Lincoln Electric Invertec Im526 B Users Manual
IM526-B to the manual 370b3826-e402-498a-9984-8d2fb7ba3054
2015-02-09
: Lincoln-Electric Lincoln-Electric-Invertec-Im526-B-Users-Manual-574547 lincoln-electric-invertec-im526-b-users-manual-574547 lincoln-electric pdf
Open the PDF directly: View PDF .
Page Count: 40
Download | |
Open PDF In Browser | View PDF |
RETURN TO MAIN MENU INVERTEC V300-PRO ™ IM526-B December,1999 For use with machines Code 10256 and 10257. Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful. Date of Purchase: Serial Number: Code Number: Model: Where Purchased: OPERATOR’S MANUAL • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com WARNING ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights. For additional safety information it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. 1.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel. 3.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products. 3.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe. 3.d. Read and understand the manufacturer’s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 1.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground. In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment: • Semiautomatic DC Constant Voltage (Wire) Welder. • DC Manual (Stick) Welder. • AC Welder with Reduced Voltage Control. 1.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically“hot”. 1.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded. 3.e. Also see item 7b. 1.e. Ground the work or metal to be welded to a good electrical (earth) ground. WELDING SPARKS can cause fire or explosion. 1.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation. 4.a..Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 1.g. Never dip the electrode in water for cooling. 1.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders. 1.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock. 4.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used. 1.j. Also see Items 4.c. and 6. 4.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. ARC RAYS can burn. 2.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned.” For information purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above). 2.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays. 2.c. Protect other nearby personnel with suitable non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal. Apr. ‘93 4.e. Vent hollow castings or containers before heating, cutting or welding. They may explode. –2– 4.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area. 7.c.Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated. --------------------------------------------------------------------------------------- 4.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail. 7.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment. 4.h. Also see item 7c. CYLINDER may explode if damaged. 7.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts. 5.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition. 7.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running. 5.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support. 7.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate. --------------------------------------------------------------------------------------- 5.c. Cylinders should be located: • Away from areas where they may be struck or subjected to physical damage. • A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame. 5.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder. 7.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot. 5.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. 5.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use. ELECTRIC AND MAGNETIC FIELDS may be dangerous 5.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,”available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202. 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines. FOR ELECTRICALLY powered equipment. 8.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding. 6.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.c. Exposure to EMF fields in welding may have other health effects which are now not known. 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 6.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. 8.d.1. Route the electrode and work cables together - Secure them with tape when possible. 8.d.2. Never coil the electrode lead around your body. FOR ENGINE powered equipment. 8.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side. 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. --------------------------------------------------------------------------------------- 8.d.4. Connect the work cable to the workpiece as close as possible to the area being welded. 8.d.5. Do not work next to welding power source. 7.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. --------------------------------------------------------------------------------------- –3– Mar. ‘93 zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains. b. Faire trés attention de bien s’isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse. c. Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement. d.Ne jamais plonger le porte-électrode dans l’eau pour le refroidir. e. Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines. f. Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage. 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. 7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie. 8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent. 9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques. 10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants. 11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974. 2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps. 3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc: a. Utiliser un bon masque avec un verre filtrant approprié ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc. b. Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de l‘arc. c. Protéger l’autre personnel travaillant à proximité au soudage à l’aide d’écrans appropriés et non-inflammables. 4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes. 5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR 1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre. 2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié. 3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles. 4. Garder tous les couvercles et dispositifs de sûreté à leur place. –4– Mar. ‘93 TABLE OF CONTENTS Page Safety Precautions .............................................................................................................2-4 Introductory Information .......................................................................................................6 Product Description..............................................................................................................7 Specifications.......................................................................................................................7 Installation .........................................................................................................................7-10 Safety Precautions ........................................................................................................7 Location .........................................................................................................................7 Electrical Installation......................................................................................................7 Input Voltage Setup .......................................................................................................8 Power Cord Connection ................................................................................................8 Connection of Wire Feeders to Invertec .....................................................................8-10 Output Cables & Plugs .................................................................................................10 Operating Instructions ......................................................................................................11-13 Safety Precautions .......................................................................................................11 Controls Description and Function.............................................................................11-13 Maintenance.....................................................................................................................13-14 