Lincoln Electric Invertec V300 Pro - 9934 Operator Manual

®
^^ WELDERS |
IM-469
Dec 1992
OPERATING MANUAL
INVERTEC" V300-PRO
DAMAGE CLAIMS
When this equipment is shipped, title passes to the pur-
chaser upon receipt by the carrier. Consequently, claims for
material damaged in shipment must be made by the
purchaser against the transportation company at the time
the equipment is received.
IM469
Invertec V300-Pro
December, 1992
9825,9934 and 9965
This manual covers
equipment which is
obsolete and no longer
in production by The
Lincoln Electric Co.
Specifications and
availability of optional
features may have
changed.
This manual covers only
the codes listed below:
9825, 9934 and 9965
SAFETY DEPENDS ON YOU
Lincoln arc welding equipment is designed and built with
safety in mind. However, your overall safety can be
increased by proper installation. ..and thoughtful operation
on your part. DO NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT WITHOUT READING
THIS OPERATING MANUAL AND THE ARC WELD-
ING SAFETY PRECAUTIONS ON PAGES 2, 3, AND 4.
And, most importantly, think before you act and be careful.
World's Leader in Welding and Cutting Products - Premier Manufacturer of Industrial Motors
Sales and Service through Subsidiaries and Distributors Worldwide
Cleveland, Ohio 44117-1199 U.S.A.
— . THE LINCOLN ELECTRIC COMPANY
ARC WELDING SAFETY PRECAUTIONS
WARNING: PROTECT YOURSELF AND OTHERS FROM
POSSIBLE SERIOUS INJURY OR DEATH.
> ELECTRIC SHOCK can kill.
1. a.
The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do not
touch these “hot” parts with your bare skin or wet
clothing. Wear dry, hole-free gloves to insulate
hands.
. Insulate yourself from workpiece 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 haz-
ardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped po-
sitions 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 Welder
DC Manual (Stick) Welder.
* AC Welder with Reduced Voltage Control.
In semiautomatic or automatic wire welding, the
electrode, electrode reel, welding head, nozzle or
semiautomatic welding gun are also electrically
“hot”.
. Always be sure the work cable makes a good elec-
trical connection with the metal being welded. The
connection should be as close as possible to the area
being welded.
Ground the work or metal to be welded to a good
electrical (earth) ground. |
Maintain the electrode holder, work clamp, weld-
ing cable and welding machine in good, safe op-
erating condition. Replace damaged insulation.
Never dip the electrode in water for cooling.
. Never simultaneously touch electrically “hot” parts
of electrode holders connected to two welders be-
cause voltage between the two can be the total of
the open circuit voltage of both welders.
When working above floor level, protect yourself
from a fall should you get a shock.
Also see Items 4c and 6.
. 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 weld-
ing. Headshield and filter lens should conform to
ANSI Z87.1 standards.
May 91
b. Use suitable clothing made from durable flame-
resistant material to protect your skin and that of
your helpers from the arc rays.
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.
3. a. Welding may produce fumes and gases hazardous
to health. Avoid breathing these fumes and gases.
When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc
to keep fumes and gases away from the breathing
zone. When welding on galvanized, lead or cad-
mium plated steel and other metals which produce
toxic fumes, even greater care must be taken.
b. Do not weld in locations near chlorinated hydro-
carbon 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.
c. Shielding gases used for arc welding can displace
air and cause injury or death. Always use enough
ventilation, especially in confined areas, to insure
breathing air is safe.
d. Read and understand the manufacturer's instruc-
tions for this equipment and the consumables to
be used, including the material safety data sheet
(MSDS) and follow your employer’s safety prac-
tices.
e. Also see item 7b.
Ne WELDING SPARKS can
| cause fire or explosion.
4. a. Remove fire hazards from the welding area. If this
is not possible, cover them to prevent the welding
sparks from starting a fire. Remember that welding
sparks and hot materials from welding can easily
go through small cracks and openings to adjacent
areas. Have a fire extinguisher readily available.
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 op-
erating information for the equipment being used.
с. When not welding, make certain no part of the
electrode circuit is touching the work or ground.
Accidental contact can cause overheating and cre-
ate a fire hazard.
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 “Recom-
mended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping
That Have Held Hazardous Substances”, AWS
F4.1-80 from the American Welding Society (see
address below).
. Vent hollow castings or containers before heating,
cutting or welding. They may explode.
. 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.
. 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 ca-
bles until they fail.
h. Also see item 7c.
6. a.
b.
FOR ELECTRICALLY
powered equipment.
Turn off input power using the disconnect switch
at the fuse box before working on the equipment.
Install equipment in accordance with the U.S. Na-
tional Electrical Code, all local codes and the man-
ufacturer’s recommendations.
Ground the equipment in accordance with the U.S.
National Electrical Code and the manufacturer’s
recommendations.
EN CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders containing the
correct shielding gas for the process used and prop-
erly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suit-
able for the application and maintained in good
condition.
. Always keep cylinders in an upright position se-
curely chained to an undercarriage or fixed sup-
port.
. Cylinders should be located:
e Away from areas where they may be struck or
subjected to physical damage.
e A safe distance from arc welding or cutting op-
erations and any other source of heat, sparks,
or flame.
. Never allow the electrode, electrode holder, or any
other electrically “hot” parts to touch a cylinder.
. Keep your head and face away from the cylinder
valve outlet when opening the cylinder valve.
. Valve protection caps should always be in place
and handtight except when the cylinder is in use
or connected for use.
. Read and follow the instructions on compressed
gas cylinders, associated equipment, and CGA pub-
lication P-1, “Precautions for Safe Handling of
Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 1235 Jefferson
Davis Highway, Arlington, VA 22202.
FOR ENGINE
powered equipment.
7. a. Turn the engine off before troubleshooting
and maintenance work unless the mainte-
nance work requires it to be running.
b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes out-
doors.
¢. 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 va-
porizing 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 elim-
inated.
- d. Keep all equipment safety guards, covers
we and devices in position and in good repair.
S
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other mov-
ing parts when starting, operating or re-
pairing equipment.
e. In some cases it may be necessary to remove
safety guards to perform required mainte-
nance. Remove guards only when necessary
and replace them when the maintenance re-
quiring their removal is complete. Always
use the greatest care when working near
moving parts.
