SWITCH - (L8441)
ELECTRICAL DIAGRAMS
G-16
Item Description Item Description
A1
A2
B1, B2, B3, B4, B5, B6,
B7, B8, B9, B10, B11,
B12
C1, C5, C6, C7
C2, C8
C3, C4
ELECTRONIC MODULE ASSEMBLY
ELECTRONIC MODULE ASSEMBLY
CONNECTOR, tab QC edge offset
1/4”
CAPACITOR,CEMO .022 50V 20%
CAPACITOR, CEMO 2700P 50V 5%
CAPACITOR-PPF, .047 1200V 5%
DIODE, AXLDS 1A 400V FR 1N4936 D1, D2, D3, D4, D5, D6,
D7, D8, D9, D10
DZ1, DZ2, DZ3, DZ12
DZ4, DZ7
DZ5, DZ6, DZ8, DZ9
Q1, Q2, Q3, Q10
R1, R3, R5, R24
DIODE, Zener 1W 10V 5% 1N4740A
DIODE, Zener 1W 15V 5% 1N4744A
DIODE, Zener 1W 6.2V 5% 1N4735A
TRANSISTOR-NMF, 4PDIP 1A 100V
Q4, Q12
RFD110
TRANSISTOR-N, T226 0.5A 40V
2N4401
Q5, Q6, Q7, Q8, Q9, Q11 TRANSISTOR-P, T226 0.5A 40V
2N4403
RESISTOR-MF, .25W 1% 100 ohm
R2, R4
R6, R8, R9, R17, R19,
R25, R26, R27, R33, R34
R7, R30
R10, R32
R11, R15, R22, R28
R12, R14, R20, R21
R13, R31
R16, R23
R18, R29, R37, R42
R35, R36
R38, R39, R40, R41
RESISTOR-MF, .25W 1% 221 ohm
RESISTOR-MF, .25W 1% 10.0 ohm
RESISTOR-MF, .25W 1% 1.50K ohm
RESISTOR-MF, .25W 1% 15.0K ohm
RESISTOR-CC, .50W 5% 1 ohm
RESISTOR-MF, .25W 1% 1.00K ohm
RESISTOR-MF, .25W 1% 20.0 ohm
RESISTOR-MF, .25W 1% 22.1K ohm
RESISTOR-MF, .25W 1% 475 ohm
RESISTOR-MF, .25W 1% 47.5 ohm
RESISTOR-MF, .25W 1% 39.2K ohm
NOTE: Individual parts listed are not available from Lincoln Electric.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
V300 PRO
G-17
SCHEMATIC - SWITCH PC BOARD (L10956)
ELECTRICAL DIAGRAMS
G-17
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
V300 PRO
G-18
PC BOARD ASSEMBLY - SWITCH - (L10958-1)
ELECTRICAL DIAGRAMS
G-18
6.40
B12 B11 B9 B10 B3
C3
B7 B5 B6 B2 B1
C4
B8 B4
Q3 Q2 Q1 Q10
ITEM REQ'D PART NO.
