INVERTEC V300-PRO
OPERATOR’S MANUAL
For use with machines Code 10256 and 10257.
IM526-BDecember,1999
Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.
™
Date of Purchase:Serial Number:Code Number:Model:Where Purchased:
• 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
• World's Leader in Welding and Cutting Products •
This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.
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PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.Read and understand the following safety highlights. For additional safety information it is strongly recommended that you pur-chase 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 theLincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WELDING SPARKS cancause fire or explosion.4.a..Remove fire hazards from the welding area.
If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot
materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.
4.b. Where compressed gases are to be used at the job site, spe-cial precautions should be used to prevent hazardous situa-tions. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for the equip-ment being used.
4.c. When not welding, make certain no part of the electrode cir-cuit is touching the work or ground. Accidental contact cancause overheating and create a fire hazard.
4.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned.” For information purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).
4.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.
ARC RAYS can burn.2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.
2.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.
2.c. Protect other nearby personnel with suitable non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK cankill.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 bareskin or wet clothing. Wear dry, hole-freegloves to insulate hands.
1.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.
In addition to the normal safety precautions, if weldingmust be performed under electrically hazardous condi-tions (in damp locations or while wearing wet clothing;on metal structures such as floors, gratings or scaf-folds; when in cramped positions such as sitting, kneel-ing or lying, if there is a high risk of unavoidable or acci-dental contact with the workpiece or ground) use the fol-lowing equipment:
• Semiautomatic DC Constant Voltage (Wire)Welder.
• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.
1.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic weld-ing gun are also electrically“hot”.
1.d. Always be sure the work cable makes a good electrical con-nection with the metal being welded. The connection shouldbe as close as possible to the area being welded.
1.e. Ground the work or metal to be welded to a good electrical(earth) ground.
1.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.
1.g. Never dip the electrode in water for cooling.
1.h. Never simultaneously touch electrically “hot” parts of elec-trode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.
1.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
1.j. Also see Items 4.c. and 6.
WARNING ARC WELDING can be hazardous.
FUMES AND GASEScan be dangerous.3.a. Welding may produce fumes and gases haz-
ardous to health. Avoid breathing thesefumes and gases.When welding, keep yourhead out of the fume. Use enough ventila-tion and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When weldingwith electrodes which require special ventilation suchas stainless or hard facing (see instructions on contain-er or MSDS) or on lead or cadmium plated steel andother metals or coatings which produce highly toxicfumes, keep exposure as low as possible and belowThreshold Limit Values (TLV) using local exhaust ormechanical ventilation. In confined spaces or in somecircumstances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.
3.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.
3.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation, espe-cially in confined areas, to insure breathing air is safe.
3.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow your employ-er’s safety practices. MSDS forms are available from yourwelding distributor or from the manufacturer.
3.e. Also see item 7b.
Apr. ‘93
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FOR ENGINEpowered equipment.
7.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.
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7.b. Operate engines in open, well-ventilatedareas or vent the engine exhaust fumes out-doors.
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FOR ELECTRICALLYpowered equipment.6.a. Turn off input power using the disconnect
switch at the fuse box before working onthe equipment.
6.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’s rec-ommendations.
6.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.
CYLINDER may explodeif damaged.5.a. Use only compressed gas cylinders contain-
ing the correct shielding gas for the processused and properly operating regulatorsdesigned for the gas and pressure used. All
hoses, fittings, etc. should be suitable for the application andmaintained in good condition.
5.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.
5.c. Cylinders should be located: • Away from areas where they may be struck or subjected to
physical damage. • A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
5.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
5.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
5.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.
5.g. Read and follow the instructions on compressed gas cylin-ders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,”available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.
7.c.Do not add the fuel near an open flame weld-ing arc or when the engine is running. Stopthe engine and allow it to cool before refuel-ing to prevent spilled fuel from vaporizing oncontact with hot engine parts and igniting.Do not spill fuel when filling tank. If fuel isspilled, wipe it up and do not start engineuntil fumes have been eliminated.
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7.d. Keep all equipment safety guards, coversand devices in position and in good repair.Keep hands, hair, clothing and tools awayfrom V-belts, gears, fans and all other mov-ing parts when starting, operating or repair-ing equipment.
7.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.
7.f. Do not put your hands near the engine fan. Do notattempt to override the governor or idler by pushing onthe throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines while turn-ing the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.
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7.h. To avoid scalding, do not remove the radia-tor pressure cap when the engine is hot.
Mar. ‘93
ELECTRIC AND MAGNETICFIELDSmay be dangerous8.a. Electric current flowing through any con-
ductor causes localized Electric andMagnetic Fields (EMF). Welding currentcreates EMF fields around welding cablesand welding machines.
8.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.
8.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.
8d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:
8.d.1. Route the electrode and work cables together - Securethem with tape when possible.
8.d.2. Never coil the electrode lead around your body.
8.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side,the work cable should also be on your right side.
8.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.
8.d.5. Do not work next to welding power source.
4.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in a weld-ing area.
4.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passing throughlifting chains, crane cables or other alternate circuits. This cancreate fire hazards or overheat lifting chains or cables untilthey fail.
4.h. Also see item 7c.
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PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:
Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nue oules vétements mouillés. Porter des gants secs et sans trouspour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un plancher met-allique 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 desoudage et la machine à souder en bon et sûr état defonc-tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.
e. Ne jamais toucher simultanément les parties sous tensiondes 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 decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.
2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partie ducorps.
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 ainsiqu’un verre blanc afin de se protéger les yeux du rayon-nement de l’arc et des projections quand on soude ouquand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peaude soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer un échauf-fement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible dela zone de travail qu’il est pratique de le faire. Si on place lamasse sur la charpente de la construction ou d’autres endroitséloignés de la zone de travail, on augmente le risque de voirpasser le courant de soudage par les chaines de levage,câbles de grue, ou autres circuits. Cela peut provoquer desrisques d’incendie ou d’echauffement des chaines et descâbles 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 tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voirle code “Code for safety in welding and cutting” CSA StandardW 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR
1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancherà l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ‘93
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TABLE OF CONTENTSPage
Safety Precautions .............................................................................................................2-4Introductory Information .......................................................................................................6Product Description..............................................................................................................7Specifications.......................................................................................................................7Installation .........................................................................................................................7-10
Safety Precautions ........................................................................................................7Location .........................................................................................................................7Electrical Installation......................................................................................................7Input Voltage Setup .......................................................................................................8Power Cord Connection ................................................................................................8Connection of Wire Feeders to Invertec .....................................................................8-10Output Cables & Plugs .................................................................................................10
Operating Instructions ......................................................................................................11-13Safety Precautions .......................................................................................................11Controls Description and Function.............................................................................11-13
Maintenance.....................................................................................................................13-14Capacitor Discharge Procedure ...................................................................................13Routine Maintenance....................................................................................................13Periodic Maintenance ...................................................................................................14
Troubleshooting Guide .....................................................................................................14-20Matched Parts.....................................................................................................................20Switch P.C. Board Replacement Procedure .......................................................................20Replacement of Power Modules and Output Diodes .......................................................20-21Connection Diagrams.......................................................................................................22-31Wiring Diagrams...............................................................................................................32-33Parts Lists ......................................................................................................................appendix
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Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:
WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.
CAUTION
Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.
Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the informationyou have recorded above.
PRODUCT DESCRIPTION
The Invertec V300-PRO is a 300 amp arc weldingpower source that utilizes single or three phase inputpower to produce either constant voltage or constantcurrent outputs. The V300-PRO is designed for 60 Hzsupply systems. The welding response of the Invertechas been optimized for GMAW, SMAW, TIG andFCAW processes. It is designed to be used with theLN-25 and LN-7 semiautomatic wire feeders.
SPECIFICATIONS
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INSTALLATION
ELECTRIC SHOCK can kill.• Have an electrician install and service
this equipment.• Turn the input power off at the fuse
box before working on equipment.• Do not touch electrically hot parts.---------------------------------------------------------------------
WARNING
LOCATION
The Invertec has been designed with many features toprotect it from harsh environments. Even so, it isimportant that simple preventative measures are fol-lowed in order to assure long life and reliable opera-tion.• The machine must be located where there is free
circulation of clean air such that air movement intothe sides and out the bottom and front will not berestricted. Dirt and dust that can be drawn into themachine should be kept to a minimum. Failure toobserve these precautions can result in excessiveoperating temperatures and nuisance shutdown ofthe Invertec.
• Keep machine dry. Shelter from rain and snow. Donot place on wet ground or in puddles.
ELECTRICAL INSTALLATION
1. The Invertec should be connected only by a quali-fied electrician. Installation should be made inaccordance with the U.S. National Electrical Code,all local codes and the information detailed below.
2. Single voltage, 575 VAC machines, can only beconnected to 575 VAC. No internal reconnectionfor other input voltages is possible.
3. Initial 208 VAC and 230 VAC operation will requirea voltage panel setup, as will later reconnectionback 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.