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.
g. To prevent accidentally starting gasoline
engines while turning the engine or welding
generator during maintenance work, dis-
connect the spark plug wires, distributor
cap Or magneto wire as appropriate,
-
; ul ya E
€ .
h. To avoid scalding, do not remove the ra-
diator pressure cap when the engine is hot.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR WORK performed by qualified people.
For more detailed information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting —
ANST Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard
.2-1974.
Мау ’91
- 3 -
PRECAUTIONS DE SORETE
Pour votre propre protection lire et observer toutes les
instructions et les précautions de sûreté specifiques qui parrais-
sent dans ce manuel aussi bien que les précautions de sûreté
générales survantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et a 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 vètements mouillés. Porter des gants
secs et sans trous pour isoler les mains.
b. Faire très 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 de
fonctionnement.
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 précau-
tions pour le porte-électrode s'applicuent aussi au
pistolet de soudage.
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.
с. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflam-
mabies.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protèger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
Sept. ?90
S. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
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
echauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on
place la masse sur la charpente de la construction ou
d’autres endroits éloignés de la zone de travail, on
augmente le risque de voir passer le courant de soudage
par les chaines de levage, câbles de grue, ou autres circuits.
Cela peut provoquer des risques d'incendie ou d’echauffe-
ment des chaines et des câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particulièrement 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 1172-1974.
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, l’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.
Invertec” V300-PRO
Safety Precautions . . . ee. 2-4
General Description . . 2. + + + + + + + + + + + + + a e. oe. o... E
Recommended Processes and Equipment . . + + + + + + + + + + + + « « o « 2 6-7
Options/Accessories and compatible Lincoln Electric Equipment . . . . . . 7-8
Specification Chart . . . + + « . e e e 4 i te ee ee eee ee eee... 8
Installation Instructions . . . + + + + + + + + + e e e e e « e + . . 10-16
Operating Instructions . . + + + e e . ele e e e 4 2 oe 4 + e eo... 17-22
Maintenance and Troubleshooting . . . . . . 2 2 24 4 4 2 e e « o + 22-33
Parts Pages . . . . . e e e i e e e e e e e e e e e e e e e a e e e e + 34-39
connection and Reference Diagrams . . . . + + + + + « « « « + + + « « . 40-51
Wiring Diagrams . . . . © e e e ele see e. eee e e... e... 52-53
GENERAL DESCRIPTION
The Invertec V300-PRO is a 300 amp arc welding power source that utilizes single
or three phase input power to produce either constant voltage or constant
current outputs.
The V300-PRO is designed for 60 Hz supply systems. The welding
response of the Invertec has been optimized for GMAW, SMAW, TIG and FCAW
processes.
It is designed to be used with the LN-25 and LN-7 Semiautomatic Wire
Feeders.
IMPORTANT SAFETY NOTE: EMF CONSIDERATIONS
Electric current flowing through any conductor causes localized Electric and
Magnetic Fields (EMF).
welding machines.
Welding current creates EMF fields around welding cables and
EMF fields may interfere with some pacemakers, and welders having
a pacemaker should consult their physician before welding. Exposure to EMF fields
in welding may have other health effects which are now not known.
All welders should use the following procedures in order to minimize exposure to EMF
fields from the welding circuit:
1.
Route the electrode and work cables together - Secure them with tape when
possible. |
Never coil the electrode lead around your body.
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.
Connect the work cable to the workpiece as close as possible to the area
being welded.
Do not work next to welding power source.
RECOMMENDED PROCESSES AND EQUIPMENT
Constant Voltages Processes
Gas Metal Arc Welding (GMAW)
GMAW welding may be performed with the Invertec using the Lincoln
Electric LN-25 or LN-7 Wire Feeders. An appropriate GMAW gun and cable
assembly and a regulated supply of shielding gas are required.
Innershield®/Outershield® (FCAW
Semiautomatic flux cored wire processes may be done with the Invertec
using the Lincoln Electric LN-25 or LN-7 Wire Feeders. An appropriate
gun and cable assembly is required.
Constant Current Processes
Manual Arc Welding (Stick)
The Invertec may be utilized as a manual DC arc welder with the electrode
cable, work cable and electrode holder being the only equipment required.
Air Carbon Arc Cutting
Air Carbon Arc Cutting may be performed with the Invertec within its
output rating, using 5/32" and 3/16" diameter carbon rods. Output
cables, an air carbon arc electrode cable assembly and a source of
compressed air are required.
NOTE:
1. Air Carbon Arc Cutting may be performed using either the Constant
Voltage modes or the Constant Current modes; however, the cutting
action will be smoother with the Constant Voltage modes. Best
performance will be at settings of 250 amps and below.
2. The electrode protection circuit in the Invertec will limit the
current to approximately 325 amps.
TIG Welding
The Invertec is capable of scratch TIG welding, can be mated with the
K900-1 DC TIG Starter, or can be used with a K799 Hi-Freg unit. Ап
electrode cable, work cable, TIG torch and gas supply are required.
WARNING: If stick welding, TIG or air carbon arc cutting
is to be done on the Invertec along with semiautomatic
welding, then all control, electrode and work leads to the
wire feed equipment must be disconnected from the Invertec
before connecting the Invertec for stick, TIG or air carbon
arc cutting.
OPTIONS /ACCESSORIES AND COMPATIBLE LINCOLN ELECTRIC EQUIPMENT
Field Installed Options/Accessories
Cable Plugs
— Cable Plug Kit for 1/0-2/0 cable (K852-70): Attaches to welding
cable to provide quick disconnect from machine.
— Cable Plug Kit for 2/0-3/0 cable (K852-95).
NOTE: Two K852-70 plugs are included with the V300-PRO.
K864 Remote Control Adapter
Plugs into the 14-pin receptacle on the rear panel of the Invertec.
Adapter splits remote control circuitry to a 6-pin receptacle and to a
1l4-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.