IDENTIFICATION
C1,C5,C6,C7 4 S16668-5 .022/50
C2,C8 2 S16668-4 2700pF/50
C3,C4 2 S13490-112 .047/1200
D1,D2,D3,D4,D5,D6,D7,D8, 10 T12705-34 1N4936
D9,D10
DZ1,DZ2,DZ3,DZ12 4 T12702-27 1N4740
DZ4,DZ7 2 T12702-29 1N4744A
DZ5,DZ8 2 T12702-53 1N4728A
DZ6,DZ9 2 T12702-40 1N4735
Q1,Q2,Q3,Q10 4 T12704-73 IC PKG MOSFET
Q4,Q12 2 T12704-68 2N4401
Q5,Q6,Q7,Q8,Q9,Q11 6 T12704-69 2N4403
R1,R3,R5,R24 4 S19400-1000 100 1/4W
R2,R4 2 S19400-2210 221 1/4W
R6,R8,R9,R17,R19,R25,R26 10 S19400-10R0 10 1/4W
R27,R33,R34
R7,R30 2 S19400-1501 1.5K 1/4W
R10,R32 2 S19400-1502 15K 1/4W
R11,R15,R22,R28,R43,R44 8 S19400-2R00 2.00 1/4W
R45,R46
R12,R14,R20,R21 4 S19400-1001 1K 1/4W
R13,R31 2 S19400-20R0 20 1/4W
R16,R23 2 S19400-2212 22.1K 1/4W
R18,R29,R37,R42 4 S19400-4750 475 1/4W
R35,R36 2 S19400-47R5 47.5 1/4W
R38,R39,R40,R41 4 S19400-3922 39.2K 1/4W
0
L10958-1 SWITCH
0 8.50
A
11/01/2002
L10958-1
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
V300 PRO
G-19
SCHEMATIC - CONTROL PC BOARD (G2525)
ELECTRICAL DIAGRAMS
+15V
14 Pin
Remote
Control
Receptacle
N
C
D
F
E
G
H
L
M
B
A
I
K
J
E
F
B
C
A
Control
R ecept acl e
D
6 Pi n
Re m o t e
42VAC
115VAC
SOFT (CC)
CRISP (CC)
FCAW (CV)
24VAC F R O M
XFRM
GMAW (CV)
AMPS
VOLTS
D15
D50
D37
J4
9
1
J4
5
7
3
J4
DP1
X9
A
4
8
J4
DPC
TO
METER
J4
2
ACTUAL
8
X8 C
9
6
4.75K
OCV
C67
.022
50V
4.75K
LOCAL
5
J4
REMOTE
OUTPUT
CONTROL
10K
CW
MAX
J5
4
14
J5
D35
3
X8 B
4
R103
56 t
D36
C59
0.1
50V
5
SOFT
SCALING
13
J5
3
J5
2
J2
R100
56 t
4.75K
R104
56 t
1
C61
.022
50V
X7 A
2
C24
.022
50V
10K
C8
.022
50V
+15V
Vref
1
13
X8 A
2
D30
D31
D41
C46
.1
50V
10K
SOFT
ARC FORCE
4.75K
R142
2
X6 A
1
C73
0.1
50V
100K
13
C30
.022
50V
C71
39
20V
D9
C72
100
20V
D38
R133
22.1K
11
X10 D
10
OCV
12
D46
47.5K
R138
26.7K
R137
26.7K
OCV
D39 10K
R141
115VAC, 42VAC are common to 4 P 2
TIG
J4
4
D
10 X8
12
11
VOLTS
C35
.022
50V
D17
J4
3
J5
6
C50
.022
50V
J5
11
R136
33.2K
9
X9 B
8
6 to TEMP.LED
DZ9
5.1V
1W
301
R73
2.67K
AMPS
OCV
OUT P UT
TERMINAL
HOT
REMOTE
3
2
1
4
5
10K
C54
.022
50V
CW
V I
12
J4
2
J5
D51
R144
4
2.67K
J2
150K
150K
R70
26.7K
C39
4.7
35V
22.1K
-
SHUNT
+15V
MODE
SWITCH
10
J4
R101
100
C48
4.7
35V
+
1
J3
2
J3
OCV
J5
8
+ ARC
+ ARC
TIG
R17
+ t
.13
60V
11
J4
R15
56
+ t
10.0
+15V
C74
R139
10K
Vref
R123
100K
CRISP
R118
100K
R125
10K
D20
CURRENT
SETTING
R72
221K
10.0
2.67K
301
10.0
22.1K
SHUNT
AMPLIFIER
R65
C31
.33
50V
475
R77