Product Ordering Input AC Rated DC Output Input Amps at Rated DC Output Output Weight DimensionsName Information Voltage Amps/Volts/Duty Cycle
208 230 460 575Range with Gun HxWxD
(continuous) (net)
208/230/460 300A / 32V / 60%(1) 48 43 24
3 Phase 250A / 30V / 100%(1) 37 33 19
60 Hz 300A / 35/39/41V /60%(2) 49 48 28 18.7*x10.8x
Invertec K1349-3 22.2”
V300- 208/230/460 250A / 30V / 60%(1) 69 62 38 AMPS 64 lbs. (475x274x
PRO 1 Phase 160A / 28V / 100%(1) 53 47 29 5-350 (29 kg) 564 mm)
60 Hz 250A / 37/41/43V / 60%(2) 75 67 42
* Includes
575 300A / 32V / 60%(1) 20 handle
K1349-4 3 Phase 250A / 30V / 100%(1) 16
60 Hz 300A / 36V / 60%(2) 22(1 )NEMA Class I Rated Output / Based on a 10 min. Period . (2 )Lincoln plus rating.
* Overall Height Including Handle, (16.4” (417mm without handle).
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INPUT VOLTAGE SETUP
POWER CORD CONNECTION
A 10 ft. (3.0m) power cord is provided and wired intothe machine. Follow the power cord connectioninstructions. Incorrect connection may result in equip-ment damage.
Single Phase Input
1. Connect green lead to ground per U.S. NationalElectrical Code.
2. Connect black and white leads to power.3. Wrap red lead with tape to provide 600V insula-
tion.
Three Phase Input
1. Connect green lead to ground per U.S. NationalElectrical Code.
2. Connect black, red and white leads to power.
Install in accordance with all local and national electriccodes.
CONNECTION OF WIRE FEEDERS TO THEINVERTEC(Note: IEC units do not have 110 VAC auxiliarypower).LN-25 Connection Instructions
1. Turn the Invertec power switch “off”.
2. Connect the electrode cable to the output terminalof polarity required by electrode. Connect the worklead to the other terminal.
3. LN-25 with remote control options K431 and K432.Use K876 adapter with K432 cable or modify K432cable with K867 universal adapter plug. See con-nection diagram S19899 and S19309 or S19405 atthe back of this manual.
4. Place the local-remote switch in the “remote” posi-tion if output control is desired at the wire feederrather than the Invertec. (LN-25 must have K431and K432 options for remote output control opera-tion).
LN-7 Connection Instructions
1. Turn the Invertec power switch “off”.
2. Connect the K480 control cable from the LN-7 tothe Invertec control cable connector. The controlcable connector is located at the rear of theInvertec.
3. Connect the electrode cable to the output terminalof polarity required by electrode. Connect the worklead to the other terminal.
4. Place the local-remote switch in the “local” posi-tion to allow output control at the Invertec. (K864
Recommended Fuse Sizes Based On The U.S.National Electrical Code And Maximum
Machine Outputs
Fuse Size in AmpsInput Volts(1) (Time Delay Fuses)
3 phase 208 6050/60 Hz 230 60
460 40
1 phase 208(2) 8550/60 Hz 230(2) 80
460 50
3 phase 575 3060 Hz
(1) Input voltage must be within ±10% of rated value.(2) When operating on these inputs, at outputs exceeding 200A/60%
or 165A/100%, the input line cord should be changed to an inputconductor of 6 AWG or larger.
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
.
.
.
.
Do not touch electrically live parts.
Only qualified persons should install,use or service this equipment.
RECONNECT PROCEDURE
REPLACE WITH A 3 AMP SLOW BLOW ONLY.
1. BE SURE POWER SWITCH IS OFF.
200-208V
220-230V
380-415V
440-460V
’A’
INPUT VOLTAGE RANGE. removed.Do not operate with wraparound
inspecting or servicing machine.
Disconnect input power before
IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)
2. CONNECT LEAD ’A’ TO DESIRED
3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.
S20324
AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;
VOLTAGE=380-460V VOLTAGE=200-230V
9-11-92
BLACKGREENREDWHITE
DO NOT ATTEMPT TO POWER THIS UNITFROM THE AUXILIARY POWER SUPPLYOF AN ENGINE WELDER.• Special protection circuits may operate, causing
loss of output.• The supply from engine welders often has exces-
sive voltage peaks because the voltage waveformis usually triangular shaped instead of sinusoidal.
• If voltage peaks from the engine welder exceed380V, the input circuits of this machine protectingthe filter capacitors, FETS and other componentsfrom damage will not be energized .
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CAUTION
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remote control adapter and K857 remote controlare required for remote output control).
5. Set the meter polarity switch on the rear of theInvertec to coincide with wire feeder polarity used.The wire feeder will now display the welding volt-age.
6. If K480 is not available, see connection diagramS19404 for modification of K291 or K404 LN-7input cable with K867 universal adapter plug.
General Instructions for Connection of WireFeeders to Invertec
Wire feeders other than LN-7 and LN-25 may be usedprovided that the auxiliary power supply capacity ofthe Invertec is not exceeded. K867 universal adapterplug is required. See connection diagram S19406 andS19386 at the back of this manual for more informa-tion.
Remote Control of Invertec
Remote control K857, hand amptrol K963 and footamptrol K870 require K864 remote control adapter.See 19309 instruction at the back of this manual forconnection information.
K954-1 MIG PULSER
The MIG Pulser is a hand-held “pendant” type GMAWPulsing option for the V300 Power Source. Refer tothe Mig Pulser’s IM manual (IM555) for connectioninformation.
Parallel Operation
The Invertec’s are operable in parallel in both CC andCV modes. For best results, the currents of eachmachine should be reasonably well shared. As anexample, with two machines set up in parallel for a400 amp procedure, each machine should be set todeliver approximately 200 amps, not 300 amps fromone and 100 amps from the other. This will minimizenuisance shutdown conditions. In general, more thantwo machines in parallel will not be effective due tothe voltage requirements of procedures in that powerrange.
To set machine outputs, start with output control potsand arc force/pinch pots in identical positions. If run-ning in a CC mode, adjust outputs and arc forces tomaintain current sharing while establishing the properoutput current. In CV modes, the pots in identicalpositions. Then switch the machine meters to ampsand adjust one of the output control pots for currentbalance. Check the voltage and if readjustment isnecessary, repeat the current balancing step. Pinchsettings should also be kept identical on themachines.
K900-1 DC TIG Starter Connection
This versatile new kit was made to mate with theInvertec.
A control cable assembly is supplied with the kit toconnect the kit to an Invertec. The cable can be con-nected, either end, at the DC TIG Starter kit and atthe Invertec by attaching to the 14-pin Amphenols onthe backs of each unit. Refer to diagram S20405 atthe back of this manual.
A negative output cable assembly is also suppliedwith the DC TIG Starter kit to connect the kit with theInvertec’s negative output terminal.
All Magnum™ one and two piece water-cooled torch-es with 7/8 left-hand threads and gas-cooled torcheswith 7/8 and 5/16 right-hand threads can be connect-ed to the starter kit.
To secure the DC TIG Starter kit to the bottom of theInvertec and for more detailed instructions, refer tothe K900-1 manual.
MAR97
LN-9 GMA Connection Instructions
1. Turn the Invertec power switch “off”.
2. Connect the K596 control cable assembly from theLN-9 GMA to the Invertec control cable connector.The control cable connector is located at the rearof the Invertec.
3. Connect the electrode cable to the output terminalof polarity required by electrode. Connect the worklead to the other terminal.
4. Place the local-remote switch in the “remote” posi-tion to allow output control at the LN-9 GMA.
5. Set the meter polarity switch on the rear of theInvertec to coincide with wire feeder polarity used.The wire feeder will now display the welding volt-age.
6. K608-1 adapter is required in LN-9 GMA for LN-9type control. K608-1 is installed in line with P10connection at the LN-9 GMA voltage board. Seediagram S20607 at the back of this manual.
7. K442-1 Pulse Power Filter Board is also requiredfor GMAW, but should be disconnected for FCAW.
8. If K596 is not available, see connection diagramS20608 at the back of this manual for modificationof K196 LN-9 GMA input cable with K867 universaladapter plug.
Output Cables
Select the output cable size based upon the followingchart.
Cable sizes for Combined Length of Electrode andWork Cable (Copper) 75° rated:
Duty Length Up 61-76mCycle Current 61m (200 ft.) (200-250 ft.)
100% 250 1/0 1/060% 300 1/0 2/0
Quick Disconnect Plugs
A quick disconnect system is used for the weldingcable connections. The welding plug included with themachine is designed to accept a welding cable size of1/0 to 2/0.
1. Remote 25mm (1 in.) of welding cable insulation.
– 10 –
2. Slide rubber boot onto cable end. The boot endmay be trimmed to match the cable diameter.Soap or other lubricant will help to slide the bootover the cable.
3. Slide the copper tube into the brass plug.
4. Insert cable into copper tube.
5. Tighten set screw to collapse copper tube. Screwmust apply pressure against welding cable. Thetop of the set screw will be well below the surfaceof the brass plug after tightening.
6. Slide rubber boot over brass plug. The rubberboot must be positioned to completely cover allelectrical surfaces after the plug is locked into thereceptacle.