K799 Hi-Freg"
For non-contact starting GTAW. High frequency unit with gas valve, rated
250A. Recommended accessories for remote control with upper limit
adjustment: K867, K775, K843 and K812 or K870. |
K876 Remote Control Adapter
For operating an LN-25 wire feeder. The adapter connects to the 14-pin
receptacle of Invertec power source and to the 6-pin connector of the LN-
25 K432 remote control cable.
K900-1 DC TIG Starter
Solid State GTAW starting unit. Rated 300A, 60%.
K904-1 Twinvertec Control
Runs two Invertecs in parallel with single knob control and wirefeeder
connection.
SPECIFICATIONS
MODEL | VI300-PRO V300-PRO
CODE 9825, 9965 9934
Input Three Phase
Frequency (Hz) 60 60
Volts (VAC) 208/230/460 575
Amperes (A):
@ 100% NEMA 37/33/19 16
@ 60% NEMA 48/43/24 20
@ 60% MAX” 49/48/28 22
Output Volts (V):
@ 250A NEMA @ 100% 30 30
@ 300A NEMA @ 60% 32 32
e 3004 MAX” € 60% 35/39/41 36
Input Single Phase
Frequency (Hz) 60 -
Volts (VAC) 208/230/460 --
Amperes (А):
@ 100% NEMA® 53/47/29 —
@ 60% NEMA” 69/62/38 --
@ 60% Max” 75/67/42 —
Output Volts (V):
200A NEMA @ 100% 28 ==
250A NEMA @ 60% 30 ==
250A MAX” @ 60% 37/41/43 -
Current Range Code 9825: 15 - 300A 5 - 300A
Code 9965: 5 - 300A
Dimensions 18.7" x 10.8" x 22.2"
Height” x Width x Depth (475mm x 274mm x 564mm)
Weight 64 Lbs.
(29 Kg)
(1)
(2)
Lincoln Plus Rating
For outputs above 200A/60% or 165A/100% with 230 VAC, or lower, single phase
inputs, the input line cord should be replaced by an input conductor of 6 AWG or
larger.
® overall height including handle, (16.4" (417mm) without handle).
INSTALLATION
Safety Precautions
WARNING:
TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH BEFORE ATTEMPTING TO
CONNECT THE INPUT POWER LINES.
- Only qualified personnel should perform this installation.
- Turn the power switch on the Invertec V300-PRO "off" before
connecting or disconnecting input power lines, output cables, or
control cable.
- Connect the green lead of the power cord to ground per U.S.
National Electrical Code.
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 V300-PRO.
Keep machine dry. Shelter from rain and snow. Do not place on wet
ground or in puddles.
Electrical Installation
1.
The Invertec V300-PRO 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.
Single voltage, 575VAC machines, can only be connected to 575VAC. No
internal reconnection for other input voltages is possible.
When received directly from the factory, multiple voltage
(208/230/460 VAC) machines are internally connected for the highest
input voltage (460VAC). If 460VAC is the desired input, then the
machine may be connected to the power system without any setup
required inside the machine.
10
3. Initial 208VAC and 230VAC operation will require a voltage panel
setup, as will later reconnection back to 460VAC:
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.
Input Voltage Setup
RECONNECT PROCEDURE A WARNING
- Di ci befo
1. BE SURE POWER SWITCH IS OFF > Disconnect input power before
2. CONNECT LEAD 'A'TO DESIRED - Do not operate with wraparound
INPUT YOLTAGE RANGE, removed.
SASSY . Do not touch electrically live ports.
440-460V
e. MI Nutr - Only qualified persons should install,
380-415V d—— Á Ed use or service this equipment.
220-230V (€, IF MACHINE CEASES TO OPERATE [NO METER, NO FAN)
200-208V (E AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;
REPLACE WITH A 3 AMP SLOW BLOW ONLY.
3. POSIMON SWITCH TO DESIRED INPUT VOLTAGE RANGE.
o © oO o
Em orrace=280-460 a a, VOLTAGE =200-230Y
o o o © |
[THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO USA. | : | > 1 520324
Power Cord Connection
A 10 foot power cord is provided and wired into the machine. Follow the
power cord connection instructions. Incorrect connection may result in
equipment damage.
Single Phase Input
POWER CORD CONNECTION Connect Green Lead to Ground Per U.S.
- National Electric Code
Connect Black & White Leads to Power
Wrap Red Lead With Tape to Provide 600V
=, BLACK Insulation
e REEN
| WHITE Three Phase Input
Connect Green Lead to Ground per U.S.
National Electric Code
Connect Black, Red and White Leads to
Power
11
Install in accordance with all local and national electric codes.
RECOMMENDED FUSE SIZES
BASED ON THE U.S. NATIONAL ELECTRICAL CODE
AND MAXIMUM MACHINE OUTPUTS
FUSE SIZE IN AMPS
INPUT VOLTS” (TIME DELAY FUSES)
3 Phase 208 60
60 Hz 230 60
460 40
1 Phase 208” 85
60 Hz 2309 80
460 50
3 Phase 575 30
60 Hz
@ Input voltage must be within ~ 10% of rated value.
© when operating on these inputs, at outputs exceeding
200A/60% or 165A/100%, the input line cord should be
changed to an input conductor of 6 AWG or larger.
Connection of Wire Feeders to the Invertec
LN-25 Connection Instructions
1.
2.
Turn the Invertec power switch "off".
Connect the electrode cable to the output terminal of polarity
required by electrode. Connect the work lead to the other terminal.
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.
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
l.
2.
Turn the Invertec power switch "off".
Connect the K480 control cable from the LN-7 to the Invertec control
cable connector. The control cable connector is located at the rear
of the Invertec.
12
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.)
5. Set the meter polarity switch on the rear of the Invertec to coincide
with wire feeder polarity used. The wire feeder will now display the
welding voltage.
6. If K480 is not available, see connection diagram S19404 for
modification of K291 or K404 LN-7 input cable with K867 Universal
Adapter Plug.
General Instructions for Connection of Wire Feeders to Invertec
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 K812 and Foot Amptrol K870 require K864
Remote Control Adapter. See S19309 instruction for connection
information.