Capacitor Discharge Procedure ...................................................................................13 Routine Maintenance....................................................................................................13 Periodic Maintenance ...................................................................................................14 Troubleshooting Guide .....................................................................................................14-20 Matched Parts.....................................................................................................................20 Switch P.C. Board Replacement Procedure .......................................................................20 Replacement of Power Modules and Output Diodes .......................................................20-21 Connection Diagrams.......................................................................................................22-31 Wiring Diagrams...............................................................................................................32-33 Parts Lists ......................................................................................................................appendix –5– Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received. Please record your equipment identification information below for future reference. This information can be found on your machine nameplate. Model Name & Number _____________________________________ Code & Serial Number _____________________________________ Date of Purchase _____________________________________ Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above. Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below: WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life. CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. –6– PRODUCT DESCRIPTION The Invertec V300-PRO is a 300 amp arc welding power source that utilizes single or three phase input power to produce either constant voltage or constant current outputs. The V300-PRO is designed for 60 Hz supply systems. The welding response of the Invertec has been optimized for GMAW, SMAW, TIG and FCAW processes. It is designed to be used with the LN-25 and LN-7 semiautomatic wire feeders. SPECIFICATIONS Product Name Invertec V300PRO Ordering Information Input AC Voltage Rated DC Output Amps/Volts/Duty Cycle 208/230/460 3 Phase Input Amps at Rated DC Output 575 Output Range (continuous) Weight with Gun (net) 208 230 460 48 43 24 60 Hz 300A / 32V / 60%(1) 250A / 30V / 100%(1) 300A / 35/39/41V /60%(2) 37 49 33 48 19 28 208/230/460 1 Phase 250A / 30V / 60%(1) 160A / 28V / 100%(1) 69 62 38 AMPS 64 lbs. 18.7*x10.8x 22.2” (475x274x 29 42 (29 kg) 564 mm) 250A / 37/41/43V / 60%(2) 47 67 5-350 60 Hz 53 75 575 3 Phase 300A / 32V / 60%(1) 250A / 30V / 100%(1) 60 Hz 300A / 36V / 60%(2) K1349-3 K1349-4 Dimensions HxWxD 20 * Includes handle 16 22 NEMA Class I Rated Output / Based on a 10 min. Period . (1 ) Lincoln plus rating. (2 ) * Overall Height Including Handle, (16.4” (417mm without handle). INSTALLATION WARNING ELECTRICAL INSTALLATION ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. --------------------------------------------------------------------LOCATION 1. The Invertec should be connected only by a qualified electrician. Installation should be made in accordance with the U.S. National Electrical Code, all local codes and the information detailed below. 2. Single voltage, 575 VAC machines, can only be connected to 575 VAC. No internal reconnection for other input voltages is possible. The Invertec has been designed with many features to protect it from harsh environments. Even so, it is important that simple preventative measures are followed in order to assure long life and reliable operation. • The machine must be located where there is free circulation of clean air such that air movement into the sides and out the bottom and front will not be restricted. Dirt and dust that can be drawn into the machine should be kept to a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown of the Invertec. 3. Initial 208 VAC and 230 VAC operation will require a voltage panel setup, as will later reconnection back to 460 VAC: a. b. c. • Keep machine dry. Shelter from rain and snow. Do not place on wet ground or in puddles. –7– Open the access panel on the right side of the machine. For 208 or 230: Position the large switch to 200-230. For 460: Position the large switch to 380-460. Move the “A” lead to the appropriate terminal. INPUT VOLTAGE SETUP Recommended Fuse Sizes Based On The U.S. National Electrical Code And Maximum Machine Outputs CAUTION DO NOT ATTEMPT TO POWER THIS UNIT FROM THE AUXILIARY POWER SUPPLY OF AN ENGINE WELDER. • Special protection circuits may operate, causing loss of output. • The supply from engine welders often has excessive voltage peaks because the voltage waveform is usually triangular shaped instead of sinusoidal. • If voltage peaks from the engine welder exceed 380V, the input circuits of this machine protecting the filter capacitors, FETS and other components from damage will not be energized . --------------------------------------------------------------------- (1) (2) Input Volts(1) Fuse Size in Amps (Time Delay Fuses) 3 phase 50/60 Hz 208 230 460 60 60 40 1 phase 50/60 Hz 208(2) 230(2) 460 85 80 50 3 phase 60 Hz 575 30 Input voltage must be within ±10% of rated value. When operating on these inputs, at outputs exceeding 200A/60% or 165A/100%, the input line cord should be changed to an input conductor of 6 AWG or larger. RECONNECT PROCEDURE . Disconnect input power before inspecting or servicing machine. 1. BE SURE POWER SWITCH IS OFF. CONNECTION OF WIRE FEEDERS TO THE INVERTEC (Note: IEC units do not have 110 VAC auxiliary power). LN-25 Connection Instructions . Do not operate with wraparound removed. 2. CONNECT LEAD ’A’ TO DESIRED INPUT VOLTAGE RANGE. . Do not touch electrically live parts. 440-460V . 380-415V ’A’ 220-230V Only qualified persons should install, use or service this equipment. IF MACHINE CEASES TO OPERATE (NO METER, NO FAN) AND THERE IS NO OTHER KNOWN FAILURE: 200-208V CHECK FUSE; REPLACE WITH A 3 AMP SLOW BLOW ONLY. 3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE. 1. Turn the Invertec power switch “off”. VOLTAGE=380-460V THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. VOLTAGE=200-230V 9-11-92 2. Connect the electrode cable to the output terminal of polarity required by electrode. Connect the work lead to the other terminal. S20324 POWER CORD CONNECTION 3. LN-25 with remote control options K431 and K432. Use K876 adapter with K432 cable or modify K432 cable with K867 universal adapter plug. See connection diagram S19899 and S19309 or S19405 at the back of this manual. A 10 ft. (3.0m) power cord is provided and wired into the machine. Follow the power cord connection instructions. Incorrect connection may result in equipment damage. 4. Place the local-remote switch in the “remote” position if output control is desired at the wire feeder rather than the Invertec. (LN-25 must have K431 and K432 options for remote output control operation). BLACK GREEN RED WHITE LN-7 Connection Instructions Single Phase Input 1. Connect green lead to ground per U.S. National Electrical Code. 2. Connect black and white leads to power. 3. Wrap red lead with tape to provide 600V insulation. 1. Turn the Invertec power switch “off”. 2. Connect the K480 control cable from the LN-7 to the Invertec control cable connector. The control cable connector is located at the rear of the Invertec. Three Phase Input 3. Connect the electrode cable to the output terminal of polarity required by electrode. Connect the work lead to the other terminal. 1. Connect green lead to ground per U.S. National Electrical Code. 2. Connect black, red and white leads to power. 4. Place the local-remote switch in the “local” position to allow output control at the Invertec. (K864 Install in accordance with all local and national electric codes. –8– – remote control adapter and K857 remote control are required for remote output control). Parallel Operation The Invertec’s are operable in parallel in both CC and CV modes. For best results, the currents of each machine should be reasonably well shared. As an example, with two machines set up in parallel for a 400 amp procedure, each machine should be set to deliver approximately 200 amps, not 300 amps from one and 100 amps from the other. This will minimize nuisance shutdown conditions. In general, more than two machines in parallel will not be effective due to the voltage requirements of procedures in that power range. 