25 mm
1 in.
WELDING CABLE
BOOT
TRIM
SET SCREW
BRASS PLUGCOPPER TUBE
– 11 –
OPERATING INSTRUCTIONS
DUTY CYCLE
The Invertec is rated at 300 amps, 60% duty cycle for3 phase inputs (based on a 10 minute cycle). It is alsorated at 250 amps, 100% duty cycle.
CONTROL FUNCTION / OPERATION
Power Switch - Place the lever in the “ON” position toenergize the machine. When the power is on, the digi-tal meter will activate and the fan will operate.
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 danger-
ous.• Keep your head out of fumes.• Use ventilation or exhaust to remove
fumes from breathing zone.------------------------------------------------------------------------
WELDING SPARKS can cause fire orexplosion.
• 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 atfront of this operator’s manual.
-----------------------------------------------------------
WARNING
Output Control - This controls the output voltage inthe CV modes and output current in the CC modes.
Control is provided over the entire output range of thepower source with 1 turn of the control knob. This con-trol may be adjusted while under load to changepower source output.
Local/Remote Switch - Place in the “LOCAL” posi-tion to allow output adjustment at the machine. Placein the “REMOTE” position to allow output adjustmentat the wire feeder or with a remote control optionpackage.
Digital Meter Switch - Select either “A” for amps or“V” for volts to display welding current or voltage onthe meter.
When welding current is not present, the meter willdisplay the set current for the CC modes or the setvoltage for the CV modes. This set reading is an indi-cation of machine control setting. For a more preciseprocess reading, read meter during actual welding.
Mode Switch
GTAW Optimized for both scratch start and Hi-Freq kit use.
CC SOFT Best for EXX18 thru EXX28 stick elec-trodes.
CC Crisp Use this mode for stick welding withEXX10 thru EXX14 electrodes. Non-welding applications such as resistiveheating or output tests with resistiveloads should be done in this mode withArc Force Control set to minimum.
OFF
OUTPUT
REMOTE
–
CV FCAW This setting has been optimized forInnershield® and Outershield® flux-coredelectrodes.
CV GMAW Short circuit, glob and spray transfersolid wire and gas welding are done inthis mode. Low end procedures, lessthan 17V, may operate better in theFCAW mode. Voltage in the GMAWmode can become erratic whenwelding is attempted using voltagesequal to or less than 17V DC+.
Output Terminals Switch
For processes and equipment that require energizedmachine terminals (stick, TIG, air-carbon arc cutting orhot tip LN-25), set the Output Terminals Switch to“ON” position.
Set to the REMOTE (OFF) position when using LN-25with K431 and K432 options or LN-7 which will allowthe gun trigger to energize the welding terminals.
Arc Force / Inductance Control
This control functions in all modes except GTAW. ForCC modes, this control acts as an Arc Force adjust-ment. The arc is soft at the minimum settings andmore forceful or driving at the maximum settings.Higher spatter levels may be present at the maximumsettings.
For CV modes, this control will set the degree of“pinch effect” which predominantly affects short circuittransfer. In FCAW, the maximum setting is generallypreferred. With GMAW, the upper half of the range ispreferred with CO2 or high content CO2 mixed. Thelower half is for inert gas mixes.
– 12 –
Recommended Arc Force / Inductance SettingsFor Selected Applications
Full Range Is 1-10,1 Is Very Soft, 10 Is Very Crisp
Nominal RecommendedMode Process Setting Adjustment Range
CC SMAW 1 EXX18 thru 5 1 (gentle, may stick) to 9EXX28 stick (forceful, more spatter)
CC SMAW 2 EXX10 thru 6 3 to 10EXX14 stick
Air Carbon Arc 1 NoneCutting
CV FCAW Innershield or 10 NoneOutershield
Air Carbon Arc 1 NoneCutting
CV GMAW* CO2 or 25% CO2 7.5 5 to 10or similargas mixes
98% Ar-2% O2Ar, 5 1 to 1090% He-7.5% Ar2.5% CO2 and
otherpredominantly
inert gases
* 1 = Lowest pinch, highest inductance and least spatter.10 = Highest pinch, lowest inductance and most spatter.
GMAW
FCAWSMAWCRISP
SMAWSOFT
GTAW
OUTPUTTERMINALS
ON
REMOTE
– 13 –
Meter Polarity Switch
The wire feeder polarity switch is located at the rear ofthe machine. The switch provides a work connectionfor wire feeder voltmeters. Place the switch in theposition of the electrode polarity indicated by thedecal. The switch does not change the weldingpolarity.
Auxiliary Power
A 24 VAC @ 1 amp supply is included for use with theLN-25 wire feeder (24 volts needed for K431 andK432 options). This supply is protected by a self-resetting current limiter.
A 42 VAC @ 5.5 amp supply is included for use withother wire feeders. This supply is protected by a 6amp breaker located on the rear of the machine.
A 110/115 VAC @ 2 amp supply is included for usewith the LN-7 or LN-9 GMA wire feeders. This supplyis protected by a 2.5 amp breaker located on the rearof the machine. It is NOT available on IEC units.
All three supplies are not to be loaded simultaneously.
MAINTENANCE
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 resis-tor terminals across the two hex head cap screwsin the position shown. Hold in each position for 1second. For 575 VAC only, repeat for secondcapacitor. Repeat for the capacitor(s) on the otherside of the machine
3. Use a DC voltmeter to check that voltage is notpresent across either capacitor.
Routine Maintenance
1. Every 6 months or so the machine should becleaned with a low pressure airstream. Keepingthe machine clean will result in cooler operationand higher reliability. Be sure to clean these areas:
• Power, switch, driver, protection and control printedcircuit 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 con-dition to insure that high voltage parts are protected andcorrect spacings are maintained. All external sheetmetal screws must be in place to insure case strengthand electrical ground continuity.
CAPACITORTERMINALS
RESISTOR
T13086-84
ELECTRIC SHOCK can kill.• Have an electrician install and service
this equipment.• Turn the input power off at the fuse
box before working on equipment.• Do not touch electrically hot parts.---------------------------------------------------------------------
EXPLODING PARTS can causeinjury.• Failed parts can explode or cause other
parts to explode when power is applied.
• Always wear a face shield and long sleeves when servicing.----------------------------------------------------------------------------------
WARNING
– 14 –
PERIODIC MAINTENANCE
Overload Protection
The machine is electrically protected from producinghigh output currents. Should the output currentexceed 340-360A, an electronic protection circuit willreduce the current to approximately 150A. Themachine will continue to produce this low current untilthe protection circuit is reset. Reset occurs when theoutput load is removed.
Thermal Protection
Thermostats protect the machine from excessiveoperating temperatures. Excessive temperatures maybe caused by a lack of cooling air or operating themachine beyond the duty cycle and output rating. Ifexcessive operating temperature should occur, thethermostat will prevent output voltage or current. Themeter will remain energized during this time.
Thermostats are self-resetting once the machine coolssufficiently. If the thermostat shutdown was caused byexcessive output or duty cycle and the fan is operatingnormally, the Power Switch may be left on and thereset should occur within a 15 minute period. If the fanis not turning or the air intake louvers were obstructed,then the power must be switched off for 15 minutes inorder to reset. The fan problem or air obstruction mustalso be corrected.
Filter Capacitor Conditioning
A protection circuit is included to monitor the voltageacross filter capacitors C1 and C2 (also C14 and C15on 575 VAC units). In the event that the capacitor volt-age is too high, the protection circuit will prevent out-put. The protection circuit may prevent output provid-ing all these circumstances are met:
1. Machine is internally connected for 380 VAC, orhigher input voltage.
2. Machine did not have power applied for manymonths.
3. Machine did not produce output when power wasfirst switched on.
If these circumstances apply, the proper action is toswitch the machine on and let it idle for up to 30 min-utes. This is required to condition the filter capacitorsafter an extended storage time. The protection circuitwill automatically reset once the capacitor conditioningand resultant voltage levels are acceptable. It may benecessary to turn the power switch off and back onagain after this period.
TROUBLESHOOTING
Visual Inspection
Clean interior of machine with a low pressureairstream. Make a thorough inspection of all compo-nents. Look for signs of overheating, broken leads orother obvious problems. Many problems can beuncovered with a good visual inspection.
Open Circuit Voltage
The open circuit voltage of the Invertec V300-PRO is60 to 75 VDC and cannot be adjusted by the outputcontrol.
Test Conditions
Perform all testing at the lowest input voltage avail-able, except where a higher voltage is required by atest step. Make ohmmeter checks only after powerhas been disconnected from machine and aftercapacitors have been discharged.
Certain high voltage connections have been insulatedwith RTV sealant. It is necessary to break through thesealant with a sharp probe in order to make voltage orresistance checks.
Disconnect any control cables from remote controlreceptacle.
ELECTRIC SHOCK can kill.• Have an electrician install and service
this equipment.• Turn the input power off at the fuse
box before working on equipment.• Do not touch electrically hot parts.---------------------------------------------------------------------
EXPLODING PARTS can causeinjury.• Failed parts can explode or cause other
parts to explode when power is applied.