475
C34
2700p
50V
5
X11 A
6
56.2K
R130
R116
47.5K
7
R140
26.7K
2
X11 B
1
3
22.1K
26.7K
R51
10K
R38
10K
43.2K
DZ11
43V
1W
DZ12
43V
1W
R121
4.75K
2 X10
A
1
FC
13
R35
390
1W
680
2W
301
VOLTAGE
SETTING
R117
332K
68.1K
R122
22.1K
D12
D11
D13
D14
TRIGGER
CIRCUIT
C37
2700p
50V
10K
R84
47. 5K
13
X4
D
12
47.5K
14
TEST PT D
V
I
C11
20
50V
DZ1
3V
500mW
R11
267
Vref
R64
10K
Vref
TO
PROTECTI ON
BOARD
D4
2
1
5
J1
5
OCI1
CNY1 7 - 3
6 4
4
J1
TRIGGER
47.5K
R12
22.1K
C6
.022
50V
R8
10K
+15V
R30
47.5K
R19
332K
OPEN
CIRCUIT
DETECTOR
C60
.022
50V
10K
C27
.022
50V
13
12
X3 B
14
D21 D45
R81
100K
4.75K
D28
+15V
TRI GGER
INTERFACE
C15
.022
50V
47.5K
C4
150p
100V
TRIG
TEST_PT_E
332K
10
9
X3
C
8
10K
R16
332K
V I
SOFT
R109
10K
V
I
392K
C16
.022
50V
3
2
X1 B
C45
.022
50V
1
C51
.022
50V
DZ5
6. 2V
1W
OCV
3
X6 C
4
5 D34 SHORT
CURRENT
CONTROL
AMPLIFIER
R36
150K
C32
.022
50V
R80
681K
OCV
18.2K
DZ4
5.1V
1W
D16
1N914
R3
475K
6
X4
B
C23
150p
100V
7
5
R43
10K
R50
100K
DZ7
10V
1W
+ARC
1
CURRENT
J2
TRANS.
3
J2
PRIMARY
CURRENT
FEEDBACK
D3
1N4936
D7
1N4936
C5
.33
200V
26.7
D2
1N4936
26.7
D1
1N4936
26.7
26.7
10
X9 D
11
4.75K
12
C52
.022
50V
CONTROL
SELECT
CRISP
R124
100K
TIG
D8
12
13
X1 A
R34
100K
14
R33
3.32K
D40
DZ14
5.1V
1W
CRISP
PINCH
CONTROL
825
V
I
D47
4 X10 B 3
CC
5
R39
221K
D33
D10
D48
100K 475K
D19
1N914
R42
475K
9
X4
330p
C22
50V
C
8
10
DZ3
3V
500mW
475K
GMAW
98
X10 C
SET
6
C68
2.7
50V
OCV
J5
12
11 X5 B 10
12
PRESET
TO
METER
DZ13
5.1V
1W
OCV TRIG
8
A
X5
6
9
10K
CW
D42
D52
Vr ef
C10
1.8
20V
11 X6 B 10
12
R87
10K
33.2K
C43
2.7
50V
D26
7
J5
R63
1.00K
ARC FORCE/PINCH
9
6
X6 D
8
R86
221K
1
C41
0.1
50V
X4 A
2
3
R66
150K C38
.022
50V
DZ8
3V
500mW
D23
1N5818
C65
4.7
35V
3
X5 D
4
22.1K
FCAW
5
C64
.022
50V
D22
AMPLIFIER
R10
475K
R52
221K
681K
GMAW
4.75K
1
X9
C
2
13
VOLTAGE
CONTROL
DZ6
1W
5.1V
Vref
1
1/2W
1
1/2W
C3
.022
50V
14
X8
4066B
7
22.1K
56. 2K
C13
330p
50V
C14
.022
50V
R46
10K
CW
R14
5K
X7
HEXTRGR
7
C57
.022
50V 4
X1
LM 224
11
C17
.022
50V
4
X3
LM 224
11
R151
10K
C75
150p
50V
C53
.022
50V
4
X4
LT1014
11
7
J1
J1
8
2.67K
TO DRIVER
BOARD
9
10
C49
.022
50V
14
12
13
X11 D
14
UNUSED
J5
10
3
J1
C19
4.7
35V
C20
.022
50V
4.75K
C63
.022
50V
C36
.022
50V
4.75K
R55
33.2K
+ ARC
R53
33.2K
V
I
332K
Vref
C25
330p
100V
C28
1.0
35V
Vref
R40
100K
D5
6
5
X3 A
7 11
X7
D
10
C26
0.1
50V
R62
8.25K
681K
D18
8
X7 E
9
R74
24.3K
R146
28.0K
Cut out for Std.
