Invertec V300-I Service manual
INVERTEC V300-I
SVM101-B
January, 2007
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.
SERVICE MANUAL
For use with machines having Code Number : 9825 THRU 10450
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• 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 •
Copyright © 2007 Lincoln Global Inc.
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i
SAFETY
i
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
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.
WARNING
Mar ‘95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines
The Above For Gasoline Engines
ii
SAFETY
ii
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
AC Welder with Reduced Voltage Control.
•
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
When working above floor level, use a safety belt to protect
3.i.
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and / or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
Do not weld in locations near chlorinated hydrocarbon
5.c.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod
ucts.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
vapors
to
-
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer
your welding distributor or from the manufacturer
5.f. Also see item 1.b.
’s safety practices. MSDS forms are available from
.
AUG 06
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SAFETY
iii iii
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FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
Mar ‘95
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
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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.
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
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soud
e 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.
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.
Mar. ‘93
iv
SAFETY
iv
V300-I
vv
MASTER TABLE OF CONTENTS FOR ALL
SECTIONS
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P243 Series
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Section A-1 Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation ..............................................................................................................Section A
Technical Specifications ........................................................................................A-2
Location .................................................................................................................A-3
Electrical Installation...............................................................................................A-3
Input Connections...................................................................................................A-4
Wire feeder and Accessory Connections .......................................................A-4, A-5
Output Connection..................................................................................................A-6
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V300-I
V300-I
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A-2
INSTALLATION
A-2
TECHNICAL SPECIFICATIONS - V300-I (K1363-8, K1363-9)
Height Width Depth Weight
18.7 in. 10.8 in. 22.2 in. 64 lbs.
475 mm 274 mm 564 mm 29 Kg
PHYSICAL DIMENSIONS
THREE PHASE SINGLE PHASE
Standard Input Current Code
V
oltage at Rated Output
Number
200/230/280-415/440 43/39/25- 9826, 9827,
50/60 25/22 10036, 10037,
10132, 10133
Volts at
Rated
Duty Cycle
Amps Amperes
60% Duty Cycle 300 32
100% Duty Cycle 250 30
Welding Constant Open Auxiliary
Current Range
Circuit Voltage Power
5-300 Amps 60-70 VDC 42 VAC, 5.5 Amps
24 VAC, 1 Amp
*115 VAC, 2 Amps
*Not on all codes
Standard Input Current Code
V
oltage at Rated Output Number
200/230/380-415/440 53/47/32- 9826, 9827,
50/60 32/29 10036, 10037,
10132, 10133
Volts at
Rated
Duty Cycle
Amps Amperes
60% Duty Cycle 200 28
100% Duty Cycle 165 26.5
Welding Constant Open Auxiliary
Current Range
Circuit Voltage Power
5-200 Amps 60-70 VDC 42 VAC, 5.5 Amps
24 VAC, 1 Amp
*115 VAC, 2 Amps
*Not on all codes
INPUT
RECOMMENDED INPUT WIRE AND FUSE SIZES
Type 75°C
Type 75°C Copper
Fuse Input Copper Ground
(Superlag) Ampere Wire in Wire in
Input or Rating Conduit Conduit
Voltage Breaker on AWG (IEC) AWG (IEC)
Frequency
(1)
Size Nameplate Sizes Sizes
200/50-60 60 43 6 (16mm2) 10 (6mm2)
220/50-60 60 39 8 (10mm2) 10 (6mm2)
380/50-60 35 25 10 (6mm2) 10 (6mm2)
415/50-60 35 25 10 (6mm2) 10 (6mm2)
440/50-60 35 22 10 (6mm2) 10 (6mm2)
Type 75°C
Type 75°C Copper
Fuse Input Copper Ground
(Superlag) Ampere Wire in Wire in
Input or Rating Conduit Conduit
Voltage Breaker on AWG (IEC) AWG (IEC)
Frequency
(1)
Size Nameplate Sizes Sizes
200/50-60 80 53 6 (16mm2) 10 (6mm2)
220/50-60 70 47 6 (16mm2) 10 (6mm2)
380/50-60 50 32 8 (10mm2) 10 (6mm2)
415/50-60 50 32 8 (10mm2) 10 (6mm2)
440/50-60 50 29 10 (6mm2) 10 (6mm2)
THREE PHASE SINGLE PHASE
THREE PHASE SINGLE PHASE
THREE PHASE SINGLE PHASE
OUTPUT
RATED OUTPUT
V300-I
INSTALLATION
A-3 A-3
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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
DO NOT ATTEMPT TO POWER THIS UNIT
FROM THE AUXILIARY POWER SUPPLY
OF AN ENGINE WELDER.