K799 Hi-Freg" Kit Connection
1. Turn the Inverter power switch "off".
2. Using a K867 Universal adapter, wire in a 115V receptacle for the
K799 plug on leads #31, #32 and GND, connect lead #21 to #225 from
the K799. -
For remote control, accessories K867, K775, K843 and K812 or K870 are
required. In this configuration, K775 Remote Control sets the upper
current limit of K812 Hand Amptrol or K870 Foot Amptrol. See
connection diagram S19432.
3. Connect an electrode cable from the K799 to the Invertec output
terminal of polarity needed. Connect the work lead to the other
Invertec output terminal.
4. Set the polarity switch on the rear of the Invertec to coincide with
the TIG polarity used.
5. Set the Local/Remote switch appropriately for control at the machine
or using the remote Amptrol.
6. Set the mode switch to GTAW.
7. Energize output terminals utilizing the Output Terminals Switch on
front panel.
13
Parallel Operation
The Invertecs are operable in parallel in both CC and CV modes. For best
results, the currents of each machine should be reasonably well shared.
As an example, with two machines set up in parallel for a 400 amp
procedure, each machine should be set to deliver approximately 200 amps,
not 300 amps from one and 100 amps from the other. This will minimize
nuisance shutdown conditions. In general, more than two machines in
parallel will not be effective due to the voltage requirements of
procedures in that power range.
To set machine outputs, start with output control pots and arc
force/pinch pots in identical positions. If running in a CC mode, adjust
outputs and arc forces to maintain current sharing while establishing the
proper output current. In CV modes, the output voltage should be set
while keeping both output control pots in identical positions. Then
switch the machine meters to amps and adjust one of the output control
pots for current balance. Check the voltage and if readjustment is
necessary, repeat the current balancing step. Pinch settings should also
be kept identical on the machines. See Section entitled, "Twinvertec
Control” below.
K900-1 DC TIG Starter Connection
This versatile new kit was made to mate with the Invertec.
À control cable assembly is supplied with the kit to connect the kit to
an Invertec. The cable can be connected, either end, at the DC TIG
Starter kit and at the Invertec by attaching to the 14-pin amphenols on
the backs of each unit. Refer to S20405 connection diagram.
A negative output cable assembly is also supplied with the DC TIG Starter
kit to connect the kit with the Invertec’s negative output terminal.
All Magnum one and two piece water-cooled torches with 7/8 left-hand
threads and gas-cooled torches with 7/8 and 5/16 right-hand threads can
be connected to the starter kit.
To secure the DC TIG Starter kit to the bottom of the Invertec and for
more detailed instructions, refer to the K900-1 manual.
K904-1 Twinvertec Control Connection
Runs two Invertecs in parallel with single knob control and wirefeeder
connection.
Connect per S20525 diagram. Upon setup, the machines need to be balanced
under load, for current sharing using the trimmer port provided on the
kit -
14
LN-9 GMA Connection Instructions
1. Turn the Invertec power switch "off".
2. Connect the K596 control cable assembly from the LN-9 GMA to the
Invertec control cable connector. The control cable connector is
located at the rear of the Invertec.
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 connection at the LN-9 GMA voltage
board. See diagram S20607.
7. K442-1 Pulse Power Filter Board is also required for GMAW, but should
be disconnected 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.
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:
LENGTH UP
DUTY CYCLE CURRENT 61m (200 FT) 61-76m (200-250 FT)
100% 250 1/0 1/0
60% 300 1/0 2/0
Quick Disconnect Plugs
A quick disconnect system is used for the welding cable connections. The
welding plug included with the machine is designed to accept a welding cable
size of 1/0 to 2/0.
1. Remote 25mm (1 in.) of welding cable insulation.
15
2. Slide rubber boot onto cable end.
match the cable diameter.
the boot over the cable.
The boot end may be trimmed to
Soap or other lubricant will help to slide
BOOT
\ CABLE
ol |
TRIM
(1 IN.)
3. Slide the Copper tube into the brass plug.
4. Insert cable into copper tube.
pa
—
~~ —
——
COPPIR TUBE
—
BRASS PLUG
5. Tighten set screw to collapse copper tube. Screw must apply pressure
against welding cable. The top of the set screw will be well below
the surface of the brass plug after tightening.
6. Slide rubber boot over brass plug. The rubber boot must be
positioned to completely cover all electrical surfaces after the plug
is locked into the receptacle.
16
OPERATING INSTRUCTIONS
ANWARNING
+ Do not touch electrically live parts
or electrode with skin or wet
clothing.
* insulate yourself from work and
ground.
ELECTRIC SHOCK
can Kill.
* Keep your head out of fumes.
* Use ventilation or exhaust to
remove fumes from breathing
zone.
FUMES AND
GASES can be
dangerous.
NN —. * Keep flammable material away.
To
WELDING SPARKS
can cause fire or
explosion.
* Wear eye, ear and body
protection.
ARC RAYS
can burn.
Power Source Operation
WARNING:
DO NOT OPERATE MACHINE IF MACHINE IS WET OR SITTING IN WATER.
Duty Cycle
The Invertec is rated at 300 amps, 60% duty cycle for 3¢ inputs (based on
a 10 minute cycle). It is also rated at 250 amps, 100% duty cycle.
17
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.
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.
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.
Mode Switch
GTAW - Optimized for both scratch start and
Hi-FregM kit use.
CC Soft - Best for EXX18 thru EXX28 stick electrodes.
CC Crisp - Use this mode for stick welding with EXX10 thru
EXX14 electrodes. Non-welding 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.
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
and K432 options or LN-7 which will allow the gun trigger to
energize the welding terminals.
©
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 CO, or
high content CO, mixed. The lower half is for inert gas
mixes.
19
APPLICATIONS
FULL RANGE IS 1-10. 1 1s VERY SOFT, 10 IS VERY CRISP
Nominal Recommended
a Mode Process Setting Adjustment Range
CC EXX18 thru 5 l (gentle, may stick)
SMAW 1 EXX28 stick to 9 (forceful, more
— spatter)
CC EXX10 thru 6 3 to 10
SMAW 2 EXX14 stick
Air Carbon arc Cutting 1 NONE
CV FCAW Innershield® or 10 NONE
Outershielde
Air Carbon Arc Cutting 1 NONE
CV GMAW” CO, or 25% CO, or 7.5 5 to 10
similar gas mixes
98% Ar-2% O,Ar, 5 1-10
90% Не-7.5% Аг-2.5% CO,
and other predominantly
inert gases
a Lowest pinch, highest inductance and least spatter.