-Pro Machines
R1 3
100K
R49
681K
C1
.022
50 V
2
3
X3 D
1
D25
47.5K
OVERCURRENT
FOLDBACK
OCV
D27
Vref
R112
22.1K
681K
D29
C62
1.0
35V
267K
150K
1
X5 C
2
13
C40
0.33
50 V
+15V
100K
+ ARC
J5
5
TO PROTECTION
1 PHASE DET.
BOARD
C42
4.7
35V
SHORT
12
X7
13
8
X1 D
9
10
D24
1N914
R59
82.5K
R58
33.2K
C2
.022
50 V
R57
10K
33.2K
10K
TEST_PT_E
33.2K
SHORTING
DETECTOR
Vref
DZ2
10V
1W
Q2
600m A
40V
+ ARC
C18
.0047
50V
16.2K
10K
TEST_PT_B
R45
10K
C29
1.8
20V
C44
.022
50V
14
C33
1.8
20V
R44
100
A
Vref
7
8
1
2
3
I-
4
CLIM
Vref
I+
5
6
V+
V-
COMP
CT
X2
SG3847
SHUT
Vin
16
15
OUT B
Vc
GND
12
11
OUT A
SYNC
RT
14
13
10
9
C12
.018
50V
26.7K
PWM
CONTROL
X5
4066B
7
8
C58
.022
50V
14
X9
4066B
7
+15V
4
X11
LM224
11
+5V
TO
METER
6
PROT E C T I ON
BOARD
C47
.022
50V
14
X6
4066B
7
+15V
POWER
BOARD
C69
.022
50V
14
X10
4066B
7
J4
C56
.022
50V
+15V
2
J1
6
J1
1
J1
NOTES :
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM
WITHOUT
MAY NOT SHOW THE EXACT
CI RCUI TRY OF C ONTROLS HAVI NG A C OMMON CODE N UMBER.
AFFECTI N G THE
COMPONENTS OR
GENERAL INFORMATION (more notes)
ELECTRI C AL SYMBOLS PER E-1537
CAPACITORS = f d (U N L E SS OTHERWI S E SPECI FI ED)
RESISTORS = Ohms (1/4W UNLESS OTHERWISE SPECIFIED)
DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED)
1
1
5
J3
J1
2
6 10
LABELS test points
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
1 2
1 7
COMMON CONNECTION
J2 J4
3 4
8
14
FRAME CONNECTION
1
5
EARTH GROUND CONNECTION
J5
6
10
INVERTEC V300
CONTROL P.C. BOARD SCHEMATIC
6-25-93A G 2525
C55
.022
50V
C70
.022
50V
2.67K
DZ10
5.1V
1W
+15V
R113
332K
C66
.022
50 V
6
5
X1 C
7
22.1K
R114
100K
OCV
HOLD DOWN
Q1
600m A
40V
33.2K
C
AUSTRALIA CANADA
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-19
V300 PRO
G-20
PC BOARD ASSEMBLY - CONTROL - (G2527-3)
ELECTRICAL DIAGRAMS
G-20
INVERTEC-300
G2527
CONTROL
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
V300 PRO
G-21
ELECTRICAL DIAGRAMS
Item Identification
C1, C2, C3, C6, C8, C14, CAPACITOR, CEMO .022 50V 20%
C15, C16, C17, C20, C24,
C27, C30, C32, C35, C36,
C38, C44, C45, C47, C49,
C50, C51, C52, C53, C54,
C55, C56, C57, C58, C60,
C61, C63, C64, C66, C67,