5. Set the meter polarity switch on the rear of the Invertec to coincide with wire feeder polarity used. The wire feeder will now display the welding voltage. 6. If K480 is not available, see connection diagram S19404 for modification of K291 or K404 LN-7 input cable with K867 universal adapter plug. General Instructions for Connection of Wire Feeders to Invertec To set machine outputs, start with output control pots and arc force/pinch pots in identical positions. If running in a CC mode, adjust outputs and arc forces to maintain current sharing while establishing the proper output current. In CV modes, the pots in identical positions. Then switch the machine meters to amps and adjust one of the output control pots for current balance. Check the voltage and if readjustment is necessary, repeat the current balancing step. Pinch settings should also be kept identical on the machines. Wire feeders other than LN-7 and LN-25 may be used provided that the auxiliary power supply capacity of the Invertec is not exceeded. K867 universal adapter plug is required. See connection diagram S19406 and S19386 at the back of this manual for more information. Remote Control of Invertec Remote control K857, hand amptrol K963 and foot amptrol K870 require K864 remote control adapter. See 19309 instruction at the back of this manual for connection information. K900-1 DC TIG Starter Connection This versatile new kit was made to mate with the Invertec. K954-1 MIG PULSER The MIG Pulser is a hand-held “pendant” type GMAW Pulsing option for the V300 Power Source. Refer to the Mig Pulser’s IM manual (IM555) for connection information. A control cable assembly is supplied with the kit to connect the kit to an Invertec. The cable can be connected, either end, at the DC TIG Starter kit and at the Invertec by attaching to the 14-pin Amphenols on the backs of each unit. Refer to diagram S20405 at the back of this manual. A negative output cable assembly is also supplied with the DC TIG Starter kit to connect the kit with the Invertec’s negative output terminal. All Magnum™ one and two piece water-cooled torches with 7/8 left-hand threads and gas-cooled torches with 7/8 and 5/16 right-hand threads can be connected to the starter kit. To secure the DC TIG Starter kit to the bottom of the Invertec and for more detailed instructions, refer to the K900-1 manual. –9– MAR97 LN-9 GMA Connection Instructions 2. Slide rubber boot onto cable end. The boot end may be trimmed to match the cable diameter. Soap or other lubricant will help to slide the boot over the cable. 1. Turn the Invertec power switch “off”. BOOT 2. Connect the K596 control cable assembly from the LN-9 GMA to the Invertec control cable connector. The control cable connector is located at the rear of the Invertec. WELDING CABLE 25 mm 3. Connect the electrode cable to the output terminal of polarity required by electrode. Connect the work lead to the other terminal. TRIM 1 in. 3. Slide the copper tube into the brass plug. 4. Insert cable into copper tube. 4. Place the local-remote switch in the “remote” position to allow output control at the LN-9 GMA. SET SCREW 5. Set the meter polarity switch on the rear of the Invertec to coincide with wire feeder polarity used. The wire feeder will now display the welding voltage. 6. K608-1 adapter is required in LN-9 GMA for LN-9 type control. K608-1 is installed in line with P10 connection at the LN-9 GMA voltage board. See diagram S20607 at the back of this manual. 7. K442-1 Pulse Power Filter Board is also required for GMAW, but should be disconnected for FCAW. BRASS PLUG COPPER TUBE 5. Tighten set screw to collapse copper tube. Screw must apply pressure against welding cable. The top of the set screw will be well below the surface of the brass plug after tightening. 6. Slide rubber boot over brass plug. The rubber boot must be positioned to completely cover all electrical surfaces after the plug is locked into the receptacle. 8. If K596 is not available, see connection diagram S20608 at the back of this manual for modification of K196 LN-9 GMA input cable with K867 universal adapter plug. Output Cables Select the output cable size based upon the following chart. Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75° rated: Duty Cycle Current Length Up 61m (200 ft.) 61-76m (200-250 ft.) 100% 60% 250 300 1/0 1/0 1/0 2/0 Quick Disconnect Plugs A quick disconnect system is used for the welding cable connections. The welding plug included with the machine is designed to accept a welding cable size of 1/0 to 2/0. 1. Remote 25mm (1 in.) of welding cable insulation. – 10 – OPERATING INSTRUCTIONS Output Control - This controls the output voltage in the CV modes and output current in the CC modes. WARNING Control is provided over the entire output range of the power source with 1 turn of the control knob. This control may be adjusted while under load to change power source output. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. -----------------------------------------------------------------------FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes from breathing zone. -----------------------------------------------------------------------WELDING SPARKS can cause fire or explosion. • Keep flammable material away. • Do not weld on closed containers. OUTPUT Local/Remote Switch - Place in the “LOCAL” position to allow output adjustment at the machine. Place in the “REMOTE” position to allow output adjustment at the wire feeder or with a remote control option package. REMOTE -----------------------------------------------------------------------ARC RAYS can burn eyes and skin. • Wear eye, ear and body protection. -----------------------------------------------------------See additional warning information at front of this operator’s manual. ----------------------------------------------------------DUTY CYCLE Digital Meter Switch - Select either “A” for amps or “V” for volts to display welding current or voltage on the meter. When welding current is not present, the meter will display the set current for the CC modes or the set voltage for the CV modes. This set reading is an indication of machine control setting. For a more precise process reading, read meter during actual welding. The Invertec is rated at 300 amps, 60% duty cycle for 3 phase inputs (based on a 10 minute cycle). It is also rated at 250 amps, 100% duty cycle. CONTROL FUNCTION / OPERATION Power Switch - Place the lever in the “ON” position to energize the machine. When the power is on, the digital meter will activate and the fan will operate. Mode Switch OFF – 11 – GTAW Optimized for both scratch start and HiFreq kit use. CC SOFT Best for EXX18 thru EXX28 stick electrodes. CC Crisp Use this mode for stick welding with EXX10 thru EXX14 electrodes. Nonwelding applications such as resistive heating or output tests with resistive loads should be done in this mode with Arc Force Control set to minimum. CV FCAW CV GMAW This setting has been optimized for Innershield® and Outershield® flux-cored electrodes. Short circuit, glob and spray transfer solid wire and gas welding are done in this mode. Low end procedures, less than 17V, may operate better in the FCAW mode. Voltage in the GMAW mode can become erratic when welding is attempted using voltages equal to or less than 17V DC+. SMAW CRISP FCAW SMAW SOFT GMAW Arc Force / Inductance Control This control functions in all modes except GTAW. For CC modes, this control acts as an Arc Force adjustment. The arc is soft at the minimum settings and more forceful or driving at the maximum settings. Higher spatter levels may be present at the maximum settings. For CV modes, this control will set the degree of “pinch effect” which predominantly affects short circuit transfer. In FCAW, the maximum setting is generally preferred. With GMAW, the upper half of the range is preferred with CO2 or high content CO2 mixed. The lower half is for inert gas mixes. GTAW Output Terminals Switch For processes and equipment that require energized machine terminals (stick, TIG, air-carbon arc cutting or hot tip LN-25), set the Output Terminals Switch to “ON” position. Recommended Arc Force / Inductance Settings For Selected Applications Set to the REMOTE (OFF) position when using LN-25 with K431 and K432 options or LN-7 which will allow the gun trigger to energize the welding terminals. Full Range Is 1-10, 1 Is Very Soft, 10 Is Very Crisp ON OUTPUT TERMINALS Nominal Setting Recommended Adjustment Range EXX18 thru EXX28 stick 5 1 (gentle, may stick) to 9 (forceful, more spatter) EXX10 thru EXX14 stick 6 3 to 10 Air Carbon Arc Cutting 1 None Innershield or Outershield 10 None Air Carbon Arc Cutting 1 None CO2 or 25% CO2 7.5 5 to 10 5 1 to 10 Mode Process CC SMAW 1 CC SMAW 2 REMOTE CV FCAW CV GMAW* or similar gas mixes 98% Ar-2% O2Ar, 90% He-7.5% Ar 2.5% CO2 and other predominantly inert gases * 1 = Lowest pinch, highest inductance and least spatter. 