• Special protection circuits may operate, causing
loss of output.
• The supply from engine welders often has excessive voltage peaks because the voltage waveform is
usually triangular shaped instead of sinusoidal.
• If voltage peaks from the engine welder are too high
(380v on 230v setting), the input circuits of this
machine protecting the filter capacitors, FETS and
other components from damage will not
be ener-
gized.
CAUTION
PRODUCT DESCRIPTION
The Invertec V300-I 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-I is designed for 50/60 Hz supply
systems. The welding response of the Invertec has
been optimized for GMAW, SMAW, TIG and FCAW
processes. It is designed to be used with the LN-25
and LN-7 semiautomatic wire feeders.
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 to
protect it from harsh environments. Even so, it is
important that simple preventative measures are followed in order to assure long life and reliable operation.
• The machine must be located where there is free circulation of clean air such that air movement into the
sides and out the bottom and front will not be
restricted. Dirt and dust that can be drawn into the
machine should be kept to a minimum. Failure to
observe these precautions can result in excessive
operating temperatures and nuisance shutdown of
the Invertec.
• Keep machine dry. Shelter from rain and snow. Do
not place on wet ground or in puddles.
ELECTRICAL INSTALLATION
1. The Invertec should be connected only by a qualified electrician. Installation should be made in
accordance with the U.S. National Electrical Code,
all local codes and the information detailed below.
2. When received from the factory, multiple voltage
(200/220/380-415/440) machines are internally
connected for 440 volt input.
3. Single voltage, 575 VAC machines, can only be
connected to 575 VAC. No internal reconnection
for other input voltages is possible.
4. Initial 208 VAC and 230 VAC operation will require
a voltage panel setup, as will later reconnection
back to 460 VAC:
a. Open the access panel on the right side of
the machine.
b. For 208 or 230: Position the large switch to
200-230.
For 460: Position the large switch to 380-460.
c. Move the “A” lead to the appropriate terminal.
CAUTION: DO NOT CHANGE SWITCH
POSITION WITH INPUT POWER
APPLIED. MAJOR DAMAGE WILL
RESULT.
INPUT VOLTAGE SETUP
V300-I
INSTALLATION
A-4 A-4
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POWER INPUT CONNECTION
Connect terminal marked to earth ground per any
existing local or national electrical codes.
Single Phase Input
Connect the supply lines to the upper and lower terminals of the line switch. Torque to 3.0 Nm. Do not use
center terminal of the line switch.
Three Phase Input
Connect the supply lines to the line switch. Torque to
3.0 Nm.
Install in accordance with all local and national electric
codes.
The V300-I is supplied with one cord connector to provide strain relief for the input power cord. It is
designed for a cord diameter of 7.9 - 27.2mm (.310-
1.070”). The jacketed portion of the cord must go
through the connector before tightening the connector
screws.
CONNECTION OF WIRE FEEDERS TO
THE INVERTEC
LN-25 Connection Instructions
1. Turn the Invertec power switch “off”.
2. Connect the electrode cable to the output terminal
of polarity required by electrode. Connect the work
lead to the other terminal.
3. LN-25 with remote control options K431 and K432.
Use K876 adapter with K432 cable or modify K432
cable with K867 universal adapter plug. See connection diagram S19899 and S19309 or S19405 in
Section F of this manual.
4. Place the local-remote switch in the “remote” position if output control is desired at the wire feeder
rather than the Invertec. (LN-25 must have K431
and K432 options for remote output control operation).
LN-7 Connection Instructions (not applicable to
IEC machines with only 42V Aux.).