C69, C70, C74
C4, C23, C75
C5
CAPACITOR, CEMO 150P
100V 5%
CAPACITOR, PEMF 0.33
200V 10%
C10, C29, C33
C11
C12
C13, C22, C25
C18
CAPACITOR, TAEL 1.8 20V 10%
CAPACITOR, ALEL 20 50V
+75/-10%
CAPACITOR, PFC .018 50V 2%
CAPACITOR, CEMO 330P
100V 5%
CAPACITOR, CEMO 4700P
50V 10%
C19, C39, C42, C48, C65
C25
C26, C41, C46, C59, C73
C28, C62
C31, C40
C34, C37
C43, C68
C71
C72
D1, D2, D3, D7
CAPACITOR, TAEL 4.7 35V 10%
CAPACITOR, CEMO 47P 100V
5%
CAPACITOR, CEMO 0.1 50V 10%
CAPACITOR, TAEL 1.0 35V 10%
CAPACITOR, TAEL 0.33 50V 10%
CAPACITOR, CEMO 2700P
50V 5%
CAPACITOR, TAEL 2.7 50V 10%
CAPACITOR, TAEL 39 20V 10%
CAPACITOR, TAEL 100 20V 10%
DIODE, AXLDS 1A 400V FR
1N4936
DIODE, AXLDS 1A 400V D4, D5, D8, D9, D10, D11,
D12, D13, D14, D15,
D17, D18, D20, D21,
D22, D25, D26, D27, D28,
D29, D30, D31, D33, D34,
D35, D36, D37, D38, D39,
D40, D41, D42, D45, D46,
D47, D48, D50, D51, D52
D16, D19, D24
D23
DZ1, DZ3, DZ8
DZ2, DZ7
DZ4, DZ6, DZ9, DZ10,
DZ13, DZ14
DZ5
DZ11, DZ12
DIODE, AXLDS 0.15A 75V 1N914
DIODE, AXLDS 1A 30V Schottky
DIODE, Zener 0.5W 3.0V 5%
1N5225B
DIODE, Zener 1W 10V 5%
1N4740A
DIODE, Zener 1W 5.1V 5%
1N4733A
DIODE, Zener 1W 6.2V 5%
1N4735A
DIODE, Zener 1W 43V 5%
1N4755A
Item Identification
J1
J2
J3
J4
RECEPTACLE, Molex mini 8 pin
RECEPTACLE, Molex mini 4 pin
RECEPTACLE, Molex mini 2 pin
RECEPTACLE, Molex mini 12 pin
J5
OCI1
RECEPTACLE, Molex mini 14 pin
OPTOCOUPLER, Photo Q 70V
P1 (plugs into J1)
P2 (plugs into J2)
P3 (plugs into J3)
P4 (plugs into J4)
P5 (plugs into J5)
Q1, Q2
CNY17-3
PLUG HOUSING, Molex 8 pin
PLUG HOUSING, Molex 4 pin
PLUG HOUSING, Molex 2 pin
PLUG HOUSING, Molex 12 pin
PLUG HOUSING, Molex 14 pin
TRANSISTOR-N, T226 0.5A 40V
2N4401
RESISTOR-MF, .25W 1% 10.0K
R2, R4, R8, R20, R23,
R32, R38, R43, R45, R46,
R51, R57, R64, R68, R87,
R109, R125, R139, R141,
R143, R151
R3, R10, R26, R42, R129
R5, R6
R7, R9, R30, R47, R71,
R11
R12, R25, R75, R98,
RESISTOR-MF, .25W 1% 475K
RESISTOR-CC, .50W 5% 1
RESISTOR-MF, .25W 1% 47.5K
RESISTOR-MF, .25W 1% 267
RESISTOR-MF, .25W 1% 22.1K
R127, R133, R149
R13, R34, R40, R48, R50, RESISTOR-MF, .25W 1% 100K
R60, R81, R94, R105,
R114, R118, R123, R124
.