• Always wear a face shield and long sleeves when servicing.----------------------------------------------------------------------------------
WARNING
– 15 –
TROUBLESHOOTING GUIDE
Trouble What To Do
Not output but fan operates and meter is on.
Poor welding, weld settings drift, or output power islow.
Main fuses open or Switch PC boards overheated.
Output turns on momentarily then switches off andrepeats. Machine is connected for 380 VAC or higherinput voltage.
OCV is normal (approx. 65-75V) but output power islow (less than 20V and 100A). Machine makessquealing noise while under load. Machine is connect-ed for 230 VAC, or lower, input voltage.
Open circuit voltage is 1-2 volts.
Output control not functioning on remote control. Localcontrol OK.
Machine does not produce more than 250A outputwhen connected to 3 phase supply.
Machine does not produce more than 200 A outputwhile connected to 1 phase supply.
Machine operates OK at 230 VAC or lower. No outputat 380 VAC or higher.
Poor EXX10 stick electrode (5P) performance. Arc“pops out”.
No output or reduced output the first time power isapplied to the machine.
Perform test steps 1A and 1B.
1. Check front panel wiring and controls.2. Replace Control PC Board.
Perform test steps 4 and 5 for both Switch PC Boardsand 7.
Perform test steps 3B, 4 and 5.
Perform test steps 4 and 5 for both Switch PC Boards.
Perform test step 6.
1. Check remote control assembly.2. Check S3, Local/Remote switch.
1. Replace main fuse if blown.2. Replace Protection PC Board.3. Replace Control PC Board.4. Perform test step 7.
Normal operation.
Perform test step 2.
Check D6 and D12, L1 and L2.
Check reconnect panel - connections and fuse.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-tact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
–– 16 –
TEST PROCEDURES
Step
1A
1B
2
3A
3B
NextTestStep
1B
2
3A
3B
4and5
Test
Output pilot circuit(set S4 on)
Protection PCboard output (setS4 on)
Static capacitorbalance (set S4off)
380 VAC inputand higher test
Dynamic capaci-tor balance (setS4 on)
380 VAC inputand higher test
Repair Action
Replace Powerand Control PCBoards
ReplaceProtection PCBoard
Check
223A to 210
302 (pos) to 275D (neg)
313 (neg) to 311 (pos)
Compare voltage acrossterminals 9 & 12 of eachSwitch PC Board.575 VAC -- 407 VDC460 VAC -- 325 VDC440 VAC -- 311 VDC415 VAC -- 293 VDC380 VAC -- 269 VDC575 VAC only - comparevoltage across 9A & 13and 13 & 12A; then, 9B &15 and 15 & 12B
Connect as in step 3A.Same voltages as above.
TestResult
24 VAC
0 VAC
15 VDC
0 VDC
<1 VDC
>5 VDC
<25 VDCdifferencebetweenreadings
>25 VDCdifference
<25 VDC
>25 VDC
Conclusion
Fan thermostat, chokethermostat, T1 trans-former and S4 all OK.
Check above compo-nents.
T1 and 15V power sup-ply OK.
Check T1 and Power PCBoard.
Protection PC Board OK
C1, C2, R1, R9 - OK(575 VAC machine C14,C15 - OK)
Check above compo-nents.
OK
Power PC Board orSwitch PC Boards aredamaged.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-tact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
– 17 –
Step
4
NextTestStep
cont
5
cont
5
cont
5
cont
5
cont
5
cont
5
cont
5
cont
5
cont
5
cont
5
cont
5
cont
5
Test
Switch PC Boardresistance test.
No dynamic testis possible.
Remove leads401/403, 1/8, 9,12, 4/5 and402/404.
Repair Action
Replace Switch PC Board
Replace Switch PC Board
Replace Switch PC Board
Replace Switch PC Board
Replace Switch PC Board
Replace Switch PC Board
Replace Switch PC Board
Replace Switch PC Board
Replace Switch PC Board
Replace Switch PC Board
Replace Switch PC Board
Replace Switch PC Board
Check
Terminals on SwitchPC Board:1/8 (pos) to12 (neg)
1/8 (neg) to12 (pos)
9 (pos) to4/5 (neg)
9 (neg) to4/5 (pos)
1/8 (pos) to9 (neg)
1/8 (neg) to 9 (pos)
12 (pos) to4/5 (neg)
12 (neg) to4/5 (pos)
12 (pos) to401/403 (neg)
12 (neg) to401/403 (pos)
9 (pos) to402/404 (neg)
9 (neg) to402/404 (pos)
TestResult
>1K ohms
<100 ohms
<100 ohms
>1K ohms
>1K ohms
<100 ohms
<100 ohms
>1K ohms
<100 ohms
>1K ohms
>1K ohms
<100 ohms
<100 ohms
>1K ohms
>1K ohms
<100 ohms
>1K ohms
<100 ohms
<100 ohms
>1K ohms
<100 ohms
>1K ohms
>1K ohms
<100 ohms
Conclusion
OK
Short
OK
Open
OK
Short
OK
Open
OK
Open
OK
Short
OK
Open
OK
Short
OK
Short
OK
Open
OK
Open
OK
Short
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-tact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
– 18 –
Step
5
6
NextTestStep
cont
cont
cont
cont
Test
SnubberResistors
Disconnect leads401, 402, 403 and404 from SwitchPC Board
Output diodes
Remove outputload
Repair Action
Replace R4
Replace R5
Replace R6
Replace R7
Test individually
Check
Lead 401 to terminal12
Lead 402 to terminal9
Lead 403 to terminal12
Lead 404 to terminal9
+ output plug (pos) to
- output plug (neg)
TestResult
25 ohms
>30 ohms<20 ohms
25 ohms
>30 ohms<20 ohms
25 ohms
>30 ohms<20 ohms
25 ohms
>30 ohms<20 ohms
<100 ohms
>200 ohms
Conclusion
OK
R4 openR4 shorted
OK
R5 openR5 shorted
OK
R6 openR6 shorted
OK
R7 openR7 shorted
Shorted outputdiode D1 thru D12
Output diodes OK
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-tact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
Repair Action
Replace D13, inspect S1,test C1 and C2
Replace D13, inspect S1,test C1 and C2
Replace D13, inspect S1,test C1 and C2
Replace D13, inspect S1,test C1 and C2
Replace D13, inspect S1,test C1 and C2
Replace D13, inspect S1,test C1 and C2
Replace D13, inspect S1,test C1 and C2
Replace D13, inspect S1,test C1 and C2
Replace D13, inspect S1,test C1 and C2
Replace D13, inspect S1,test C1 and C2
Replace D13, inspect S1,test C1 and C2
Replace D13, inspect S1,test C1 and C2
Check
9 (pos) to H1 (neg)
9 (pos) to A (neg)
9 (pos) to H5 (neg)
12 (neg) to H1 (pos)
12 (neg) to A (pos)
12 (neg) to H5 (pos)
9 (neg) to H1 (pos)
9 (neg) to A (pos)
9 (neg) to H5 (pos)
12 (pos) to H1 (neg)
12 (pos) to A (neg)
12 ( pos) to H5 (neg)
Conclusion
OK
Shorted
OK
Shorted
OK
Shorted
OK
Shorted
OK
Shorted
OK
Shorted
OK
Open
OK
Open
OK
Open
OK
Open
OK
Open
OK
Open
– 19 –
Step
7
NextTestStep
cont
4-5
cont
4-5
cont
4-5
cont
4-5
cont
4-5
cont
4-5
cont
4-5
cont
4-5
cont
4-5
cont
4-5
cont
4-5
cont
4-5
Test
D13 InputRectifier
TestResult
>1K ohms
<100 ohms
>1K ohms
<100 ohms
>1K ohms
<100 ohms
>1K ohms
<100 ohms
>1K ohms
<100 ohms
>1K ohms
<100 ohms
<100 ohms
>1K ohms
<100 ohms
>1K ohms
<100 ohms
>1K ohms
<100 ohms
>1K ohms
<100 ohms
>1K ohms
<100 ohms
>1K ohms
–
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 D5Output diodes: D7, D8, D9, D10 and D11Capacitor bleeder resistors: R1 and D9Capacitors: C1 and C2Capacitors: C1, C2, C14 and C15 (575 VAC only)
Switch PC Board Repairs
If a test indicates that a Switch PC Board is defective,both Switch PC Boards must be replaced.Replacement boards must have completely identicalpart numbers. A defective module is likely to damageother devices in the power circuitry. The defect maybe subtle and not detectable by an ohmmeter mea-surement. Unknown defective parts may cause newlyreplaced parts to fail.
In addition to replacing the Switch PC Boards, replaceC1 and C2 (also C14 and C15 of the 575 VAC V300-PRO) if the following conditions are met:
1. Machine was operating from 380 VAC or highersupply when failure occurred.
2. Switch PC Boards have burned areas.
Switch PC Board Replacement Procedure
1. Carefully disconnect the leads at the top of theSwitch PC Board.
2. Remove the four socket head cap screws with a3/16” hex key wrench.
3. While holding the Switch PC Board, remove thehex head cap screws from the center area of theboard.
4. Remove the board.
– 20 –
5. Thoroughly clean the heat sink surface.
6. Apply a thin layer (ideally .005-.010”) of Dow 340Heat Sink Compound to the module mounting sur-faces of the new Switch PC Board and a thinnerlayer (.002”) to the capacitor terminals. Keep theheat sink compound away from the screw threadssince this compound will affect the torque specifi-cations.