1. Turn the Invertec power switch “off”.
2. Connect the K480 or K1818-10 control cable from
the LN-7 to the Invertec control cable connector.
The control cable connector is located at the rear
of the Invertec.
3. Connect the electrode cable to the output terminal
of polarity required by electrode. Connect the work
lead to the other terminal.
4. Place the local-remote switch in the “local” position
to allow output control at the Invertec. (K864
remote control adapter and K857 remote control
are required for remote output control - see con-
nection diagram S19901.
5. Set the meter polarity switch on the rear of the
Invertec to coincide with wire feeder polarity used.
The wire feeder will now display the welding voltage.
6. If a K480 or K1818-10 is not available, see con-
nection diagram S19404 for modification of K291
or K404 LN-7 input cable with K867 universal
adapter plug..
Recommended Fuse Sizes Based On The U.S.
National Electrical Code And Maximum Machine
Outputs
Fuse Size in Amps
Input Volts
(1)
(Time Delay Fuses)
200 60
3 phase 220 60
50/60 Hz 380-415 35
440 35
200 80
1 phase 220 70
50/60 Hz 380-415 50
440 50
(1)
Input voltage must be within ±10% of rated value.
V300-I
INSTALLATION
A-5 A-5
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LN-9 GMA Connection Instructions (Not applicable
to machines with only 42V Aux.)
1. Turn the Invertec power switch “off”.
2. Connect the K596 or K1820-10 control cable
assembly from the LN-9 GMA to the Invertec control
cable connector. The control cable connector is
located at the rear of the Invertec.
3. Connect the electrode cable to the output terminal
of polarity required by electrode. Connect the work
lead to the other terminal.
4. Place the local-remote switch in the “remote” position to allow output control at the LN-9 GMA.
5. Set the meter polarity switch on the rear of the
Invertec to coincide with wire feeder polarity used.
The wire feeder will now display the welding voltage.
6. K608-1* adapter is required in LN-9 GMA for LN-9
type control. K608-1 is installed in line with P10. See
diagram S20607.
7. K442-1* Pulse Power Filter Board is also required
for GMAW,but should beremoved for FCAW.
8. If K596 is not available, see connection diagram
S20608 for modification of K196 LN-9 GMA input
cable with K867 universal adapter plug.
* These kits are no longer available.
GENERAL INSTRUCTIONS FOR CONNECTION OF WIRE FEEDERS TO INVERTEC
Wire feeders other than LN-7 and LN-25 may be used
provided that the auxiliary power supply capacity of the
Invertec is not exceeded. K867 universal adapter plug
is required. See connection diagram S19406 and
S19386 for more information.
Remote Control of Invertec
Remote control K857, hand amptrol K963 and foot
amptrol K870 require K864 remote control adapter.
See connection diagram S19309.
K954-1 MIG PULSER
The MIG Pulser is a hand-held “pendant” type GMAW
Pulsing option for the V300-I Power Source. See the
Mig Pulser’s IM manual (IM555) for connection
information.
K900-1 DC TIG STARTER CONNECTION
This versatile new kit was made to mate with the
Invertec
A control cable assembly is supplied with the kit to
connect the kit to an Invertec. The cable can be connected, either end, at the DC TIG Starter kit and at
the Invertec by attaching to the 14-pin Amphenols on
the backs of each unit. See diagram S20405.
A negative output cable assembly is also supplied
with the DC TIG Starter kit to connect the kit with the
Invertec’s negative output terminal.
All Magnum™ one and two piece water-cooled
torches with 7/8 left-hand threads and gas-cooled
torches with 7/8 and 5/16 right-hand threads can be
connected to the starter kit.
To secure the DC TIG Starter kit to the bottom of the
Invertec and for more detailed instructions, see the
K900-1 (IM465) manual.
PARALLEL OPERATION
The Invertec is operable in parallel in both CC and
CV modes. For best results, the currents of each
machine should be reasonably well shared. As an
example, with two machines set up in parallel for a
400 amp procedure, each machine should be set to
deliver approximately 200 amps, not 300 amps from
one and 100 amps from the other. This will minimize
nuisance shutdown conditions. In general, more than
two machines in parallel will not be effective due to
the voltage requirements of procedures in that power
range.