R14
R15, R100, R103, R104
TRIMMER-ST, .50W 10% 5K linear
THERMISTOR-PT, 56 ohms 9 oma
R16, R19, R28, R41, R113, RESISTOR-MF, .25W 1% 332K
R17 THERMISTOR-PTC,.08-0.19 ohms
R18
R21, R73, R102, R119,
R144
1.85A
RESISTOR-CC, 2W 5% 680
RESISTOR-MF, .25W 1% 2.67K
R22, R70, R126, R132,
R137, R140
R24, R130
R27, R37, R53, R55,
R58, R92, R115, R136
RESISTOR-MF, .25W 1% 26.7K
RESISTOR-MF, .25W 1% 56.2K
RESISTOR-MF, .25W 1% 33.2K
R29 RESISTOR-MF, .25W 1% 392K
R31, R79, R88, R90, R93, RESISTOR-MF, 25W 1% 4.75K
R97, R99, R121, R135,
R142
R33
R35
R36, R66, R85, R91, R110
R39, R52, R72, R86
R44, R101
R49, R67, R80, R107,
R54
R56
R59
RESISTOR-MF, .25W 1% 3.32K
RESISTOR-CC, 1W 5% 390
RESISTOR-MF, .25W 1% 150K
RESISTOR-MF, .25W 1% 221K
RESISTOR-MF, 25W 1% 100
RESISTOR-MF, .25W 1% 681K
RESISTOR-MF, .25W 1% 16.2K
RESISTOR-MF, .25W 1% 43.2K
RESISTOR-MF, .25W 1% 82.5K
Item
R61, R147, R148
R62
R63
R65, R77
R69
R74
R82, R120, R128
R83
R95
R96
R131
R146
R152, R153, R154, R155
TERMINALS (P1, P2, P3,
P4, P5)
X1, X3, X11
X2
X4
X5, X6, X8, X9, X10
X7
Identification
RESISTOR-MF, .25W 1% 10.0
RESISTOR-MF, .25W 1% 8.25K
RESISTOR-MF, .25W 1% 1.00K
RESISTOR-MF, .25W 1% 475
RESISTOR-MF, .25W 1% 18.2K
RESISTOR-MF, .25W 1% 24.3K
RESISTOR-MF, .25W 1% 301
RESISTOR-MF, .25W 1% 267K
TRIMMER-ST, .50W 10% 10K linear
RESISTOR-MF, .25W1 825 %
RESISTOR-MF, .25W 1% 68.1K
RESISTOR-MF, .25W 1% 28.0K
RESISTOR-MF,.25W 1% 26.7K
TERMINALS, Molex mini
QUAD, IC-OP-AMP. gen. purpose
224J
CONTROLLER, IC-PWM I-mode
3847
QUAD, IC-OP-AMP high-perf 1014
SWITCH, IC-CMOS analog quad
4066
INVERTER,IC-CMOS Schmitt h ex 4584
NOTE: Individual parts listed are not available from Lincoln Electric.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
G-21
V300 PRO
G-22
SCHEMATIC - PROTECTION PC BOARD (M16097)
ELECTRICAL DIAGRAMS
G-22
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
V300 PRO
G-23
PC BOARD ASSEMBLY - PROTECTION - (L7915-2)
ELECTRICAL DIAGRAMS
G-23
Item
B5, B14, B51, B52, B53
C1, C3, C4, C5, C6
C2
D1, D3, D4, D5, D6, D7
D8
DZ1
J8
J15
OCI1, OCI2, OCI3, OCI4
P8 (plugs into J8)
P15 (plugs into J15)
R1, R2
R3, R13, R16
R4, R5, R11, R12
R6, R8, R9, R10, R27
R7, R20
R14
R15
R18, R26, R28, R32
R19
R21, R23, R24, R25,
R29, R30, R31, R33
R22
R34, R36
R35, R37
TERMINALS (P8, P15)
X1
X2
Identification
CONNECTOR, tab 1/4”
CAPACITOR, ceramic
CAPACITOR, tantlm etc.