7. Carefully place the Switch PC Board onto the heatsink. Be sure the mounting holes are lined upbefore making full contact with the heat sink.
8. Caution: The heat sink and the capacitor terminalsare relatively soft material and it is very easy tocross-thread the mounting screws. Holding theSwitch PC Board, install the 4 socket head capscrews, finger tight only. Then install the hex headcap screws into the capacitor, finger tight only.
9. Torque the 4 socket head cap screws to 44 inch-lbs force (5 N - m). Then torque the capacitor hexhead cap screws to 55 inch-lbs force (6 N - m).
10. Reconnect all the leads to the board.
Before applying input power to the machine, check allelectrical connections. An incorrect connection will resultin machine damage when the power is switched on.
Test After Repair
1. Short terminals 14 and 53 of the Protection PCBoard. Connect an ohmmeter, set for X1000range, to terminals 9 (+) and 12 (-) of the SwitchPC Board. The meter will show the capacitorscharging up. The meter may take a minute or so tostabilize. The value must not exceed 8600 ohms.Test both boards. For 575V only units - measureacross each power capacitor, 2 per switch board;All four readings should be approximately 5,000ohms.
2. If OK, remove the short and proceed with thepower test.
3. Fuse input supply with 5 amp fuses.
4. Check output open circuit voltages. Do not applyoutput load.
5. Connect machine for 460 (V300-PRO), or 575(V300-PRO, 575V), or 380, 415 or 440 (V300-I)VAC input.
6. Check output open circuit voltages. Do not applyoutput load.
7. Fuse for 20 amps and test under load.
ELECTRIC SHOCK can kill.• Have an electrician install and service
this equipment.• Turn the input power off at the fuse
box before working on equipment.• Do not touch electrically hot parts.---------------------------------------------------------------------
EXPLODING PARTS can causeinjury.• Failed parts can explode or cause other
parts to explode when power is applied.
• Always wear a face shield and long sleeves when servicing.----------------------------------------------------------------------------------
WARNING
– 21 –
Replacement of Power Modules and OutputDiodes
Input rectifier, D13, is a power module. When mount-ing power modules, the heat sink and module mount-ing surface should be clean and free of burrs and for-eign material. Apply heatsink compound (Dow 340) asa uniform layer ideally .010” thick, to eliminate all airpockets. This may be verified by mounting and thenremoving the module. When removed, the compoundon both surfaces will appear textured as if a vacuumhad created veinlike ridges when the parts were sepa-rated. If the compound does not have this appear-ance, apply more heatsink compound and recheck.
Replacement of output diodes D1 thru D12 is similar.Clean and brighten mounting surface with fine steelwool. Compound should be used on surface betweendiode and heat sink when mounting individual diodes.
The compound should be applied to the heat sink in avery thin layer, less than 0.001 in. DO NOT apply ondiode stud and mounting nut threads.
Components must have proper torque applied tomounting screws and to electrical terminals. Torquethe modules according to the following:
Component to Heat Sink TerminalComponent Torque ±10% Torque ±10%
Switch Board
Module 44 Inch - Lbs.(1) N.A.(5N - m)
Capacitor N.A. 55 Inch - Lbs.(6.3 N - m)
Input Rectifier 6 Inch - Lbs.(2) 26 Inch - Lbs.(M15454-1) (0.7 N - m) 3 (N - m)
Output Diode 25 Inch - Lbs. N.A.(M15482-2) (3 N - m)
(1) Retorque after 3 hours to allow for spread of compound.(2) Tighten in staggered fashion one quarter turn at a time.
Environment Protection
High voltage connections are covered with an RTVsealant to prevent malfunction in severe environ-ments. Sealant must be applied to connections whichhave been opened or otherwise lost their protection. Anoncorrosive electronic grade sealant such as DowCorning 3140, 3145, 738, Columbus Adhesives 0172or GE RTV-162 is recommended. Sealant may alsobe purchased from Lincoln Electric (order E2519Silicone Rubber RTV Coating). Apply sealant aftermachine is repaired and tested.
High voltage areas which require sealant are as listed:- Input rectifier D13, all 5 terminals.
Printed Circuit Board Replacement
1. Handle PC Boards by edges only.
2. Store PC Boards only in the bags that dispersestatic charges.
3. Inspect PC Board for burned conductors or com-ponents. If damage is visible, inspect the machinewiring for grounds or shorts to avoid damaging anew PC Board.
4. If there is no visible damage to the PC Board,install a new PC Board and see if the problem isfixed. If the problem is fixed by the new board,reinstall the old board and see if the problem reoc-curs. If the problem does not reoccur, check thewiring harness and plugs for loose connections.
– 22 –
TURN THE POWER SWITCH OF THE WELDING POWER
SOURCE "OFF" BEFORE INSTALLING PLUGS ON CABLES
OR WHEN CONNECTING OR DISCONNECTING PLUGS TO
WELDING POWER SOURCE.
STRAIGHT PLUG (14 PIN)
TO POWER SOURCE
CABLE RECEPTACLE (6 SOCKET)
CABLE RECEPTACLE (14 SOCKET)
TO: 1) LN-7 WIRE FEEDERS
TO: 1) K857 REMOTE CONTROL
2) K963 HAND AMPTROL
3) K870 FOOT AMPTROL
K864 STRAIGHT PLUG (14 PIN)
TO POWER SOURCE
K876
CABLE RECEPTACLE (6 SOCKET)
TO: 1) LN-25 WIRE FEEDERS
S19309
4-19-96D
REMOTE CONTROL ADAPTERS
– 23 –
INSTALLATION INSTRUCTIONS
THIS CONNECTOR IS MEANT TO BE USED WITH LINCOLN POWER SOURCES WHICH HAVE A 14-PIN
TO ANY OF THE 14 CIRCUITS PRESENT IN THE WIRE FEEDER RECEPTACLE.
WIRE FEEDER RECEPTACLE. IT IS DESIGNED TO ALLOW THE USER TO MAKE CONNECTIONS
CONSULT THE WIRING DIAGRAM OF THE POWER SOURCE AND WIRE FEEDER THIS ADAPTER WILL BE USED WITH.
2. CONSULT THE APPROPRIATE EQUIPMENT WIRING DIAGRAMS FOR THE CONNECTIONS TO UNIVERSAL ADAPTER.
THE STANDARD CONNECTOR PIN DESIGNATIONS AND FUNCTIONS ARE SHOWN BELOW.
MAY OR MAY NOT BE ISOLATED, INDEPENDENT CIRCUITS INSIDE THE WELDER.
3. USE LUG, CRIMP SPLICE OR SOLDER CONNECTIONS AS REQUIRED AND INSULATE EACH USED AND UNUSED LEAD
14-PIN BOX RECEPTACLE, FRONT VIEW
AND 14-PIN CABLE PLUG, REAR VIEW
14-PIN BOX RECEPTACLE, REAR VIEW
AND 14-PIN CABLE PLUG, FRONT VIEW
K=42
A=32 B=GND
C=2
L=82
D=4
E=77
M=81
F=76
G=75
N=SPARE
H=21I=41J=31
K=42
J=31 I
=41
H=21
N=SPARE
G=75
F=76
M=81
E=77
D=4
C=2
L=82
B=GND
A=32
PIN
SPARE
WELDING MODE CONTROL
A B C D E F G H I J K L M N
81
82
42
31
41
21
75
76
7742
GND
32
LEAD
WELDING MODE CONTROL
STANDARD FUNCTION
24V AC
42V AC
115V AC
42V AC
WORK
OUTPUT CONTROL
OUTPUT CONTROL
OUTPUT CONTROL
TRIGGER CIRCUIT
TRIGGER CIRCUIT
CHASSIS CONNECTION
115V AC
NOTE: 115V AC (31, 32), 42V AC (41, 42), 24V AC (SPARE) AND TRIGGER CIRCUIT (2, 4)
1. TURN THE POWER SWITCH OF THE WELDING POWER SOURCE OFF BEFORE INSTALLING
THIS ADAPTER TO WIRE FEEDER CABLE.
(SEE APPROPRIATE WIRING DIAGRAM)
THESE FUNCTIONS ARE LISTED FOR
REFERENCE ONLY AND EACH MAY OR
MAY NOT BE PRESENT IN YOUR EQUIPMENT.
NOT ALL CIRCUITS ARE PRESENT IN EVERY POWER SOURCE, NOR ARE THEY REQUIRED FOR PROPER WIRE FEEDER OPERATION.
IN THE UNIVERSAL ADAPTER. THE INSULATING METHOD MUST BE RATED FOR 120V AC OR GREATER.
S19386
3-16-90
K867 UNIVERSAL ADAPTER FOR 14-PIN WIRE FEEDER RECEPTACLE
– 24 –
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
ELECTRODE CABLE
TO LN-7
TO
WORK
-+
14 PIN
AMPHENOL
SPARE
82
81
42
41
31
322421
GND
75
76
77
31
322421
GND
N.C.