10 = Highest pinch, lowest inductance and most spatter. – 12 – – Meter Polarity Switch MAINTENANCE The wire feeder polarity switch is located at the rear of the machine. The switch provides a work connection for wire feeder voltmeters. Place the switch in the position of the electrode polarity indicated by the decal. The switch does not change the welding polarity. WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. --------------------------------------------------------------------- EXPLODING PARTS can cause injury. T13086-84 • Failed parts can explode or cause other parts to explode when power is applied. • Always wear a face shield and long sleeves when servicing. ---------------------------------------------------------------------------------Capacitor Discharge Procedure Auxiliary Power 1. Obtain a power resistor (25 ohms, 25 watts). A 24 VAC @ 1 amp supply is included for use with the LN-25 wire feeder (24 volts needed for K431 and K432 options). This supply is protected by a selfresetting current limiter. A 42 VAC @ 5.5 amp supply is included for use with other wire feeders. This supply is protected by a 6 amp breaker located on the rear of the machine. 2. Hold resistor body with electrically insulated glove. DO NOT TOUCH TERMINALS. Connect the resistor terminals across the two hex head cap screws in the position shown. Hold in each position for 1 second. For 575 VAC only, repeat for second capacitor. Repeat for the capacitor(s) on the other side of the machine A 110/115 VAC @ 2 amp supply is included for use with the LN-7 or LN-9 GMA wire feeders. This supply is protected by a 2.5 amp breaker located on the rear of the machine. It is NOT available on IEC units. RESISTOR All three supplies are not to be loaded simultaneously. CAPACITOR TERMINALS 3. Use a DC voltmeter to check that voltage is not present across either capacitor. Routine Maintenance 1. Every 6 months or so the machine should be cleaned with a low pressure airstream. Keeping the machine clean will result in cooler operation and higher reliability. Be sure to clean these areas: • Power, switch, driver, protection and control printed circuit boards. • Power switch • Main transformer • Input rectifier (located in front of fan blade) • Heat sink fins 2. Examine the sheet metal case for dents or breakage. Repair the case as required. Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained. All external sheet metal screws must be in place to insure case strength and electrical ground continuity. – 13 – PERIODIC MAINTENANCE TROUBLESHOOTING WARNING Overload Protection ELECTRIC SHOCK can kill. The machine is electrically protected from producing high output currents. Should the output current exceed 340-360A, an electronic protection circuit will reduce the current to approximately 150A. The machine will continue to produce this low current until the protection circuit is reset. Reset occurs when the output load is removed. • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. --------------------------------------------------------------------- EXPLODING PARTS can cause injury. Thermal Protection • Failed parts can explode or cause other parts to explode when power is applied. Thermostats protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating. If excessive operating temperature should occur, the thermostat will prevent output voltage or current. The meter will remain energized during this time. • Always wear a face shield and long sleeves when servicing. ---------------------------------------------------------------------------------Visual Inspection Thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the Power Switch may be left on and the reset should occur within a 15 minute period. If the fan is not turning or the air intake louvers were obstructed, then the power must be switched off for 15 minutes in order to reset. The fan problem or air obstruction must also be corrected. Clean interior of machine with a low pressure airstream. Make a thorough inspection of all components. Look for signs of overheating, broken leads or other obvious problems. Many problems can be uncovered with a good visual inspection. Open Circuit Voltage The open circuit voltage of the Invertec V300-PRO is 60 to 75 VDC and cannot be adjusted by the output control. Test Conditions Filter Capacitor Conditioning A protection circuit is included to monitor the voltage across filter capacitors C1 and C2 (also C14 and C15 on 575 VAC units). In the event that the capacitor voltage is too high, the protection circuit will prevent output. The protection circuit may prevent output providing all these circumstances are met: 1. Machine is internally connected for 380 VAC, or higher input voltage. 2. Machine did not have power applied for many months. 3. Machine did not produce output when power was first switched on. Perform all testing at the lowest input voltage available, except where a higher voltage is required by a test step. Make ohmmeter checks only after power has been disconnected from machine and after capacitors have been discharged. Certain high voltage connections have been insulated with RTV sealant. It is necessary to break through the sealant with a sharp probe in order to make voltage or resistance checks. Disconnect any control cables from remote control receptacle. If these circumstances apply, the proper action is to switch the machine on and let it idle for up to 30 minutes. This is required to condition the filter capacitors after an extended storage time. The protection circuit will automatically reset once the capacitor conditioning and resultant voltage levels are acceptable. It may be necessary to turn the power switch off and back on again after this period. – 14 – TROUBLESHOOTING GUIDE Trouble What To Do Not output but fan operates and meter is on. Perform test steps 1A and 1B. Poor welding, weld settings drift, or output power is low. 1. 2. Main fuses open or Switch PC boards overheated. Perform test steps 4 and 5 for both Switch PC Boards and 7. Output turns on momentarily then switches off and repeats. Machine is connected for 380 VAC or higher input voltage. Perform test steps 3B, 4 and 5. OCV is normal (approx. 65-75V) but output power is low (less than 20V and 100A). Machine makes squealing noise while under load. Machine is connected for 230 VAC, or lower, input voltage. Perform test steps 4 and 5 for both Switch PC Boards. Open circuit voltage is 1-2 volts. Perform test step 6. Output control not functioning on remote control. Local control OK. 1. 2. Check remote control assembly. Check S3, Local/Remote switch. Machine does not produce more than 250A output when connected to 3 phase supply. 1. 2. 3. 4. Replace main fuse if blown. Replace Protection PC Board. Replace Control PC Board. Perform test step 7. Machine does not produce more than 200 A output while connected to 1 phase supply. Normal operation. Machine operates OK at 230 VAC or lower. No output at 380 VAC or higher. Perform test step 2. Poor EXX10 stick electrode (5P) performance. Arc “pops out”. Check D6 and D12, L1 and L2. No output or reduced output the first time power is applied to the machine. Check reconnect panel - connections and fuse. Check front panel wiring and controls. Replace Control PC Board. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. – 15 – TEST PROCEDURES Step Test 1A Output pilot circuit (set S4 on) 1B 2 Check 223A to 210 302 (pos) to 275D (neg) Protection PC board output (set S4 on) 313 (neg) to 311 (pos) Test Result Conclusion 24 VAC Fan thermostat, choke thermostat, T1 transformer and S4 all OK. 0 VAC Check above components. 15 VDC T1 and 15V power supply OK. 0 VDC Check T1 and Power PC Board. <1 VDC Protection PC Board OK Static capacitor balance (set S4 off) 380 VAC input and higher test 3B Dynamic capacitor balance (set S4 on) 380 VAC input and higher test Compare voltage across terminals 9 & 12 of each Switch PC Board. 