27
µ f 35VDC
DIODE, 1A 400V
DIODE, 1A 1000V
DIODE, IN4740 Zener 10V 1W
RECEPTACLE, Molex mini 4 pin
RECEPTACLE, Molex mini 6 pin
OPTO, Isolator CNY17-3
PLUG HOUSING, Molex mini 4 pin
PLUG HOUSING, Molex mini 6 pin
RESISTOR, MF .25W 1% 681K ohm
RESISTOR, MF .25W 1% 1.82K ohm.
RESISTOR, MF .25W 1% 150K ohm
RESISTOR, MF .25W 1% 56.2K ohm
POTENTIOMETER, Cermet trmr
.25W 1% 5K ohm
RESISTOR, MF .25W 1% 100K ohm
RESISTOR, MF .25W 1% 475 ohm
RESISTOR, MF .25W 1% 10K ohm
RESISTOR, MF .25W 1% 3.32K ohm
RESISTOR, MF.25W 1% 15K ohm
RESISTOR, MF .25W 1% 332K ohm
RESISTOR, MF .25W 1% 276K ohm
RESISTOR, MF .25W 1% 332 ohm
TERMINALS, Molex mini
QUAD OP-AMP
VOLTAGE REGULATOR, linear
7805 5VDC
NOTE: Individual parts listed are not available from Lincoln Electric.
52
51 H5 53 14
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
V300 PRO
G-24
SCHEMATIC - POWER PC BOARD (M16018)
ELECTRICAL DIAGRAMS
G-24
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
V300 PRO
G-25
PC BOARD ASSEMBLY - POWER - (L8033-7)
ELECTRICAL DIAGRAMS
L8033-4 POWER BOARD
G-25
E
B
D
C
A
F
Item
X1
C2,C7,C11
J7
X5
C3
D1,D2,D3,D4,D5,D8,D9,
D10,D11,D12,D13
C6
C4
C5
C1
OCI1
X2,X3
C8,C9,C12,C13
J6
C10
DZ1
DZ2,DZ3
Q1,Q3
Q2,Q4
Q5
D6,D7
R1
Identification
REGULATOR ASBLY
.022/50
CONNECTOR
VOLT. REG. & HEAT SINK ASBLY.
150/50
1N4004
1.8/20
4.7/35
39uF/20VDC
3300/50
OPTO ISOLATOR
8 PIN I.C. (SS)
.1/50
HEADER
500/50
1N4744A
1N4746A
3A/60V. TRANSISTOR
3A ,60V. PNP TRANSISTOR
3.5A. 60V. MOSFET (SS)
1N5822 SCHOTTKY BARRIER DIODE
.0 OHM, 5W RESISTOR
Item
TP1,TP2
R11,R19,R26,R27
R5,R6,R10,R22
R4
R14,R41
R9
R21
R3
R7,R8,R24
R2
R18
R20
R13,R15,R16,R17
R23
R12
R25
X4
J14
Q40
R42,R43
DZ4,DZ5
R28,R29
D14
Identification
15J
10K 1/4W
100K 1/4W
1.5K 1/4W
15K 1/4W
1150K 1/4W
2.21K 1/4W
243 1/4W
267 1/4W
2.67K 1/4W
26.7K 1/4W
267K 1/4W
33.2K 1/4W
4.75K
475K 1/4W
5.11K 1/4W
LM224 OP-AMP
HEADER
2N4401
100 1/4W
1N4742A
10 1/4W
1N4936
Item
R44
Identification
THERMISTOR
NOTE: Individual parts listed are not available from Lincoln Electric.
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
V300 PRO
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Key features
- Advanced inverter technology for superior arc stability and control
- Multi-process welding capabilities (MIG, TIG, Stick)
- Digital display for precise parameter adjustment and monitoring
- Auto-set function for simplified setup and operation
- Excellent duty cycle for extended welding sessions
- Durable construction for demanding environments