10 = Highest pinch, lowest inductance and most spatter.
- Meter Polarity Switch
@ = + =D The wire feeder polarity switch is located at the rear of the
т machine. The switch provides a work connection for wire
feeder voltmeters. Place the switch in the position of the
LS) electrode polarity indicated by the decal. The switch does
—-— = not change the welding polarity.
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 self-resetting
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 115 VAC € 2 amp supply is included for use with the LN-7 wire feeder. This
supply is protected by a 2.5 amp breaker located on the rear of the machine.
All three supplies are not to be loaded simultaneously.
21
MAINTENANCE
A WARNING
— e
A
ELECTRIC
SHOCK
can kill.
* Turn the input power off at the
disconnect switch before working
inside the machine case.
DANGER:
TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH AND DISCHARGE
INPUT CAPACITORS BEFORE WORKING INSIDE MACHINE.
- Only qualified personnel should perform installation,
maintenance and troubleshooting work.
Capacitor Discharge Procedure
1. Obtain a power resistor (25 ohms, 25 watts).
2. Hold resistor body with electrically insulated glove. DO NOT TOUCH
TERMINALS. Connect the resistor terminals across the two hex head cap
screws in the position shown. Hold in each position for 1 second. For
575VAC only, repeat for second capacitor. Repeat for the capacitor (s) on
the other side of the machine.
[ a
RESISTOR AT
3. Use a DC voltmeter to check that voltage is not present across either
capacitor.
Routine Maintenance
1. Every 6 months or so the machine should be cleaned with a low pressure
airstream. Keeping the machine clean will result in cooler operation and
higher reliability. Be sure to clean these areas:
- Power, Switch, Driver, Protection and Control printed circuit boards
- Power switch
— Main transformer
- Input rectifier (located in front of fan blade)
— Heat sink fins
2. Examine the sheet metal case for dents or breakage. Repair the case as
required. Keep the case in good condition to insure that high voltage parts
are protected and correct spacings are maintained. All external sheet metal
screws must be in place to assure case strength and electrical ground
continuity.
Periodic Maintenance
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 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.
Thermostats are self-resetting once the machine cools sufficiently. If
the thermostat shutdown was caused by excessive output or duty cycle and
the fan is operating normally, the Power Switch may be left on and the
reset should occur within a 15 minute period. If the fan is not turning
or the air intake louvers were obstructed, then the power must be
switched off for 15 minutes in order to reset. The fan problem or air
obstruction must also be corrected.
Filter Capacitor Conditioning
A protection circuit is included to monitor the voltage across filter
capacitors Cl and C2 (also Cl4 and C15 on 575VAC units). In the event
that the capacitor voltage is too high, the protection circuit will
prevent output. The protection circuit may prevent output providing all
these circumstances are met:
1. Machine is internally connected for 380VAC, or higher input voltage.
2. Machine did not have power applied for many months.
3. Machine did not produce output when power was first switched on.
23
If these circumstances apply, the proper action is to switch the machine
on and let it idle for up to 30 minutes. This is required to condition
the filter capacitors after an extended storage time. The protection
circuit will automatically reset once the capacitor conditioning and
resultant voltage levels are acceptable. It may be necessary to turn the
power switch off and back on again after this period.
Troubleshooting Procedures
DANGER: TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH AND
DISCHARGE INPUT CAPACITORS BEFORE WORKING INSIDE MACHINE.
Only qualified personnel should perform installation, maintenance
and troubleshooting work.
Use a battery powered VOM only for all troubleshooting.
Do not troubleshoot the machine with an oscilloscope.
Do not use any electrical test equipment which uses a 115VAC
power plug.
51 power switch, D13 input rectifier, C1 and C2 capacitors, (and
Cl4 and Cl5 capacitors in the 575 VAC V300-PRO), Switch PC
boards, Driver and Protection PC boards, R4 thru R9 resistors and
T2 main transformer are all connected to the main lines.
Use care when making voltage measurements.
Visual Inspection
Clean interior of machine with a low pressure airstream. Make a thorough
inspection of all components. Look for signs of overheating, broken
leads or other obvious problems. Many problems can be uncovered with a
good visual inspection.
Open Circuit Voltage
The open circuit voltage of the Invertec V300-PRO is 60 to 75VDC and
cannot be adjusted by the output control.
Test Conditions
Perform all testing at the lowest input voltage available, except where a
higher voltage is required by a test step. Make ohmmeter checks only
after power has been disconnected from machine and after capacitors have
been discharged.
Certain high voltage connections have been insulated with RTV sealant.
It is necessary to break through the sealant with a sharp probe in order
to make voltage or resistance checks.
Disconnect any control cables from remote control receptacle.
24
Troubleshooting Guide
TROUBLE
WHAT TO DO
No output but fan operates and meter is
on.
Perform test steps 1A and 1B.
Poor welding, weld settings drift, or
output power is low.
1. Check front panel wiring and
controls.
2. Replace Control PC board.
Main fuses open or Switch PC boards
overheated.
Output turns on momentarily then
switches off and repeats. Machine is
connected for 380VAC or higher input
voltage.
Perform test steps 4 and 5 for both
Switch PC boards and 7.
Perform test steps 3B, 4 and 5.
OCV is normal (approx. 65-75V) but
output power is low (less than 20V and
100A). Machine makes squealing noise
while under load. Machine is connected
for 230VAC, or lower, input voltage.
Perform test steps 4 and 5 for both
Switch PC boards.
Open circuit voltage is 1-2 volts.
Perform test step 6.
Output control not functioning on remote | 1. Check remote control assembly.
control. Local control OK. 2. Check $3, Local/Remote switch.
Machine does not produce more than 250A 1. Replace main fuse if blown.
output when connected to 3 phase supply. | 2. Replace Protection PC Board.
3. Replace Control PC Board.
4. Perform test step 7.
Machine does not produce more than 250A
output while connected to single phase
supply.
Machine operates OK at 230VAC or lower.
No output at 380VAC or higher.
Normal operation.
Perform test step 2.