575 VAC -- 407 VDC 460 VAC -- 325 VDC 440 VAC -- 311 VDC 415 VAC -- 293 VDC 380 VAC -- 269 VDC 575 VAC only - compare voltage across 9A & 13 and 13 & 12A; then, 9B & 15 and 15 & 12B Connect as in step 3A. Same voltages as above. <25 VDC difference between readings Repair Action 1B 2 Replace Power and Control PC Boards 3A >5 VDC 3A Next Test Step C1, C2, R1, R9 - OK (575 VAC machine C14, C15 - OK) 3B >25 VDC difference Check above components. <25 VDC OK >25 VDC Power PC Board or Switch PC Boards are damaged. Replace Protection PC Board 4 and 5 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. – 16 – – Step Test 4 Switch PC Board resistance test. No dynamic test is possible. Remove leads 401/403, 1/8, 9, 12, 4/5 and 402/404. Check Terminals on Switch PC Board: 1/8 (pos) to 12 (neg) 1/8 (neg) to 12 (pos) 9 (pos) to 4/5 (neg) 9 (neg) to 4/5 (pos) 1/8 (pos) to 9 (neg) 1/8 (neg) to 9 (pos) 12 (pos) to 4/5 (neg) 12 (neg) to 4/5 (pos) 12 (pos) to 401/403 (neg) 12 (neg) to 401/403 (pos) 9 (pos) to 402/404 (neg) 9 (neg) to 402/404 (pos) Test Result Conclusion >1K ohms OK <100 ohms Short <100 ohms OK >1K ohms Open >1K ohms OK <100 ohms Short <100 ohms OK >1K ohms Open <100 ohms OK >1K ohms Open >1K ohms OK <100 ohms Short <100 ohms OK >1K ohms Open >1K ohms OK <100 ohms Short >1K ohms OK <100 ohms Short <100 ohms OK >1K ohms Open <100 ohms OK >1K ohms Open >1K ohms OK <100 ohms Short Next Test Step Repair Action cont 5 Replace Switch PC Board cont 5 Replace Switch PC Board cont 5 Replace Switch PC Board cont 5 Replace Switch PC Board cont 5 Replace Switch PC Board cont 5 Replace Switch PC Board cont 5 Replace Switch PC Board cont 5 Replace Switch PC Board cont 5 Replace Switch PC Board cont 5 Replace Switch PC Board cont 5 Replace Switch PC Board cont 5 Replace Switch PC Board CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. – 17 – Step 5 Test Snubber Resistors Disconnect leads 401, 402, 403 and 404 from Switch PC Board Check Lead 401 to terminal 12 Lead 402 to terminal 9 Lead 403 to terminal 12 Lead 404 to terminal 9 6 Test Result Repair Action 25 ohms OK >30 ohms <20 ohms R4 open R4 shorted 25 ohms OK >30 ohms <20 ohms R5 open R5 shorted 25 ohms OK >30 ohms <20 ohms R6 open R6 shorted 25 ohms OK >30 ohms <20 ohms R7 open R7 shorted Replace R7 <100 ohms Shorted output diode D1 thru D12 Test individually >200 ohms Output diodes OK Output diodes + output plug (pos) to - output plug (neg) Conclusion Next Test Step cont Replace R4 cont Replace R5 cont Replace R6 cont Remove output load CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. – 18 – Step 7 Test D13 Input Rectifier Check 9 (pos) to H1 (neg) 9 (pos) to A (neg) 9 (pos) to H5 (neg) 12 (neg) to H1 (pos) 12 (neg) to A (pos) 12 (neg) to H5 (pos) 9 (neg) to H1 (pos) 9 (neg) to A (pos) 9 (neg) to H5 (pos) 12 (pos) to H1 (neg) 12 (pos) to A (neg) 12 ( pos) to H5 (neg) Test Result Conclusion Next Test Step >1K ohms OK cont <100 ohms Shorted 4-5 >1K ohms OK cont <100 ohms Shorted 4-5 >1K ohms OK cont <100 ohms Shorted 4-5 >1K ohms OK cont <100 ohms Shorted 4-5 >1K ohms OK cont <100 ohms Shorted 4-5 >1K ohms OK cont <100 ohms Shorted 4-5 <100 ohms OK cont >1K ohms Open 4-5 <100 ohms OK cont >1K ohms Open 4-5 <100 ohms OK cont >1K ohms Open 4-5 <100 ohms OK cont >1K ohms Open 4-5 <100 ohms OK cont >1K ohms Open 4-5 <100 ohms OK cont >1K ohms Open 4-5 – 19 – Repair Action Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Matched Parts 5. Thoroughly clean the heat sink surface. Certain parts must be replaced in matched sets. Matched sets are required in the following areas: 6. Apply a thin layer (ideally .005-.010”) of Dow 340 Heat Sink Compound to the module mounting surfaces of the new Switch PC Board and a thinner layer (.002”) to the capacitor terminals. Keep the heat sink compound away from the screw threads since this compound will affect the torque specifications. Output diodes: D1, D2, D3, D4 and D5 Output diodes: D7, D8, D9, D10 and D11 Capacitor bleeder resistors: R1 and D9 Capacitors: C1 and C2 Capacitors: C1, C2, C14 and C15 (575 VAC only) Switch PC Board Repairs 7. Carefully place the Switch PC Board onto the heat sink. Be sure the mounting holes are lined up before making full contact with the heat sink. If a test indicates that a Switch PC Board is defective, both Switch PC Boards must be replaced. Replacement boards must have completely identical part numbers. A defective module is likely to damage other devices in the power circuitry. The defect may be subtle and not detectable by an ohmmeter measurement. Unknown defective parts may cause newly replaced parts to fail. 8. Caution: The heat sink and the capacitor terminals are relatively soft material and it is very easy to cross-thread the mounting screws. Holding the Switch PC Board, install the 4 socket head cap screws, finger tight only. Then install the hex head cap screws into the capacitor, finger tight only. In addition to replacing the Switch PC Boards, replace C1 and C2 (also C14 and C15 of the 575 VAC V300PRO) if the following conditions are met: 9. Torque the 4 socket head cap screws to 44 inchlbs force (5 N - m). Then torque the capacitor hex head cap screws to 55 inch-lbs force (6 N - m). 10. Reconnect all the leads to the board. 1. Machine was operating from 380 VAC or higher supply when failure occurred. 2. Switch PC Boards have burned areas. Before applying input power to the machine, check all electrical connections. An incorrect connection will result in machine damage when the power is switched on. Switch PC Board Replacement Procedure Test After Repair WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. --------------------------------------------------------------------- EXPLODING PARTS can cause injury. • Failed parts can explode or cause other parts to explode when power is applied. • Always wear a face shield and long sleeves when servicing. ---------------------------------------------------------------------------------1. Carefully disconnect the leads at the top of the Switch PC Board. 2. Remove the four socket head cap screws with a 3/16” hex key wrench. 3. While holding the Switch PC Board, remove the hex head cap screws from the center area of the board. 1. Short terminals 14 and 53 of the Protection PC Board. Connect an ohmmeter, set for X1000 range, to terminals 9 (+) and 12 (-) of the Switch PC Board. The meter will show the capacitors charging up. The meter may take a minute or so to stabilize. The value must not exceed 8600 ohms. Test both boards. For 575V only units - measure across each power capacitor, 2 per switch board; All four readings should be approximately 5,000 ohms. 2. If OK, remove the short and proceed with the power test. 3. Fuse input supply with 5 amp fuses. 4. Check output open circuit voltages. Do not apply output load. 5. Connect machine for 460 (V300-PRO), or 575 (V300-PRO, 575V), or 380, 415 or 440 (V300-I) VAC input. 6. Check output open circuit voltages. Do not apply output load. 4. Remove the board. 7. Fuse for 20 amps and test under load. – 20 – – Replacement of Power Modules and Output Diodes The compound should be applied to the heat sink in a very thin layer, less than 0.001 in. DO NOT apply on diode stud and mounting nut threads. Input rectifier, D13, is a power module. When mounting power modules, the heat sink and module mounting surface should be clean and free of burrs and foreign material. Apply heatsink compound (Dow 340) as a uniform layer ideally .010” thick, to eliminate all air pockets. This may be verified by mounting and then removing the module. When removed, the compound on both surfaces will appear textured as if a vacuum had created veinlike ridges when the parts were separated. If the compound does not have this appearance, apply more heatsink compound and recheck. Components must have proper torque applied to mounting screws and to electrical terminals. Torque the modules according to the following: Replacement of output diodes D1 thru D12 is similar. Clean and brighten mounting surface with fine steel wool. Compound should be used on surface between diode and heat sink when mounting individual diodes. Component to Heat Sink Torque ±10% Terminal Torque ±10% Module 44 Inch - Lbs.(1) (5N - m) N.A. Capacitor N.A. 55 Inch - Lbs. (6.3 N - m) Input Rectifier (M15454-1) 6 Inch - Lbs.