K291 OR K404
INPUT CABLE
K775 OPTIONAL
REMOTE CONTROL
K867 UNIVERSAL
ADAPTER PLUG
LN-7
CONTROL
BOX
75
76
77 GREEN
N.D.
N.D. SPLICE LEADS AND INSULATE.
POWER SOURCE
AUXILIARY POWER
Only qualified persons should install, use or
service this machine.
using the disconnect switch at the fuse box
WARNINGTurn off input power to the Welding Power Source
Before connecting the wire feeder.
ELECTRIC
SHOCK
CAN KILL
INVERTEC
WITH 115VAC
S19404
K867 PLUG TO LN-7 - CONNECTION DIAGRAM
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
ELECTRODE CABLE
TO LN-7
TO
WORK
-+
14 PIN
AMPHENOL
SPARE
82
81
42
41
31
322421
GND
75
76
77
31
322421
GND
N.C.
K291 OR K404
INPUT CABLE
K775 OPTIONAL
REMOTE CONTROL
K867 UNIVERSAL
ADAPTER PLUG
LN-7
CONTROL
BOX
75
76
77 GREEN
N.D.
N.D. SPLICE LEADS AND INSULATE.
POWER SOURCE
AUXILIARY POWER
Only qualified persons should install, use or
service this machine.
using the disconnect switch at the fuse box
WARNINGTurn off input power to the Welding Power Source
Before connecting the wire feeder.
ELECTRIC
SHOCK
CAN KILL
INVERTEC
WITH 115VAC
S19404
12-10-93A
K867 PLUG TO LN-7 - CONNECTION DIAGRAM
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
ELECTRODE CABLE
TO LN-7
TO
WORK
- +
14 PIN
AMPHENOL
SPARE
82
81
42
41
31
32 2 4 21
GND
75
76
77
31
32 2 4 21
GND
N.C.
K291 OR K404
INPUT CABLE
K775 OPTIONAL
REMOTE CONTROL
K867 UNIVERSAL
ADAPTER PLUG
LN-7
CONTROL
BOX
75
76
77GREEN
N.D.
N.D. SPLICE LEADS AND INSULATE.
POWER SOURCE
AUXILIARY POWER
Only qualified persons should install, use or
service this machine.
using the disconnect switch at the fuse box
WARN
ING
Turn off input power to the Welding Power Source
Before connecting the wire feeder.
ELEC
TRIC
SHOC
K
CAN
KILL
INVERTEC
WITH 115VAC
S19404
K867 PLUG TO LN-7 - CONNECTION DIAGRAM
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
ELECTRODE CABLE
TO LN-7
TO
WORK
- +
14 PIN
AMPHENOL
SPARE
82
81
42
41
31
32 2 4 21
GND
75
76
77
31
32 2 4 21
GND
N.C.
K291 OR K404
INPUT CABLE
K775 OPTIONAL
REMOTE CONTROL
K867 UNIVERSAL
ADAPTER PLUG
LN-7
CONTROL
BOX
75
76
77GREEN
N.D.
N.D. SPLICE LEADS AND INSULATE.
POWER SOURCE
AUXILIARY POWER
Only qualified persons should install, use or
service this machine.
using the disconnect switch at the fuse box
WARN
ING
Turn off input power to the Welding Power Source
Before connecting the wire feeder.
ELEC
TRIC
SHOC
K
CAN
KILL
INVERTEC
WITH 115VAC
S19404
12-10-93A
K867 PLUG TO LN-7 - CONNECTION DIAGRAM
– 25 –
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
TO
WORK
- +
14 PIN
AMPHENOL
N.C.
ELECTRODE CABLE
TO LN-25
K867 ADAPTER
LN-25 WITH
K431 OPTION
K432 REMOTE
CONTROL CABLE
E F D A B C77
76
75
SPARE
4221
82
81
42
41
GND
31
32
N.D.
N.D. REMOVE 6 PIN PLUG FROM K432 CABLE IN ORDER TO CONNECT K867 PLUG.
LABEL EACH LEAD (A THRU F) AS THEY ARE REMOVED FROM 6 PIN PLUG.
N.E.
N.E. SPLICE LEADS AND INSULATE.
Only qualified persons should install, use or
service this machine.
using the disconnect switch at the fuse box
WARN
ING
Turn off input power to the Welding Power Source
Before connecting the wire feeder.
ELEC
TRIC
SHOC
K
CAN
KILL
INVERTEC
POWER SOURCE
S19405
1-25-91
K867 PLUG TO LN-25 - CONNECTION DIAGRAM
– 26 –
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
TO
WORK
- +
14 PIN
AMPHENOL
N.C.
76
82
K867 UNIVERSAL
ADAPTER PLUG
81
SPARE
2 4 41
42
31
32
GND
21
77
75
REMOTE OUTPUT CONTROL
NOT USED ON INVERTEC
24 VAC / 1 AMP
CONNECT TOGETHER FOR
WELDING OUTPUT
42 VAC / 5.5 AMP
115 VAC / 2 AMP
INVERTEC FRAME CONNECTION
N.D.
N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION
RELAY TO CLOSE LEADS 2 & 4.
2 4
TO
K867
ELECTRODE CABLE
WIRE FEEDER VOLTMETER CONNECTION
CONNECTS TO (WORK TERMINAL) OF INVERTEC
TO
WIRE FEEDER
10K
MIN.
Only qualified persons should install, use or
service this machine.
using the disconnect switch at the fuse box
WARN
ING
Turn off input power to the Welding Power Source
Before connecting the wire feeder.
ELEC
TRIC
SHOC
K
CAN
KILL
INVERTEC
POWER SOURCE
WITH 115VAC
AUXILIARY POWER
S19406
12-10-93A
K867 UNIVERSAL ADAPTER / INVERTEC - CONNECTION DIAGRAM
– 27 –
Only qualified persons should install, use or
service this machine.
using the disconnect switch at the fuse box
WARN
ING
Turn off input power to the Welding Power Source
Before connecting the wire feeder.
ELEC
TRIC
SHOC
K
CAN
KILL
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
TO
WORK
- +
14 PIN
AMPHENOL
ELECTRODE CABLE
TO LN-25
LN-25 WITH
K431 OPTION
K432 REMOTE
CONTROL CABLE
6 PIN
AMPHENOL
N.C. FOR INVERTECS WITH 6 PIN AMPHENOL, K432 CABLE CAN BE CONNECTED DIRECTLY.
K876 ADAPTER
INVERTEC
POWER SOURCE
S19899
1-25-91
K876 ADAPTER TO LN-25 - CONNECTION DIAGRAM
– 28 –
Only qualified persons should install, use or
service this machine.
using the disconnect switch at the fuse box
WARN
ING
Turn off input power to the Welding Power Source
Before connecting the wire feeder.
ELEC
TRIC
SHOC
K
CAN
KILL
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
ELECTRODE CABLE
TO LN-7
TO
WORK
- +
14 PIN
AMPHENOL
LN-7
CONTROL
BOX
POWER SOURCE
INVERTEC
K864
K480-7 INPUT CABLE
14 PIN
AMPHENOL
K857
REMOTE CONTROL
K963
HAND AMPTROL
K870
FOOT AMPTROL
N.C. K480-7 INPUT CABLE CAN BE CONNECTED DIRECTLY IF REMOTE CONTROL IS NOT REQUIRED.
6 PIN
AMPHENOL
ADAPTER
OR
OR
N.D. K864 ADAPTER CANNOT BE USED WITH AN LN-25.
WITH 115VAC
AUXILIARY POWER
S19901
4-19-96D
K864 ADAPTER TO LN-7 & REMOTE CONTROL - CONNECTION DIAGRAM
– 29 –
TO
WORK
+
POWER SOURCE
INVERTEC
DC TIG STARTER
-
WARN
ING
ELEC
TRIC
SHOC
KCA
N KI
LL
Only qualified persons should install, use or service this machine.
Turn off input power to the Welding Power Source using the
disconnect switch at the fuse box before connecting the DC Tig
IN
OUT
K900-1
TO TIG
TORCH
K963
HAND AMPTROL
K870
FOOT AMPTROL
OR
K814
OR
ARC START SWITCH
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
AUXILIARY POWER
WITH 5.5 AMP 42 VOLT
Starter to the power source, or the Amptrol or Wire Feeder
to the DC Tig Starter.
TOP 14 PIN
AMPHENOL
WIRE FEEDER
N.B. A WIRE FEEDER CAN BE PLUGGED INTO THE DC TIG STARTER TO REDUCE PROCESS CONVERSION TIME.
N.C.
N.B.
BOTTOM 14 PIN
AMPHENOL
CONSULT INVERTEC INSTRUCTION MANUAL FOR
APPROPRIATE WIRE FEEDERS AMD CONNECTORS.
N.C. SET UP SHOWN IS FOR DC NEGATIVE TIG WELDING. DC POSITIVE WELDING IS OBTAINED BY REVERSING
THE OUTPUT CONNECTIONS ON THE INVERTEC AND SETTING THE INVERTEC’S ELECTRODE POLARITY
SWITCH TO POSITIVE.