To set machine outputs, start with output control pots
and arc force/pinch pots in identical positions. If running in a CC mode, adjust output and arc force to
maintain current sharing while establishing the proper output current. In CV modes, 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.
A-6 A-6
25 mm
1 in.
WELDING CABLE
BOOT
TRIM
S
ET SCREW
BRASS PLUG
C
OPPER TUBE
INSTALLATION
OUTPUT CABLES
elect the output cable size based upon the following
S
chart.
Cable sizes for Combined Length of Electrode and
ork Cable (Copper) 75° rated:
W
Duty Length Up 61-76m
Cycle Current 61m (200 ft.) (200-250 ft.)
100% 250 1/0 1/0
0% 300 1/0 2/0
6
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.
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.
. Slide the copper tube into the brass plug.
3
4. Insert cable into 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.
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V300-I
Section B-1 Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation ................................................................................................................Section B
Operating Instructions............................................................................................ B-2
Controls and Settings .....................................................................................B-2, B-4
Auxillary Power ...................................................................................................... B-4
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V300-I
V300-I
OPERATION
B-2 B-2
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OPERATING INSTRUCTIONS
DUTY CYCLE
The Invertec is rated at 300 amps, 60% duty cycle for
3 phase inputs (based on a 10 minute cycle). It is also
rated at 250 amps, 100% duty cycle.
CONTROL FUNCTION / OPERATION
POWER SWITCH - Place the lever in the “ON” position
to energize the machine. When the power is on, the
digital meter will activate and the fan will operate.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
-------------------------------------------------------
-----------------
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
• Do not weld on closed containers.
------------------------------------------------------------------------
ARC RAYS can burn eyes and skin.
• Wear eye, ear and body
protection.
------------------------------------------------------------
See additional warning information at
front of this operator’s manual.
-----------------------------------------------------------
WARNING
OUTPUT CONTROL - This controls the output voltage
in the CV modes and output current in the CC modes.
Control is provided over the entire output range of the
power source with 1 turn of the control knob. This control may be adjusted while under load to change power
source output.
LOCAL/REMOTE SWITCH - Place in the “LOCAL”
position to allow output adjustment at the machine.
Place in the “REMOTE” position to allow output adjustment at the wire feeder or with a remote control option
package.
DIGITAL METER SWITCH - Select either “A” for amps
or “V” for volts to display welding current or voltage on
the meter.
When welding current is not present, the meter will display the set current for the CC modes or the set voltage for the CV modes. This set reading is an indication
of machine control setting. For a more precise process
reading, read meter during actual welding.
.
OUTPUT
OFF
B-3 B-3
GMAW
FCAW
SMAW
SOFT
GTAW
OUTPUT
ON
REMOTE
OPERATION
MODE SWITCH
GTAW
Optimized for both scratch start and HiFreq kit use.
CC SOFT Best for EXX18 thru EXX28 stick elec-
rodes.
t
CC Crisp Use this mode for stick welding with
EXX10 thru EXX14 electrodes. Nonwelding applications such as resistive
heating or output tests with resistive
loads should be done in this mode with
Arc Force Control set to minimum.
CV FCAW This setting has been optimized for
Innershield®and Outershield®flux-cored
electrodes.
CV GMAW Short circuit, glob and spray transfer
solid wire and gas welding are done in
this mode. Low end procedures, less
than 16V, may operate better in the
FCAW mode.
ARC FORCE/INDUCTANCE CONTROL
This control functions in all modes except GTAW. For
C modes, this control acts as an Arc Force adjust-
C
ment. The arc is soft at the minimum settings and more
forceful or driving at the maximum settings. Higher
spatter levels may be present at the maximum settings.
For CV modes, this control will set the degree of “pinch
effect” which predominantly affects short circuit transfer. In FCAW, the maximum setting is generally preferred. With GMAW, the upper half of the range is preferred with CO
or high content CO
2
mixed gases. The
2
lower half is for other inert gas mixes.
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OUTPUT TERMINALS SWITCH
For processes and equipment that require energized
machine terminals (stick, TIG, air-carbon arc cutting or
hot tip LN-25), set the Output Terminals Switch to “ON”
position.