(2) (0.7 N - m) 26 Inch - Lbs. 3 (N - m) Output Diode (M15482-2) 25 Inch - Lbs. (3 N - m) N.A. Component Switch Board (1) (2) Retorque after 3 hours to allow for spread of compound. Tighten in staggered fashion one quarter turn at a time. Environment Protection Printed Circuit Board Replacement High voltage connections are covered with an RTV sealant to prevent malfunction in severe environments. Sealant must be applied to connections which have been opened or otherwise lost their protection. A noncorrosive electronic grade sealant such as Dow Corning 3140, 3145, 738, Columbus Adhesives 0172 or GE RTV-162 is recommended. Sealant may also be purchased from Lincoln Electric (order E2519 Silicone Rubber RTV Coating). Apply sealant after machine is repaired and tested. 1. Handle PC Boards by edges only. 2. Store PC Boards only in the bags that disperse static charges. 3. Inspect PC Board for burned conductors or components. If damage is visible, inspect the machine wiring for grounds or shorts to avoid damaging a new PC Board. High voltage areas which require sealant are as listed: - Input rectifier D13, all 5 terminals. 4. If there is no visible damage to the PC Board, install a new PC Board and see if the problem is fixed. If the problem is fixed by the new board, reinstall the old board and see if the problem reoccurs. If the problem does not reoccur, check the wiring harness and plugs for loose connections. – 21 – – 22 – K876 TO POWER SOURCE STRAIGHT PLUG (14 PIN) K864 STRAIGHT PLUG (14 PIN) TO POWER SOURCE 3) K870 FOOT AMPTROL 1) K857 REMOTE CONTROL 2) K963 HAND AMPTROL 1) LN-7 WIRE FEEDERS TO: 1) LN-25 WIRE FEEDERS CABLE RECEPTACLE (6 SOCKET) TO: CABLE RECEPTACLE (14 SOCKET) TO: CABLE RECEPTACLE (6 SOCKET) OR WHEN CONNECTING OR DISCONNECTING PLUGS TO WELDING POWER SOURCE. TURN THE POWER SWITCH OF THE WELDING POWER SOURCE "OFF" BEFORE INSTALLING PLUGS ON CABLES REMOTE CONTROL ADAPTERS S19309 4-19-96D – 23 – IT IS DESIGNED TO ALLOW THE USER TO MAKE CONNECTIONS 115V AC (31, 32), 42V AC WELDING MODE CONTROL 82 81 SPARE L M N WELDING MODE CONTROL 115V AC 31 42V AC 41 I 42 WORK 21 H K OUTPUT CONTROL J OUTPUT CONTROL 77 E 76 OUTPUT CONTROL 4 D 75 TRIGGER CIRCUIT 2 F CHASSIS CONNECTION TRIGGER CIRCUIT GND B C G 115V AC 32 A STANDARD FUNCTION LEAD PIN AND TRIGGER CIRCUIT (2, 4) E=77 M=81 K=42 AND 14-PIN CABLE PLUG, 14-PIN BOX RECEPTACLE, D=4 C=2 L=82 B=GND A=32 REAR VIEW FRONT VIEW F=76 G=75 N=SPARE H=21 I=41 J=31 F=76 M=81 K=42 AND 14-PIN CABLE PLUG, 14-PIN BOX RECEPTACLE, G=75 H=21 N=SPARE I=41 J=31 THE INSULATING METHOD MUST BE RATED FOR 120V AC OR GREATER. CRIMP SPLICE OR SOLDER CONNECTIONS AS REQUIRED AND INSULATE EACH USED AND UNUSED LEAD MAY NOT BE PRESENT IN YOUR EQUIPMENT. REFERENCE ONLY AND EACH MAY OR 24V AC (SPARE) INDEPENDENT CIRCUITS INSIDE THE WELDER. 42V AC (41, 42), MAY OR MAY NOT BE ISOLATED, IN THE UNIVERSAL ADAPTER. USE LUG, NOTE: THE STANDARD CONNECTOR PIN DESIGNATIONS AND FUNCTIONS ARE SHOWN BELOW. CONSULT THE APPROPRIATE EQUIPMENT WIRING DIAGRAMS FOR THE CONNECTIONS TO UNIVERSAL ADAPTER. THESE FUNCTIONS ARE LISTED FOR 24V AC NOR ARE THEY REQUIRED FOR PROPER WIRE FEEDER OPERATION. TURN THE POWER SWITCH OF THE WELDING POWER SOURCE OFF BEFORE INSTALLING THIS ADAPTER TO WIRE FEEDER CABLE. (SEE APPROPRIATE WIRING DIAGRAM) 3. 2. 1. NOT ALL CIRCUITS ARE PRESENT IN EVERY POWER SOURCE, CONSULT THE WIRING DIAGRAM OF THE POWER SOURCE AND WIRE FEEDER THIS ADAPTER WILL BE USED WITH. TO ANY OF THE 14 CIRCUITS PRESENT IN THE WIRE FEEDER RECEPTACLE. WIRE FEEDER RECEPTACLE. THIS CONNECTOR IS MEANT TO BE USED WITH LINCOLN POWER SOURCES WHICH HAVE A 14-PIN INSTALLATION INSTRUCTIONS K867 UNIVERSAL ADAPTER FOR 14-PIN WIRE FEEDER RECEPTACLE S19386 3-16-90 FRONT VIEW REAR VIEW E=77 D=4 L=82 C=2 B=GND A=32 N.D. N.C. N.B. SPLICE LEADS AND INSULATE. INSULATE EACH UNUSED LEAD INDIVIDUALLY. REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE. DIAGRAM SHOWS ELECTRODE POSITIVE. + INVERTEC POWER SOURCE WITH 115VAC AUXILIARY POWER LN-7 CONTROL BOX - K291 OR K404 INPUT CABLE WORK TO CHANGE POLARITY, TURN POWER "OFF", 77 76 75 N.D. 77 76 GREEN 75 GND GND 4 21 21 K867 UNIVERSAL ADAPTER PLUG 2 4 81 42 41 31 32 2 75 14 PIN AMPHENOL 76 K775 OPTIONAL REMOTE CONTROL TO N.C. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. service this machine. Only qualified persons should install, use or CAN KILL SHOCK ELECTRIC 82 SPARE service this machine. Only qualified persons should install, use or Before connecting the wire feeder. using the disconnect switch at the fuse box 32 31 N.C. Turn off input power to the Welding Power Source K867 PLUG TO LN-7 - CONNECTION DIAGRAM WARNING REMOTE CONTROL K775 OPTIONAL LN-7 CONTROL BOX K291 OR K404 INPUT CABLE SPLICE LEADS AND INSULATE. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.A. Before connecting the wire feeder. using the disconnect switch at the fuse box Turn off input power to the Welding Power Source K867 PLUG TO LN-7 - CONNECTION DIAGRAM WARNING SHOCK ELECTRIC CAN KILL 82 SPARE 81 42 41 31 4 75 2 2 21 14 PIN AMPHENOL 31 32 4 32 21 GND 76 77 GREEN GND K867 UNIVERSAL ADAPTER PLUG 77 WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. ELECTRODE CABLE TO LN-7 ELECTRODE CABLE TO LN-7 TO WORK + INVERTEC POWER SOURCE WITH 115VAC N.D. N.A. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF", REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE. AUXILIARY POWER N.B. N.D. N.C. S19404 12-10-93A – 24 – S19404 12-10-93A – 25 – A B 75 76 N.E. D N.E. REMOVE 6 PIN PLUG FROM N.D. SPLICE LEADS AND INSULATE. LABEL EACH LEAD (A THRU F) AS THEY ARE REMOVED FROM 6 PIN PLUG. K432 CABLE IN ORDER TO CONNECT K867 PLUG. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.C. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF", REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE. N.B. N.D. C F SPARE 77 E 2 4 32 31 GND N.C. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. K867 ADAPTER AMPHENOL 14 PIN 41 42 81 82 21 service this machine. Only qualified persons should install, use or Before connecting the wire feeder. using the disconnect switch at the fuse box Turn off input power to the Welding Power Source N.A. INVERTEC POWER SOURCE + - TO WORK ELECTRODE CABLE TO LN-25 CAN KILL SHOCK ELECTRIC WARNING K867 PLUG TO LN-25 - CONNECTION DIAGRAM K432 REMOTE CONTROL CABLE S19405 1-25-91 LN-25 WITH K431 OPTION – 26 – / VAC VAC / REMOTE OUTPUT N.D. N.C. TO CHANGE POLARITY, TURN POWER "OFF", K867 4 WIRE FEEDER FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION 2 RELAY TO CLOSE LEADS 2 & 4. TO TO INSULATE EACH UNUSED LEAD INDIVIDUALLY. REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE. N.C. N.D. CONTROL VOLTMETER CONNECTION (WORK TERMINAL) OF INVERTEC CONNECTION AMP AMP FOR DIAGRAM SHOWS ELECTRODE POSITIVE. MIN. 10K 2 5.5 FRAME / WIRE FEEDER CONNECTS TO INVERTEC 115 42 AMP INVERTEC TOGETHER OUTPUT 1 ON N.B. 75 76 77 21 GND 32 VAC USED CONNECT WELDING 24 NOT WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. K867 UNIVERSAL ADAPTER PLUG 42 AMPHENOL 31 41 14 PIN 4 2 SPARE 82 81 service this machine. Only qualified persons should install, use or Before connecting the wire feeder. using the disconnect switch at the fuse box Turn off input power to the Welding Power Source N.A. AUXILIARY POWER POWER SOURCE WITH 115VAC INVERTEC + - WORK TO ELECTRODE CABLE CAN KILL SHOCK ELECTRIC WARNING K867 UNIVERSAL ADAPTER / INVERTEC - CONNECTION DIAGRAM S19406 12-10-93A – 27 – DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF", REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE. FOR INVERTECS WITH 6 PIN AMPHENOL, K432 CABLE CAN BE CONNECTED DIRECTLY. N.B. N.C. AMPHENOL 6 PIN WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. K876 ADAPTER AMPHENOL 14 PIN service this machine. Only qualified persons should install, use or Before connecting the wire feeder. using the disconnect switch at the fuse box Turn off input power to the Welding Power Source N.A. INVERTEC POWER SOURCE + - TO WORK ELECTRODE CABLE TO LN-25 CAN KILL SHOCK ELECTRIC WARNING K876 ADAPTER TO LN-25 - CONNECTION DIAGRAM CONTROL CABLE K432 REMOTE K431 OPTION LN-25 WITH S19899 1-25-91 – 28 – DIAGRAM SHOWS ELECTRODE POSITIVE. K480-7 INPUT CABLE CAN BE CONNECTED DIRECTLY IF REMOTE CONTROL IS NOT REQUIRED. K864 ADAPTER CANNOT BE USED WITH AN LN-25. N.C. N.D. REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE. TO CHANGE POLARITY, TURN POWER "OFF", WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.B. OR K870 FOOT AMPTROL HAND AMPTROL K963 K857 REMOTE CONTROL 6 PIN AMPHENOL K480-7 INPUT CABLE ADAPTER OR AMPHENOL 14 PIN CONTROL BOX LN-7 K864 AMPHENOL 14 PIN service this machine. Only qualified persons should