4-19-96D
S20405
K900-1 DC TIG STARTER - CONNECTION DIAGRAM
– 30 –
Only qualified persons should install, use or
service this machine.
using the disconnect switch at the fuse box
WARN
ING
Turn off input power to the Welding Power Source
Before connecting the wire feeder.
ELEC
TRIC
SHOC
K
CAN
KILL
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
TO
WORK
- +
14 PIN
AMPHENOL
ELECTRODE CABLE
TO LN-9 GMA
K596 REMOTE
CONTROL CABLE
ASSEMBLY
INVERTEC
POWER SOURCE
WITH 110/115V AUX.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF", REVERSE
ELECTRODE AND WORK CABLE AT POWER SOURCE. SET METER POLARITY SWITCH ON REAR
OF INVERTEC TO COINCIDE WITH POLARITY USED. SET LN-9 GMA POLARITY SWITCH ALSO.
N.D. FOR GMAW WELDING, INSTALL PULSE POWER FILTER KIT K442-1 IN LN-9 GMA.
N.C. INSTALL K608-1 ADAPTER IN LINE WITH P10 TO LN-9 GMA VOLTAGE BOARD
PER INSTRUCTIONS IN V300 MANUAL.
LN-9 GMA WITH
K608-1 AND
K442-1 KITS.
S20607
P10’,J10
2 3 4 5 6 7 10
11
12
P10,J10’
2 3 4 5 6 11
12
7
3.9K
K608-1
CONNECTION
DETAIL
530A
521
500
500
524 C B
533
9-29-95C
LN-9 GMA WITH K596 CABLE TO INVERTEC - CONNECTION DIAGRAM
– 31 –
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
TO
WORK
- +
14 PIN
AMPHENOL
SPARE
82
81
42
41
31
32 2 4 21
GND
75
76
77
31
32 2 4 21
GND
N.C.
K867 UNIVERSAL
ADAPTER PLUG
N.D.
N.D. SPLICE LEADS AND INSULATE.
Only qualified persons should install, use or
service this machine.
using the disconnect switch at the fuse box
WARN
ING
Turn off input power to the Welding Power Source
Before connecting the wire feeder.
ELEC
TRIC
SHOC
K
CAN
KILL
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF", REVERSE
ELECTRODE AND WORK CABLE AT POWER SOURCE. SET METER POLARITY SWITCH ON REAR
OF INVERTEC TO COINCIDE WITH POLARITY USED. SET LN-9 GMA POLARITY SWITCH ALSO.
N.F. FOR GMAW WELDING, INSTALL PULSE POWER FILTER KIT K442-1 IN LN-9 GMA.
A
K196
INPUT CABLE
ELECTRODE CABLE
TO LN-9 GMA
INVERTEC
POWER SOURCE
WITH 110/115V AUX.
LN-9 GMA WITH
K608-1 AND
K442-1 KITS.
N.E. INSTALL K608-1 ADAPTER IN LINE WITH P10 TO LN-9 GMA VOLTAGE BOARD AND SECURE TO
ADJACENT HARNESS WITH WIRE TIE PROVIDED. TURN "START" TRIMMER ON VOLTAGE BOARD FULLY ’CCW’.
S20608
P10’,J10
2 3 4 5 6 7 10
11
12
P10,J10’
2 3 4 5 6 11
12
7
3.9K
K608-1
CONNECTION
DETAIL
530A
521
500
500
524 C B
533
CB
9-11-92
LN-9 GMA WITH K196 CABLE AND K867 PLUG TO INVERTEC - CONNECTION DIAGRAM
– 32 –
CONTROL
CONTROL PANEL
ARC FORCE/INDUCTANCE
2
2W
R11
227
/INDUCTANCE
CONTROL
TERMINAL
CHOKE
10K
215
227
4
303
301
CW (MAX)
METER
TOP
S2
C5
L3
R8
D2
SHUNT
1
211A
3 8 1
BOARD
9
CONNECTOR CAVITY NUMBERING SEQUENCE
OUTPUT TERMINAL
S4
R = RED
243J2
J1
1
301
4
TP4
45
W
L4
9D
12B 12D
9C
1
5
R5
R12
275C
204B
65
206
3
215
AV
LAYOUT
N.A.
NOTES:
B = BLACK
G = GREEN
W = WHITE
Y = YELLOW
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
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.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.
RECEPTACLE
CONTROL
SWITCH
REMOTE
POLARITY
285
WELDING
WIRE FEEDER
N
AUXILIARY
SPARE
-
T1
GND
CW (MAX)
275F
275D
303
302
304
J7
504
2
212A
J3
229
317
13
87
1
N.G.
N.F.
14
14
R7
52
BOARD
2200 F
214
3J15
U
H1 82
SWITCH
METER FUNCTION
S5
S2
OUTPUT CONTROL
R11
INDICATOR
OVERLOAD
THERMAL
SWITCH
OUTPUT
REMOTE
223B
IG
MIN
9A9A
BOARD
52
1
311
V W
6
H5 A
B
TP3
76
F -
FEEDER
12D
12D
12C
9B
51
N.H.
0V
2
503
4
150 5W
H1
N.C.
WIRE
COLOR CODE:
MODE SWITCH
MODE SWITCH
OUTPUT
CONTROL
503A
Y
306
75
532
212B
42A
42
J13
W
212D
F1
INSIDE
S
BOTTOM
THERMAL
F229
11
12B
213
208
77A
S
R4
J3
C1+
25
208V
85
203
D3
76
SWITCH
MODE
211A
S
220
J4
Y
AUX
77A
226
Y
R
CONTROL
BOARD
12C
12B
523
G
41
J5, J16
D
2
W
ON
4
A
316
4,5
D +
25W
-
12A
RIGHT
9D
212D
54 632
4
PANEL
226
CV GMAW
2
3
TP6
5
25W
1
400A
BOTTOM
401, 403
TOP
450V
25W
(RIGHT)
2200 F
25
BOARD
H125W
1200-
5
H2
302
4,5
6
2
N.G.
9B
275D
42
24V
2
211B
H4
64501
H3
L
AUX
TOP
11,8
212A
W
14 4
RW
R315
53
12
12A
5
317
23
TRIGGER
F8
7
305
304
SWITCH
212B
10
H1
CC CRISP
CC SOFT
LOCAL
275B
OVERLOAD
502
TP5
250
BOTTOM
401, 403
6H6
440-
A42A
+
R
214
12D
R
SWITCH
H2
H3
220-
H3
309
212
J31
3
S
N.D.
FAN
311
229
THERMOSTAT
H5
6
ARC FORCE
6
11
S4
5
4
ON
223A
MOTOR
Y
206
110V
275A
E
2
S
3
C6
R12
INDICATOR
(V300-I ONLY)
(V300-I ONLY)
LOCAL/REMOTE
REMOTE
SWITCH
FUNCTION
METER
S5
R
72
212C
3
224
J6
J1, J7
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I)
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
(VIEWED FROM COMPONENT SIDE OF BOARD)
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
2W
208
1
116
7
54287
81,8
-
FR9
504
7500
F
402, 404
I
CU
RREN
T
CHOKE
+
207
204C
204B
228
3
275A
228
502
276
77B
21
4
218
SWITCH
S3
LOCAL/REMOTE
308
INPUT
S1
RECTIFIER
9D
9C
D13
9A
R6
450V
8
2
4
POWER
CB2
32A
212
CB1
6AMP
REMOTE
460V
S6
BLOW
SLOW
T3
229
D1A
(LEFT)
L10189
6OFF
307
CC GTAW
TP1
C
CV FCAW
R12
6
BOTTOM
OUTSIDE
3 AMP
A
L5
R11
12
TOP
207
INSIDE
9
204A
J5
F
I
S
9
4
310
5
501
J16
13
276
RECONNECT
9D
9B
TRAN
SFOR
MER
12A
VAC
32
310
309
310
203
275C
75
OUTPUT
76
F
77
3
313
316
H1
314315
9B
W
12A
9
W
12A
TP2
SWITCH
9B
12
A
42V
230V
FAN
H4
75
380-
415V
77B
TRANSFORMER
32
A
42
110/115
212
212
212C
H B
21
L2
4
MAIN
34
53
53
S3
1
J10
12 7
210
J6
308
J12
210
14
DRIVER
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.
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECTION SHOWN IS FOR 380-460V OPERATION.
14
52
63
J11
43
21
309
B
WIRING DIAGRAM V300-PRO Code 10256, V300-I Code 10258
THERMOSTAT
503A
224
S2
R
1
BOARD
INPUT
S7
12
PER
CR2
CR1
POWER
J9
1S
286
SWITCH
C2
N.A.
B
211B
- ARC
OUTSIDE
+ ARC
314
25W
H5
PROTECTION
H5
J8
51
9
1
285
204C
C9
SS
51
204A
25
213
229
T2
FS F
TRANSFORMER
4F
313306
402, 404
275F
F
52
+25
+
R1
7500
25W
ELECTRICAL SYMBOLS PER E1537
J2, J8
J11, J14
J13, J15
J9, J10, J12
J4
3503
5
305
2307
32A
LEFT
2AMP
M81
21
GND
Y
1
L1
10K
18V
H3
12B
10
25W
J14
KVAC
N.F.