Poor EXX10 stick electrode (5P)
performance. Arc "pops out”.
Check D6 and D12, Li and L2.
No output or reduced output the first
time power is applied to the machine.
25
Check reconnect panel - connections and
fuse.
Test Procedures
Next
Test Test Repair
Step Test Check Result Conclusion Step Action
1A Output pilot 223A to 210 Fan thermostat, choke
circuit thermostat, T1
(set Sá on) 24 VAC transformer and S4 all 18
OK
0 VAC Check above components
18 302 (pos) to 15 VDC T1 and 15V power supply 2
2750 (neg) OK
0 VDC Check T1 and Power PC
Board
2 Protection PC 313 (neg) to ; Replace Power and
board output 311 (pos) <1 Voc Protection PC board OK Control PC boards
(set S4 on)
>5 VDC 3A
3A Static capacitor Compare voltage across <25VDC C1, C2, R1, R9 - OK
balance terminals 9 & 12 of difference (575VAC machine C14,
(set S4 off) each Switch PC Board. between C15 - OK)
575VAC -- 407VDC readings L ion PC
380VAC input and | 460VAC -- 325VDC Replace Protection
higher test 440VAC -- 311V0C 38 | board.
415VAC -- 293VDC >25VDC Check above components.
380VAC -- 269VDC :
difference
575VAC only - compare
voltage across 9A € 13
and 13 € 12A; then, 98
& 15 and 15 & 128
3B Dynamic capacitor Connect as in step 3A.
balance Same voltages as <25vD
(set $4 оп) above. С OK
. >25VDC Power PC Bd. or Switch 4
380VAC input and PC Boards are damaged and
higher test 5
26
Next
Test Test Repair
Step Test Check Result Conclusion Step Action
4 Switch PC board | Terminals on Switch PC >1K ohms OK cont
resistance test | Board:
1/8 (pos) to <100 ohms Short 5 Replace Switch PC Board
No dynamic test 12 (neg)
is possible
1/8 (neg) to <100 ohms OK cont
Remove leads 12 (pos) |
401/403, 1/8, >1K ohms Open 5 Replace Switch PC Board
1 and 9 (pos) to >1K ohms OK cont
/ 4/5 (neg)
<100 ohms Short 5 Replace Switch PC Board
9 (neg) to <100 ohms OK cont
4/5 (pos)
>1K ohms Open 5 Replace Switch PC Board
1/8 (pos) to <100 ohms OK cont
9 (neg)
>1K ohms Open 5 Replace Switch PC Board
1/8 (neg) to >1K ohms OK cont
9 (pos)
<100 ohms Short 5 Replace Switch PC Board
12 (pos) to <100 ohms OK cont
4/5 (neg)
>1K ohms Open 5 Replace Switch PC Board
12 (neg) to >1K ohms OK cont
4/5 (pos)
<100 ohms Short 5 Replace Switch PC Board
12 (pos) to >1K ohms OK cont
401/403 (neg)
<100 ohms Short 5 Replace Switch PC Board
12 (neg) to <100 ohms OK cont
401/403 (pos)
>1K ohms Open 5 Replace Switch PC Board
9 (pos) to <100 ohms OK cont
402/404 (neg)
>1K ohms Open 5 Replace Switch PC Board
9 (neg) to >1K ohms OK cont
402/404 (pos)
<100 ohms Short 5 Replace Switch PC Board
27
Next
Test Test Repair
Step Test Check Result Conclusion Step Action
5 Snubber Lead 401 to 25 ohms OK cont
Resistors terminal 12
>30 ohms R4 open Replace Rá
Disconnect leads <20 ohms R4 shorted
401, 402, 403 and
404 from Switch Lead DE г 25 ohms OK cont
ermina
PC board >30 ohms RS open Replace RS
<20 ohms RS shorted
Lead 403 to 25 ohms oK cont
terminal 12
>30 ohms R6 open Replace Ró
<20 ohms R6 shorted
Lead 404 to 25 ohms OK cont
terminal 9
>30 ohms R7 open Replace R7
<20 ohms R7 shorted
6 Output diodes <100 ohms Shorted output diode Test individually
+ output plug (pos) D1 thru D12
Remove output to ,
Load - output plug (neg) >200 ohms Output diodes OK
28
Next
Test Test Repair
Step Test Check Result Conclusion Step Action
7 013 Input 9 (pos) to >1K ohms OK cont
Rectifier H1 (neg)
<100 ohms Shorted 4-5 Replace D13
` Inspect S1
Test C1 and C2
9 (pos) to >1K ohms OK cont
A (neg)
<100 ohms Shorted 4-5 Replace D13
Inspect $1
Test C1 and C2
9 (pos) to >1K ohms OK cont
H5 (neg)
<100 ohms Shorted 4-5 Replace D13
Inspect 51
Test C1 and C2
12 (neg) to >1K ohms OK cont
H1 (pos)
<100 ohms Shorted 4-5 Replace D13
Inspect $1
Test C1 and C2
12 (neg) to >1K ohms OK cont
A (pos)
<100 ohms Shorted 4-5 Replace D13
Inspect $1
Test C1 and C2
12 (neg) to >1K ohms OK cont
HS (pos)
<100 ohms Shorted 4-5 Replace D13
Inspect $1
Test C1 and C2
9 (neg) to <100 ohms OK cont
H1 (pos)
>1K ohms Open 4-5 Replace D13
Inspect St
Test C1 and C2
9 (neg) to <100 ohms OK cont
A (pos)
>1K ohms Open 4-5 Replace D13
Inspect $1
Test C1 and C2
9 (neg) to <100 ohms OK cont
H5 (pos)
>1K ohms Open 4-5 Replace D13
Inspect $1
Test C1 and C2
12 (pos) to <100 ohms OK cont
H1 (neg)
>1K ohms Open 4-5 Replace D13
Inspect $1
Test C1 and C2
12 (pos) to <100 ohms OK cont
A (neg)
>1K ohms Open 4-5 Replace D13
Inspect $1
Test C1 and C2
12 (pos) to <100 ohms OK cont
H5 (neg)
>1K ohms Open 4-5 Replace D13
Inspect S1
Test C1 and C2
29
Matched Parts
Certain parts must be replaced in matched sets. Matched sets are
required in the following areas: |
Output diodes: D1, D2, D3, D4 and DS
Output diodes: D7, D8, D9, D10 and D11
Capacitor bleeder resistors: R1 and RS
Capacitors: Cl and C2
Capacitors: Cl, C2, Ci4 and C15 (575VAC only)
Switch PC Board Repairs
If a test indicates that a Switch PC board is defective, both Switch PC
boards must be replaced. A defective module is likely to damage other
devices in the power circuitry. The defect may be subtle and not
detectable by an ohmmeter measurement. Unknown defective parts may cause
newly replaced parts to fail.