install, use or Before connecting the wire feeder. using the disconnect switch at the fuse box Turn off input power to the Welding Power Source N.A. AUXILIARY POWER WITH 115VAC POWER SOURCE INVERTEC + - WORK TO TO LN-7 ELECTRODE CABLE CAN KILL SHOCK ELECTRIC WARNING K864 ADAPTER TO LN-7 & REMOTE CONTROL - CONNECTION DIAGRAM S19901 4-19-96D – 29 – AMPHENOL TOP 14 PIN AMPHENOL SET UP SHOWN IS FOR DC NEGATIVE TIG WELDING. N.C. THE OUTPUT CONNECTIONS ON THE INVERTEC AND SETTING THE INVERTEC’S ELECTRODE POLARITY SWITCH TO POSITIVE. K814 FOOT AMPTROL K870 HAND AMPTROL K963 ARC START SWITCH DC POSITIVE WELDING IS OBTAINED BY REVERSING A WIRE FEEDER CAN BE PLUGGED INTO THE DC TIG STARTER TO REDUCE PROCESS CONVERSION TIME. TO WORK OR OR N.B. + N.C. TO TIG TORCH WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. AUXILIARY POWER - IN OUT WITH 5.5 AMP 42 VOLT POWER SOURCE INVERTEC DC TIG STARTER K900-1 APPROPRIATE WIRE FEEDERS AMD CONNECTORS. CONSULT INVERTEC INSTRUCTION MANUAL FOR Only qualified persons should install, use or service this machine. Starter to the power source, or the Amptrol or Wire Feeder to the DC Tig Starter. Turn off input power to the Welding Power Source using the disconnect switch at the fuse box before connecting the DC Tig N.A. BOTTOM 14 PIN N.B. WIRE FEEDER ELECTRIC SHOCK CAN KILL WARNING K900-1 DC TIG STARTER - CONNECTION DIAGRAM S20405 4-19-96D – 30 – CONTROL CABLE ASSEMBLY K596 REMOTE LN-9 GMA WITH K608-1 AND K442-1 KITS. FOR GMAW WELDING, INSTALL PULSE POWER FILTER KIT K442-1 IN LN-9 GMA. INSTALL K608-1 ADAPTER IN LINE WITH P10 TO LN-9 GMA VOLTAGE BOARD PER INSTRUCTIONS IN V300 MANUAL. N.C. N.D. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF", REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE. SET METER POLARITY SWITCH ON REAR OF INVERTEC TO COINCIDE WITH POLARITY USED. SET LN-9 GMA POLARITY SWITCH ALSO. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. 14 PIN AMPHENOL service this machine. Only qualified persons should install, use or Before connecting the wire feeder. using the disconnect switch at the fuse box Turn off input power to the Welding Power Source N.B. N.A. INVERTEC POWER SOURCE WITH 110/115V AUX. + - TO WORK ELECTRODE CABLE TO LN-9 GMA CAN KILL SHOCK ELECTRIC WARNING LN-9 GMA WITH K596 CABLE TO INVERTEC - CONNECTION DIAGRAM C 7 B 533 11 12 3.9K 524 6 10 500 500 4 5 521 530A 3 2 P10,J10’ DETAIL S20607 9-29-95C 12 7 11 6 5 4 3 2 P10’,J10 CONNECTION K608-1 – 31 – 4 21 4 21 N.D. 2 2 A B C 75 76 77 GND 32 32 GND 31 31 41 42 N.C. K196 INPUT CABLE N.F. SPLICE LEADS AND INSULATE. INSTALL K608-1 ADAPTER IN LINE WITH P10 TO LN-9 GMA VOLTAGE BOARD AND SECURE TO FOR GMAW WELDING, INSTALL PULSE POWER FILTER KIT K442-1 IN LN-9 GMA. ADJACENT HARNESS WITH WIRE TIE PROVIDED. TURN "START" TRIMMER ON VOLTAGE BOARD FULLY ’CCW’. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.D. N.E. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF", REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE. SET METER POLARITY SWITCH ON REAR OF INVERTEC TO COINCIDE WITH POLARITY USED. SET LN-9 GMA POLARITY SWITCH ALSO. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. K867 UNIVERSAL ADAPTER PLUG 14 PIN AMPHENOL 81 82 SPARE service this machine. Only qualified persons should install, use or Before connecting the wire feeder. using the disconnect switch at the fuse box Turn off input power to the Welding Power Source N.C. N.B. N.A. POWER SOURCE WITH 110/115V AUX. INVERTEC + - TO WORK ELECTRODE CABLE TO LN-9 GMA CAN KILL SHOCK ELECTRIC WARNING LN-9 GMA WITH K196 CABLE AND K867 PLUG TO INVERTEC - CONNECTION DIAGRAM 533 B 3.9K K608-1 AND K442-1 KITS. LN-9 GMA WITH 12 11 10 C 524 6 7 500 5 500 521 3 4 530A 2 P10,J10’ DETAIL S20608 9-11-92 12 7 11 6 5 4 3 2 P10’,J10 CONNECTION K608-1 – 32 – MAR97 W V U 3 AMP SLOW BLOW ON N.C. J15 4 REMOTE CONTROL RECEPTACLE GND 211B 21 N H B L 21 GND M 81 82 223B 212C 212 42 212 32 SPARE D 2 4 I K C 41 42 A 32 212 77B E 77 J 76 F 75 76 31 9D 12D F - 12C TP2 G A A C D + TP3 TP1 B 9C 51 H5 314 51 H5 1 2 3 4 5 6 51 42A C R1 H1 A 285 229 - + 3 10 25 25W S6 460V 440- 415V 380- 230V 220- H3 208V 200- R4 3 09 H6 H4 H3 H2 H1 9B 6 3 2 4 1 J13 12B 12B + 9B C1 2200 F 450V C R2 310 12 H1 H5 H4 H3 H2 12B 7 0V 24V 42V 110V 18V N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. 2 3 5 6 4 1 4 W 212D 503 42A 32A 501 504 J12 4,5 1 4 212A FAN 5 T3 8 COLOR B = G = R = W = Y = 150 5W Y CODE: BLACK GREEN RED WHITE YELLOW 210 Y CURRENT TRANSFORMER THERMOSTAT 1 L5 212C 224 6 2 5 4 J9 1,8 3 3 4 308 J11 1 2 307 1,8 R SWITCH BOARD (RIGHT) R 317 316 12D 12 13 14 J10 W 4,5 I I T2 4 307 313 311 504 501 310 309 308 S 8 F INSIDE TOP F F S S F S OUTSIDE BOTTOM 5 1 INSIDE BOTTOM OUTSIDE TOP MAIN TRANSFORMER J6 J11, J14 J2, J8 10 9 5 4 1 8 3 6 7 2 J4 J9, J10, J12 J13, J15 212D 212B 211B 211A 275D 304 303 302 301 305 D1B 224 1 10 6 ELECTRICAL SYMBOLS PER E1537 J5, J16 J1, J7 304 303 305 302 301 275D 275F 226 8 7 6 4 5 3 1 2 7 8 9 275B 213 2 502 R W 6 218 75 275A 210 Y Y 306 215 77A THERMAL OVERLOAD INDICATOR (V300-I ONLY) R11 OUTPUT CONTROL S3 LOCAL/REMOTE SWITCH S4 OUTPUT TERMINAL SWITCH 2 4 3 1 9 5 10 11 4 276 207 208 228 7 3 14 C6 229 C9 C5 12 13 2 8 1 1 2 TP4 L4 J3 J2 J1 J5 J4 R W 286 TP5 229 250 25W CONTROL BOARD 11 12 4 5 3 214 227 211A 223A 206 203 76 220 204A 503A CHOKE L3 400A SHUNT CHOKE THERMOSTAT CONNECTOR CAVITY NUMBERING SEQUENCE J6 J3 J14 J7 POWER BOARD F D3 D2 D1A (VIEWED FROM COMPONENT SIDE OF BOARD) 2 3 4 1 3 1 6 5 4 2 7 8 L1 LEFT S F AUX S TOP F TOP S S F BOTTOM AUX S F L2 RIGHT F BOTTOM S R8 229 215 503A 503 502 223A 223B 212B 212A 208 207 204C 204B 228 275A 275B 275C 276 77A 77B 218 213 204B 204A 206 Y 275C 227 226 214 220 204C 203 285 TP6 229 5 4 REMOTE LAYOUT CONTROL PANEL 10K 2W CW (MAX) REMOTE LOCAL 10K 2W ON CV GMAW CV FCAW CC CRISP CC SOFT CC GTAW CW (MAX) 3 2 1 A V S5 METER FUNCTION SWITCH - ARC + ARC 3 4 5 6 3 4 5 6 L10189 B R12 ARC FORCE/INDUCTANCE CONTROL S5 METER FUNCTION SWITCH S2 MODE SWITCH THERMAL OVERLOAD INDICATOR (V300-I ONLY) S4 OUTPUT TERMINAL SWITCH R12 ARC FORCE /INDUCTANCE CONTROL S3 LOCAL/REMOTE SWITCH R11 OUTPUT CONTROL S2 MODE SWITCH 1 2 1 2 PANEL METER NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.. CONNECTION SHOWN IS FOR 380-460V OPERATION. N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE. N.G. C1, C2 CAPACITORS ARE A MATCHED SET. N.F. R1, R9 BLEEDER RESISTORS ARE A MATCHED SET. N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR 440-460V OPERATION. N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "I". 9D 8 401, 403 12 T1 - 52 3 R 3 2 5 1 W W 402, 404 9 315 2 + 314 1 J16 6 R 401, 403 SWITCH BOARD (LEFT) 402, 404 DRIVER BOARD - + 9 AUXILIARY TRANSFORMER 12A 12A + 9A 9A C2 2200 F 450V N.G. 12D R5 25 25W 12A 12A 12A 9B 9B 12B R6 25 25W R7 25 25W N.G. WIRE FEEDER WELDING POLARITY SWITCH N.D. H3 7500 25W N.F. N.H. 9B 12C 9C RECONNECT S7 9D 9A 30 9 53 14 7500 25W 52 N.F. CB1 6AMP 32A CB2 2AMP FAN MOTOR 12D 9D 317 316 315 52 14 53 52 14 53 75 MIN A H5 H1 H1 A INPUT RECTIFIER D13 WIRE FEEDER TRIGGER 42 VAC 110/115 VAC G B R J8 3 306 NOTES: N.A. 1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO) FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT. WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. 2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I) FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. CONNECT TERMINALS U & W TO SUPPLY CIRCUIT. FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT. REMOTE OUTPUT CONTROL INPUT PER N.A. S1 POWER OFF W 2 313 PROTECTION BOARD 1 275F R1 R9 311 WIRING DIAGRAM V300-PRO Code 10256, V300-I Code 10258 R11 R12 – 33 – MAR97 J8 3 W V N.C. TRIGGER REMOTE CONTROL RECEPTACLE WIRE FEEDER 21 GND 211B H 21 N L B M 81 82 223B 212C 212 42 212 32 F - GND D C 2 4 K J A 31 32 42 E 212 76 77B F 75 12B 77 I D + TP2 76 41 9D TP3 G C B TP1 75 MIN H6 H5 H1 H1 A INPUT RECTIFIER D13 51 H5 314 51 H5 1 2 3 4 5 6 H1 53 14 42A H3 51 285 229 - + 9D 9A 10K 25W 10K 25W 52 CB1 6AMP 32A CB2 2AMP FAN MOTOR 9D 317 316 315 52 14 53 52 14 53 SPARE 42 VAC 110/115 VAC REMOTE OUTPUT CONTROL G B R U ON POWER OFF W S1 J15 4 306 R1 309 H6 575V 220230V H3 H1 12B 12B + + T1 0V 24V 42V 110V 18V 12 AUXILIARY TRANSFORMER H5 H3 52 317 2 3 5 6 4 1 4 W 3 W 212D 503 42A 32A 501 504 J12 1 COLOR B = G = R = W = Y = 212A 1 4 FAN 5 8 150 5W CODE: BLACK GREEN RED WHITE YELLOW T3 Y 210 Y CURRENT TRANSFORMER THERMOSTAT L5 212C 224 1, 8 R 4,5 6 2 5 4 J9 3 4 308 J11 1 2 307 1, 8 SWITCH BOARD (RIGHT) R 316 12 13 14 J10 401, 403 13,15 R 3 2 5 1 W W 402, 404 9 9D 8 J16 