C
D1B
214
8
218
275B
10
223B
223A
CONTROL
220
NO
TE:
This
dia
gram
is fo
r ref
eren
ce o
nly.
It
may
not
be
accu
rate
for a
ll m
achi
nes
cove
red
by th
is m
anua
l. T
he s
peci
fic d
iagr
am fo
r a p
artic
ular
cod
e is
pas
ted
insi
deth
e m
achi
ne o
n on
e of
the
encl
osur
e pa
nels
. If
the
diag
ram
is il
legi
ble,
writ
e to
the
Serv
ice
Dep
artm
ent f
or a
repl
acem
ent.
Giv
e th
e eq
uipm
ent c
ode
num
ber..
MAR97
– 33 –
21
2
RECTIFIER
9D
C2
R7
9A9A
N.F.
CONTROL PANEL
J11, J14
SF
9
H5
402, 404
ON
OFF
H1
RV
CH6
12B
BOTTOM
51
WIRING DIAGRAM V300-PRO CODE 10257 (575V)
SHUNT
R8
250
L3
L1
C1
TP2
9D
S1
1, 8
POWER
J12
401, 403
12B
12B
25
J13
G
25W
R = RED
R4
W = WHITE
1
32
1
J11
J9
45
26
3
F
D13
317
6
9A
J16
514
315
316
51
LAYOUT
504
4H3
6
J5, J16
32
32
227
213
214
INSIDE
STOP
+
S
TOP
5
2
W
303
3 8J6
1
18V
285
AUX
TOP
OUTSIDE
SBOTTOM
F
226
S
F4
FS
TRANSFORMER
MAIN
L2
CHOKE
FS
53
41
52
36
52
53
53
14
REMOTE
214
SWITCH
POLARITY
WELDING
WIRE FEEDER
S6
42A
+
5
W
501
R
7
317316
9D
6
314
RW
POWER
R
BOARD
8
5
8
402, 404
307
+T2
+
CU
RREN
T
J2
M
J2, J8
S4
OUTPUT TERMINAL
SWITCH
25W
CV FCAW
+25
+Y
10K
YR5
9B
N.F.
912
2W
10K
R12REMOTE
275A
LOCAL
2W
275B
207
77A
275C
276
150 5W
204B
228
212C
208
20376
77B
204C
204A
220
229
R11
285
MODE SWITCH
S2
/INDUCTANCE
LOCAL/REMOTE
NSPARE
GND
218
BGND
275C
227
226
275B
CONTROL
4
77A
75218
276
208
207
228
229
275D
301
305
4
D3
S
1
12
(V300-I ONLY)
210
211B
1
J1, J7
J9, J10, J12
J13, J15
6
J3
302
J7
4
309
224
TOP
AUX
H1
42
WB
N.A.
H5
H1
2H3
75
MIN
G75
76
24V
F76
E77
31
212C
CR1
+ ARC
400A
C6
RIGHT
C9
BOARD
S
W R
215
4
5
203
310
S5
503A 1
229
1
4
J14
32
CW (MAX)
215
CW (MAX)
306
212A
212B
J5
223B
712
210
13
J1
275A
2
309
J4
J6
COLOR CODE:
B = BLACK
1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO)
Y = YELLOW
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.
LEFT
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
25
25W
42A
2AMP
H1
6AMP
212
212
212
I C D H
42 81
42
VAC
S2
MODE
SWITCH
R11
OUTPUT
CONTROL
S3
R12
S4
SWITCH
SWITCH
CONTROL
TERMINAL
THERMAL
OVERLOAD
INDICATOR
SWITCH
FUNCTION
METER
REMOTE
3503
313
6H6
H5
0V
FAN
212D
2
THERMOSTAT
AV
310
D1B
5 6
8F
4
301
8
2
4
223A
303
304
304
213
G = GREEN
2
FEEDER
NOTES:
N.A.
3
2
LOCAL/REMOTE
R11
F
501
2
2 3 4
PROTECTION
R1
B
+
912
25W
R9
D2
D1A
C15
L10191
CONTROL
ARC FORCE/INDUCTANCE
R12SWITCH
METER FUNCTION
(V300-I ONLY)
INDICATOR
OVERLOAD
THERMAL
OUTPUT CONTROL
N.F. C1, C2, C14, C15 CAPACITORS ARE A MATCHED SET.
N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "I".
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.
212D
212B
211B
211A
8
302
275D
CV GMAW
5 3
502
4 12
11
211A
2
3
9
6
6
Y
14
8
4
7
11
Y
10 5
Y
503
9
503A
2
1
TP6
3
3
C5
4
204C
L4
42V
32A
110V
25W
313
311
306
275F
44, 5
25W
BOARD
13,15
13
C14
(LEFT)
401, 403
DRIVER
BOARD
19D
L5
N.C.
L82
230V
4
220-
TRIGGER
54,5
I
10K
ON
223A
502
FAN
S3
MOTOR
SWITCH
CB2
J
575V
32A
A
CB1
212A
52 14
J15
51
J8
H5 1
1
INPUT
314
23
12A
7
R
812
13
14
229
SWITCH
BOARD
A
F -
H3
OUTPUT
OUTPUT
ARC FORCE
3
21
220
204B
204A
F1
INSIDE
1, 8
286
CHOKE
1
BOARD
305
5
308
-
1
CC SOFT
BOTTOM
S
206
-
J10
ELECTRICAL SYMBOLS PER E1537
(VIEWED FROM COMPONENT SIDE OF BOARD)
CONNECTOR CAVITY NUMBERING SEQUENCE
311
RECEPTACLE
TRANSFORMER
CONTROL
AUXILIARY
T1
REMOTE
WIRE
-21
43
52
25
10K
TP1 TP3
212
VAC
21
223B
PANEL
3
METER
4 5 6
5
- ARC
6
TP4
THERMOSTAT
W
J4
27
275F
7
504
1
CONTROL
1 3
9 10
224
PER
CC GTAW
CC CRISP
52
315
INPUT
TRAN
SFOR
MER
I
F
BOTTOM
9
206
U
OUTSIDE
WD +
308
307
229
S5
TP5
K
41
H1
77B
(RIGHT)
T3
110/115
13,15
15
1W
R
12
SWITCH
R6
25W
1J3
10
B
NO
TE:
This
dia
gram
is fo
r ref
eren
ce o
nly.
It
may
not
be
accu
rate
for a
ll m
achi
nes
cove
red
by th
is m
anua
l. T
he s
peci
fic d
iagr
am fo
r a p
artic
ular
cod
e is
pas
ted
insi
deth
e m
achi
ne o
n on
e of
the
encl
osur
e pa
nels
. If
the
diag
ram
is il
legi
ble,
writ
e to
the
Serv
ice
Dep
artm
ent f
or a
repl
acem
ent.
Giv
e th
e eq
uipm
ent c
ode
num
ber..
MAR97
INVERTEC V300-PRO & V300-I
NOTES
INVERTEC V300-PRO & V300-I
NOTES
INVERTEC V300-PRO & V300-I
NOTES
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5 weeks of fundamentalsThere is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.Prices include shipment by 4 thClass Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:
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For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.METHOD OF PAYMENT: (Sorry, No C.O.D. Orders)
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USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
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Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH(ED-45) How to Read Shop Drawings $4.50 H
Educational Video Information Incentive Management $5.00 IM(ED-93) A New Approach to Industrial Economics $5.00 NA
James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 ACFoundation Book Information Welding Preheat Calculator $3.00 WC-8
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Additional Shipping Costs if anyTOTAL COST
– 38 –
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Do not touch electrically live parts orelectrode with skin or wet clothing.
● Insulate yourself from work andground.
● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.
● Aislese del trabajo y de la tierra.
● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!
● Isolieren Sie sich von denElektroden und dem Erdboden!
● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.
● Isole-se da peça e terra.
● Keep flammable materials away.
● Mantenga el material combustiblefuera del área de trabajo.
● Gardez à l’écart de tout matérielinflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-dos.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y elcuerpo.
● Protégez vos yeux, vos oreilles etvotre corps.
● Tragen Sie Augen-, Ohren- und Kör-perschutz!
● Use proteção para a vista, ouvido ecorpo.
– 39 –
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.
● Keep your head out of fumes.● Use ventilation or exhaust to
remove fumes from breathing zone.
● Los humos fuera de la zona de res-piración.
● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.
● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zonesde travail.
● Vermeiden Sie das Einatmen vonSchweibrauch!
● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Turn power off before servicing.
● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-tien.
● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)
● Não opere com as tampas removidas.● Desligue a corrente antes de fazer
serviço.● Não toque as partes elétricas nuas.
● Do not operate with panel open orguards off.
● No operar con panel abierto oguardas quitadas.
● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.
● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!
● Mantenha-se afastado das partesmoventes.
● Não opere com os paineis abertosou guardas removidas.
–• Sales and Service through Subsidiaries and Distributors Worldwide •
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