In addition to replacing the Switch PC boards, replace Cl and C2 (also
Cl4 and C15 of the 575VAC) if the following conditions are met:
1. Machine was operating from 380VAC or higher supply when failure
occurred.
2. Switch PC boards have burned areas.
Switch PC Board Replacement Procedure
DANGER: TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH
AND DISCHARGE INPUT CAPACITORS BEFORE WORKING INSIDE THE
MACHINE.
Only qualified personnel should perform installation,
maintenance and troubleshooting work.
1. Carefully disconnect the leads at the top of the Switch PC
board.
2. Remove the four socket head cap screws with a 3/16" hex key
wrench.
3. While holding the Switch PC board, remove the hex head cap
screws from the center area of the board.
4. Remove the board.
5. Thoroughly clean the heat sink surface.
6. Apply a thin layer (ideally -002") of Dow 340 Heat Sink
Compound to the module mounting surfaces of the new Switch PC
board and also to the capacitor terminals. Keep the heat sink
compound away from the screw threads since this compound will
affect the torque specifications.
7. Carefully place the Switch PC board onto the heat sink, being
sure the mounting holes are lined up before making full
contact with the heat sink.
8. Caution: The heat sink and the capacitor terminals are
relatively soft material and it is very easy to cross-thread
the mounting screws. Holding the Switch PC board, install the
4 socket head cap screws, finger tight only. Then install the
hex head cap screws into the capacitor, finger tight only.
9. Torque the 4 socket head cap screws to 44 inch-lbs force (5
Nm). Then torque the capacitor hex head cap screws to 55
inch-lbs force (6 Nm).
10. Reconnect all the leads to the board.
Before applying input power to the machine, check all electrical
connections. An incorrect connection will result in machine damage
when the power is switched on.
Test After Repair
l. Short terminals 14 and 53 of the Protection PC board. Connect
an ohmmeter, set for X1000 range, to terminals 9 (+) and 12
(=) of the Switch PC board. The meter will show the
capacitors charging up. The meter may take a minute or so to
stabilize. The value must not exceed 8600 ohms. Test both
boards. For 575V only units - measure across each power
capacitor, 2 per switch board; All four readings should be
approximately 5,000 ohms.
2 If OK, remove the short and proceed with the power test.
3. Fuse input supply with 5 amp fuses.
4. Check output open circuit voltages. Do not apply output load.
5. Connect machine for 460 or 575.
6. Check output open circuit voltages. Do not apply output load.
7. Fuse for 20 amps and test under load.
Replacement_of Power Modules and Output Diodes
Input rectifier, D13, and the large devices on the Switch PC boards are
power modules. When mounting power modules, the heat sink and module
mounting surface should be clean and free of burrs and foreign material.
For Switch PC board modules, apply an even coating of joint compound to
the module mounting surfaces. For the input rectifier, use the thin
sheet of thermal material supplied. The joint compound should be,
ideally, .002" thick to eliminate all air pockets. This may be verified
by mounting and then removing the module. When removed, the compound on
both surfaces will appear textured as if a vacuum had created veinlike
ridges when the parts were separated. If the compound does not have this
appearance, apply more joint compound and recheck.
31
Replacement of output diodes D1 thru D12 is similar. Clean and brighten
mounting surface with fine steel wool. Compound should be used on
surface between diode and heat sink when mounting individual diodes. The
compound should be applied to the heatsink in a very thin layer, less
than 0.001 in. Do NOT apply on diode stud and mounting nut threads.
Components must have proper torque applied to mounting screws and to
electrical terminals. Torque the modules according to the following:
COMPONENT TO HEAT SINK TERMINAL
COMPONENT TORQUE ~ 10% TORQUE ~ 10%
Switch Board
Module 44 Inch - lbs.” М.А.
(SN-m)
Capacitor N.A. 55 Inch - lbs.
(6.3 N-m)
Input Rectifier 6 Inch - lbs.” 26 Inch - lbs.
(M15454-1) (0.7 N-m) (3 N-m)
Output Diode 25 Inch - lbs. N.A.
(M15482-2) (3 N-m)
© Retorque after 3 hours to allow for spread of compound.
@ Tighten in staggered fashion one quarter turn at a time.
Environmental Protection
High voltage connections are covered with an RTV sealant to prevent
malfunction in severe environments. Sealant must be applied to
connections which have been opened or otherwise lost their protection. A
noncorrosive electronic grade sealant such as Dow Corning 3140, 3145,
738, Columbus Adhesives 0172 or GE RTV-162 is recommended. Sealant may
also be purchased from Lincoln Electric (order E2519 Silicone Rubber RTV
Coating). Apply sealant after machine is repaired and tested.
High voltage areas which require sealant are as listed:
= Input rectifier D13, all 5 terminals.
32
Printed Circuit Board Replacement
Handle PC boards by edges only.
Store PC boards only in the bags that they were shipped in. Some PC
boards require special bags that disperse static charges.
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.
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.
CONNECTION AND REFERENCE DIAGRAMS
K867 Adapter Connection Diagram (£19406)
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NOTE: This dia
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52
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write
т
ide the machine on one of the enclosure panels. If the diagram is illegible
This diagram is for reference only. it is not accurate for all machines covered by this manual. The specific dia-
to the Service Department for a replacement. Give the welder code number.
gram for a particular code is pasted ins
NOTE
53
WARNING
e De not touch electrically live parts or
electrode with skin or wet clothing.
e insulste yoursalf from work and
ground.