7 + - 3 H1 315 2 6 R 401, 403 12 4, 5 I I T2 4 J6 F J11, J14 J2, J8 J14 J7 POWER BOARD L1 LEFT S F AUX S TOP F TOP S S F BOTTOM F J4 J9, J10, J12 J13, J15 212D 212B 9 10 211B 211A 4 5 275D 304 303 302 301 305 1 8 3 6 7 2 D1B D3 D2 D1A (VIEWED FROM COMPONENT SIDE OF BOARD) CONNECTOR CAVITY NUMBERING SEQUENCE J6 2 3 4 1 3 S AUX S F BOTTOM L2 RIGHT 1 10 5 6 304 303 305 302 301 275D 275F 226 8 7 6 4 5 3 1 J2 J1 J5 J3 R W J4 229 208 77A 4 275A 210 Y Y 306 THERMAL OVERLOAD INDICATOR (V300-I ONLY) R11 OUTPUT CONTROL S3 LOCAL/REMOTE SWITCH S4 OUTPUT TERMINAL SWITCH 2 4 3 1 9 5 10 215 75 14 11 218 6 276 207 7 3 228 229 502 R W C9 C6 TP6 C5 12 13 2 8 1 1 2 L4 TP4 286 TP5 250 25W CONTROL BOARD 2 7 8 9 275B 213 2 11 12 4 3 214 227 211A 223A 206 203 76 220 204A J1, J7 224 503A CHOKE L3 400A SHUNT CHOKE THERMOSTAT J5, J16 ELECTRICAL SYMBOLS PER E1537 313 311 5 1 4 6 2 7 8 504 F 501 J3 8 310 309 308 307 S INSIDE TOP F F S S F S OUTSIDE BOTTOM 5 1 INSIDE BOTTOM OUTSIDE TOP MAIN TRANSFORMER R8 229 285 229 503A 503 502 223A 223B 212B 212A 208 207 204C 204B 228 275A 275B 275C 276 77A 77B 218 213 204B 204A 206 215 203 275C 227 226 214 220 204C 10K 2W CW (MAX) REMOTE LOCAL 10K 2W CW (MAX) REMOTE ON CV GMAW CV FCAW CC CRISP CC SOFT CC GTAW CONTROL PANEL LAYOUT Y 5 4 3 2 1 A V - ARC S5 METER FUNCTION SWITCH + ARC 3 4 5 6 3 4 5 6 B L10191 CONTROL R12 ARC FORCE/INDUCTANCE SWITCH S5 METER FUNCTION S2 MODE SWITCH THERMAL OVERLOAD INDICATOR (V300-I ONLY) S4 OUTPUT TERMINAL SWITCH R12 ARC FORCE /INDUCTANCE CONTROL S3 LOCAL/REMOTE SWITCH R11 OUTPUT CONTROL 1 2 2 S2 MODE SWITCH PANEL METER 1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.. 6 2 1 J13 C15 314 1 9B C1 - SWITCH BOARD (LEFT) 402, 404 13,15 + 9 V300-PRO CODE 10257 (575V) DRIVER BOARD 912 912 + + 9A 9A 12A 15 WIRE FEEDER WELDING POLARITY SWITCH S6 R4 25 25W C2 C14 N.F. 310 13 R5 25 25W CR1 R6 25 25W R7 25 25W N.F. NOTES: N.A. 1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO) FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT. WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. 2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I) FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. CONNECT TERMINALS U & W TO SUPPLY CIRCUIT. FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT. N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "I". N.F. C1, C2, C14, C15 CAPACITORS ARE A MATCHED SET. INPUT PER N.A. 2 313 PROTECTION BOARD 1 275F R9 311 WIRING DIAGRAM R11 R12 NOTES INVERTEC V300-PRO & V300-I NOTES INVERTEC V300-PRO & V300-I NOTES INVERTEC V300-PRO & V300-I Now Available...12th Edition The Procedure Handbook of Arc Welding New Lessons in Arc Welding This printing will go fast so don’t delay. Place your order now using the coupon below. Lessons, simply written, cover manipulatory techniques; machine and electrode characteristics; related subjects, such as distortion; and supplemental information on arc welding applications, speeds and costs. Practice materials, exercises, questions and answers are suggested for each lesson. The hardbound book contains over 750 pages of welding information, techniques and procedures. Much of this material has never been included in any other book. 528 pages, well illustrated, 6” x 9” size, bound in simulated, gold embossed leather. $5.00 postage paid U.S.A. Mainland With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry. A must for all welders, supervisors, engineers and designers. Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post. $15.00 postage paid U.S.A. Mainland Need Welding Training? How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols. Detailed discussion tells how engineers and draftsmen use the “short-cut” language of symbols to pass on assembly and welding information to shop personnel. Practical exercises and examples develop the reader’s ability to visualize mechanically drawn objects as they will appear in their assembled form. The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland, Ohio. Over 100,000 students have graduated. Tuition is low and the training is “hands on” For details write: Lincoln Welding School 22801 St. Clair Ave. Cleveland, Ohio 44117-1199. and ask for bulletin ED-80 or call 216-383-2259 and ask for the Welding School Registrar. 187 pages with more than 100 illustrations. Size 8-1/2” x 11” Durable, cloth-covered board binding. $4.50 postage paid U.S.A. Mainland Lincoln Welding School BASIC COURSE 5 weeks of fundamentals $700.00 There 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 th Class 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: $5.00 For order value up to $49.99 $10.00 For order value between $50.00 & $99.99 $15.00 For order value between $100.00 & $149.00 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) Name: _______________________________________________ CHECK ONE: Please Invoice (only if order is over $50.00) Check or Money Order Enclosed, U.S. Funds only Credit Card Account No. Address: _______________________________________________ Telephone: _______________________________________________ |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| USE THIS FORM TO ORDER: BOOKS OR FREE INFORMATIVE CATALOGS Lincoln Welding School (ED-80) Seminar Information (ED-45) Educational Video Information (ED-93) James F. Lincoln Arc Welding Foundation Book Information (JFLF-515) Order from: _______________________________________________ Exp Date |_|_| |_|_| Month Year Signature as it appears on Charge Card: ______________________ BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901. Titles: Price New Lessons in Arc Welding $5.00 Procedure Handbook “Twelfth Edition” $15.00 How to Read Shop Drawings $4.50 Incentive Management $5.00 A New Approach to Industrial Economics $5.00 The American Century of John C. Lincoln $5.00 Welding Preheat Calculator $3.00 Pipe Welding Charts $4.50 Code L PH H IM NA AC WC-8 ED-89 Quantity SUB TOTAL Additional Shipping Costs if any TOTAL COST Cost ● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra. ● Ne laissez ni la peau ni des vête- ments mouillés entrer en contact avec des pièces sous tension. ● Isolez-vous du travail et de la terre. ● Berühren Sie keine stromführenden Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung! ● Isolieren Sie sich von den Elektroden und dem Erdboden! ● Não toque partes elétricas e elec- trodos com a pele ou roupa molhada. ● Isole-se da peça e terra. fuera del área de trabajo. ● Gardez à l’écart de tout matériel inflammable. ● Entfernen Sie brennbarres Material! cuerpo. ● Protégez vos yeux, vos oreilles et votre corps. ● Tragen Sie Augen-, Ohren- und Kör- perschutz! ● Mantenha inflamáveis bem guarda- dos. ● Use proteção para a vista, ouvido e corpo. Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR. LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR. LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN. – 38 – ● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio. ● Débranchez le courant avant l’entre- tien. Schweibrauch! ● Sorgen Sie für gute Be- und Entlüftung des Arbeitsplatzes! ● Mantenha seu rosto da fumaça. ● Use ventilação e exhaustão para remover fumo da zona respiratória. guardas quitadas. ● N’opérez pas avec les panneaux ouverts ou avec les dispositifs de protection enlevés. teur pour ôter les fumées des zones de travail. ● Vermeiden Sie das Einatmen von ● No operar con panel abierto o ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse abschalten! (Netzstrom völlig öffnen; Maschine anhalten!) oder Innenschutzverkleidung in Betrieb setzen! ● Não opere com as tampas removidas. ● Desligue a corrente antes de fazer ● Mantenha-se afastado das partes serviço. ● Não toque as partes elétricas nuas. ● Não opere com os paineis abertos moventes. WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ou guardas removidas. Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. – 39 – • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com –
Source Exif Data:
File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.4 Linearized : No XMP Toolkit : Adobe XMP Core 4.0-c316 44.253921, Sun Oct 01 2006 17:14:39 Producer : Acrobat Distiller 8.1.0 (Windows) Modify Date : 2008:08:12 14:05:04-04:00 Create Date : 2008:08:07 14:35:51-04:00 Metadata Date : 2008:08:12 14:05:04-04:00 Document ID : uuid:0351c6fa-619c-428e-a134-4218e46534d7 Instance ID : uuid:a20a969b-a167-4e74-90e9-52d2b2f592a4 Format : application/pdf Title : im526.pdf Has XFA : No Page Count : 40 Page Layout : SinglePageEXIF Metadata provided by EXIF.tools