Set to the REMOTE (OFF) position when using LN-25
with K431/K432 or K624-1 options or other wirefeeders
which allow the gun trigger to energize the welding terminals.
V300-I
RECOMMENDED SETTINGS FOR SELECTED
APPLICATIONS
Full Range Is 1-10,
1 Is Very Soft, 10 Is Very Crisp
Mode Process Setting Adjustment Range
CC SMAW 1
CC SMAW 2 EXX10 thru 6 3 to 10
CV FCAW Innershield or 10 None
CV
GMA
* 1 = Lowest pinch, highest inductance and least spatter.
10 = Highest pinch, lowest inductance and most spatter
EXX18 thru 5 1 (gentle, may stick) to 9
EXX28 stick (forceful, more spatter)
EXX14 stick
Air Carbon Arc 1 None
Cutting
Outershield
Air Carbon Arc 1 None
Cutting
W* CO2or 25% CO27.5
or similar
gas mixes
Ar-2% O
98%
90% He-7.5%
2.5% CO2and
other
predominantly
inert gases
Nominal Recommended
5
,
Ar
2
Ar
5 to 10
1 to 10
.
V300-I
OPERATION
B-4 B-4
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METER POLARITY SWITCH
The wire feeder polarity switch is located at the rear of
the machine. The switch provides a work connection
for wire feeder voltmeters. Place the switch in the position of the electrode polarity indicated by the decal.
The switch does not change the welding polarity.
AUXILIARY POWER
A 24 VAC @ 1 amp supply is included for use with the
LN-25 wire feeder (24 volts needed for K431 and
K432 options). This supply is protected by a selfresetting current limiter.
A 42 VAC @ 5.5 amp supply is included for use with
other wire feeders. This supply is protected by a 6
amp breaker located on the rear of the machine.
A110/115 VAC @ 2 amp supply is included for use
with the LN-7 or LN-9 GMA wire feeders. This supply
is protected by a 2.5 amp breaker located on the rear
of the machine. It is NOT
available on IEC units.
All three supplies are not to be loaded simultaneously
T13086-84
Section C-1 Section C-1
TABLE OF CONTENTS
- ACCESSORIES SECTION -
Accessories ............................................................................................................Section C
Options/Accessories...............................................................................................C-2
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V300-I
V300-I
ACCESSORIES
C-2 C-2
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OPTIONS / ACCESSORIES
CABLE PLUGS
Cable Plug Kit for 1/0-2/0 cable (K852-70) attaches to
welding cable to provide quick disconnect from
machine.
Cable Plug Kit for 2.0-3/0 cable (K852-95).
NOTE: Two K852-70 plugs are included with the V300-I.
K864 REMOTE CONTROL
ADAPTER
Plugs into the 14-pin receptacle on the rear panel of the
Invertec. Adapter splits remote control circuitry to a 6pin receptacle and to a 14-pin receptacle. Adapter permits remote output control of Invertec by means of
K857 Remote Control, K812 Hand Amptrol or K870
Foot Amptrol. Allows remote while using LN-7 K480-7
control cable.
K867 UNIVERSAL ADAPTER
PLUG
Consisting of a 14-pin plug connected to labeled wires,
the adapter allows user connection of any suitable
accessory or wire feeder to the remote control, contactor, and auxiliary power circuitry of the Invertec.
K876 REMOTE CONTROL
ADAPTER
For operating an LN-25 wire feeder. The adapter
connects to the 14-pin receptacle of Invertec power
sources and to the 6-pin connector of the LN-25
K432 remote control cable.
K900-1 DC TIG STARTER
Solid state GTAW starting unit. Rated 300 A, 60%.
Section D-1 Section D-1
TABLE OF CONTENTS
- MAINTENANCE SECTION -
Maintenance ...........................................................................................................Section D
Input Filter Capacitor Discharge Procedure ...........................................................D-2
Preventive maintenance.........................................................................................D-3
Overload/Thermal Protection ................................................................................ D-3
Printed Circuit Board Replacement ....................................................................... D-3
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V300-I
V300-I
MAINTENANCE
D-2 D-2
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5. Locate the two capacitor terminals (large hex
head capscrews)shown in Figure D.1.