”” AVISO DE
PRECAUCION
e No toque las partes o los electrodos
bajo carga con la piel e ropa mojada.
e Aislese del trabajo y de la tierra.
e Mantenga el material combustible fuera
del área de trabajo.
* Protéjase los ojos, los oldes y el cuerpo.
ATTENTION
@ Ne laissez ni la peau ni des vêtements
mouillés entrer en contaci avec des
pièces sous tension.
© isolez-vous du travail et de ia terre.
© Gardez à l'écart de tout matériel
inflammable.
e Protégez vos yeux, ves oreilles et votre
corps.
© Entiernen Sis brennbarres Material!
German @ Berühren Sie keine stromführenden © Tragen Sie Augen-, Ohren- und Kür-
Teile oder Elektroden mit Ihrem Körper perschutz!
WARNUNG |. oso tuchter Keidung
e isoñeren Sie sich von den Elektroden
und dem Erdboden!
Portuguese € Nao toque partes elétricas e electrodos e Use proteçäo para a vista, ouvido e
ATENGAO
com a pele ou roupa molhada.
© isole-se da peca e terra.
e Mantenha inflamáveis bem guardados.
corpo.
iz 0 ARTPORASA. Ni2B/HICE O MALT ENDOMTONSETE e E. ERUS A <QMAELTT
I TRRNLEBFTRAE VE, REPL TRENELA, & ti,
IF = CRIMP? —2 ro SAFER
ATUSHELTFEUL,
Chinese e ERZAZ 97 EMPRESA LR e £—ENRMLEMIFA. ORNE. FRINELDREAL.
ax AF, set.
= = ÉRAERHTOIHBK,
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= Dez BU YA AL. ARIAL.
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=
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” 9 peal ala 3 9 ASN $ res Ba y
Juda ALL AU AD
Jail DA Dama Ae INC pío
READ AND UNDERSTAND THE MANUFACTURER'S INSTRUCT
ION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER'S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES
DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS
DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN
CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE
EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE
VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER
ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS.
DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS
SIND EBENFALLS ZU BEACHTEN.
e Ksep your head out of fumes.
© Use ventilation or exhaust to remove
fumes from bresthing zone.
“= O
e Turn power off befors servicing.
N
| e Do not operate with panel open or
guards ofl.
WARNING
e Los humos fuera de la zona de
respiración.
e Mantenga la cabeza fuera ds los
humos. Utica ventilación o aspiración.
para gases.
e Desconectar el cable de alimentación de
poder de la máquina antes de iniciar
cualquier servicio.
|AVISO DE
PRECAUCIÓN
© Gardez la tête à l'écart des fumées.
© Utilisez un ventilateur ou un aspirateur
pour ôter les fumées des zones de
travail.
e Débranchez le courant avant l'entretion.
e N'opérez pas avec les panneaux
ouverts ou avec les disposlifs de pro-
tection enievés
ATTENTION
e Vermeiden Sie das Einatmen von
Schweirauch!
® Sorgen Sie für gute Be- und Entlüftung
des Arbeitspiatzes!
e Strom vor Wartungsarbeiten abschaften!
(Netzstrom völlig öffnen; Maschine
anhalten!)
e Anlage nis ohne Schutzgehäuse oder
Innenschutzverkleidung in Betrieb
setzen!
J Germa
WARNUNG
e Mantenha seu rosto da fumaça.
e Uss ventilacao e exhsustdo para
€ Nio opere com as tampas removidas.
e Desiigue 3 corrents antes de fazer
® Mantenha-ss afastado das partes
|
Portug
ATENÇAO
remover fumo da zona respiratéris. servico. e Ndo opere com os paineis abertos ou
e Nao toque as partes elétricas nuas. guardas removidas.
e El-2PSEMENTLSELT |ex7747-2-4-E1CRU> |enanPAN-EMUALESS [IP
Fa, PEIRCE, ETRE FE TMMMNELLOTFEU, a = I
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EU 550 ia Sle y Me ggóll Jaiiio ale Caray] A y Magia и
e a E A CE CAD das S а
LEIA E COMPREENDA AS INSTRUGDES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO,
E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR.
ES MHPRHO—D—DIERVEL<HH. ETMLTTFEUL, FLTRHEDRERELE>TTF EL,
EEN EEE MNAE LEZEANEEHNEA, EMUETFTRINANEPORERE,
0| AS ==
SUXIAME SASALD MANI HA AATES EFSAD| SERICH
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LIMITED WARRANTY
STATEMENT OF WARRANTY:
The Lincoln Electric Company (Lincoln) warrants to the original
purchaser (end-user) of new equipment that it will be free of
defects in workmanship and material.
This warranty is void if Lincoln finds that the equipment has
been subjected to improper care or abnormal operation.
WARRANTY PERIOD:
All warranty periods date from the date of shipment to the
original purchaser and are as follows:
Three Years:
Transformer Welders
Motor-generator Welders
Semiautomatic Wire Feeders
Plasma-cutting Power Source
Engine Driven Welders (except engine and engine
sories) with operating speed under 2,000 RPM
Two Years:
Engine Driven Weiders (except engine a
sories) with operating speed over 2,000 RY.
or engine accessory manufacturer =
warranty.
Equipment not listed above suff
automatic wire feeders and
warranted for one year.
AN
TO OBTAIN WARRANTY COVERAGE:
You are required to notify Lincotn Electric, your Lincoln Distribu-
tor, Lincoln Service Center or Field Service Shop of any defect
within the warranty period. Written notification is recommended.
e ter or Field Sey:ce Shop as well as return shipment
» CHA
loss of business, etc.) caused by the defect or reasonable
delay in correcting the defect.
» Lincoln's liability under this warranty shall not exceed the
cost of correcting the defect |
* This written warranty is the only express warranty provided
by Lincoin with respect to its products. Warranties implied by
law such as the Warranty of Merchantability are limited to the
duration of this limited warranty for the equipment involved.
PERFORMANCE
PLUSPROTECTION
ELECTRIC
World's Leader in Welding and Cutting Products « Premier Manufacturer of industrial Motors
Sales and Service through Subsidiaries and Distributors Worldwide
Cleveland, Ohio 44117-1199 U.S.A.
, THE LINCOLN ELECTRIC COMPANY
Litho in U.S.A.