6. Use electrically insulated gloves and insulated pliers. Hold body of the resistor and connect resistor
leads across the two capacitor terminals. Hold
resistor in place for 10 seconds. DO NOT TOUCH
CAPACITOR TERMINALS WITH YOUR BARE
HANDS.
7. Repeat discharge procedure for capacitor on
other side of machine. If you are working on a
575 VAC machine, repeat discharge procedure
for second capacitor on each side of machine.
8. Check voltage across terminals of all capacitors
with a DC voltmeter. Polarity of capacitor terminals is marked on PC board above terminals.
Voltage should be zero. If any voltage remains,
repeat this capacitor discharge procedure.
INPUT FILTER CAPACITOR
DISCHARGE PROCEDURE
1. Turn off input power or disconnect input power
lines.
2. Remove 14 5/16” hex head screws from side and
top of machine (6 screws on each side and 2
screws on top) and remove wrap-around machine
cover.
3. Be careful not to make contact with the capacitor
terminals that are located in the center of the
Switch Boards.
4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This
resistor is not supplied with machine. NEVER
USE A SHORTING STRAP FOR THIS PROCEDURE. .
FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS.
Failure to follow this capacitor
discharge procedure can result
in electric shock.
WARNING
D-3 D-3
MAINTENANCE
PREVENTIVE MAINTENANCE
. Perform the following preventive maintenance
1
rocedures at least once every six months. It is
p
ood practice to keep a preventive maintenance
g
ecord; a record tag attached to the machine
r
works best.
2. Remove the machine wrap-around cover and perform the input filter capacitor discharge procedure
(detail at the beginning of this chapter).
3. Clean the inside of the machine with a low pressure airstream. Be sure to clean the following
components thoroughly. See Figure D.2 for location of these components.
• Power Switch, Driver, Protection, and Control
printed circuit boards
• Power Switch
• Main Transformer
• Input Rectifier
• Heat Sink Fins
• Input Filter Capacitors
OVERLOAD PROTECTION
he machine is electrically protected from producing
T
high output currents. Should the output current
exceed 340-360A, an electronic protection circuit will
reduce the current (“Fold Back”) to approximately
150A. The machine will continue to produce this low
current until the protection circuit is reset. Reset
occurs when the output load is removed.
THERMAL PROTECTION
Thermostats protect the machine from excessive
operating temperatures. Excessive temperatures
may be caused by a lack of cooling air or operating
the machine beyond the duty cycle and output rating. If excessive operating temperature should
occur, the thermostat will prevent output voltage or
current. The meter will remain energized during this
time.
PC BOARD REPLACEMENT
1. Handle PC Boards by edges only.
2. Store PC Boards only in the bags that disperse
static charges.
• Output Terminals
4. Examine capacitors for leakage or oozing.
Replace if needed.
5. Examine wrap-around cover for dents or breakage. Repair as needed. Cover must be kept in
good condition to assure high voltage parts are
protected and correct spacings are maintained.
6. Check electrical ground continuity. Using an ohmmeter, measure resistance between either output
stud and an unpainted surface of the machine
case. (See Figure D.2 for locations.) Meter reading should be 500,000 ohms or more. If meter
reading is less than 500,000 ohms, check for
electrical components that are not properly insu
lated from the case. Correct insulation if needed.
7. Replace machine cover and screws.
3. Inspect PC Board for burned conductors or components. If damage is visible, inspect the
machine wiring for grounds or shorts to avoid
damaging a new PC Board.
4. If there is no visible damage to the PC Board,
install a new PC Board and see if the problem is
fixed. If the problem is fixed by the new board,
reinstall the old board and see if the problem
reoccurs. If the problem does not reoccur, check
the wiring harness and plugs for loose connections.
-
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V300-I
V300-I
MAINTENANCE
D-4 D-4
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FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS.
ITEM
COMPONENT QTY, NO.
PC BOARDS
CONTROL 1 1
DRIVER 1 2
PROTECTION 1 3
SWITCH 2 7
POWER 1 10
INPUT RECTIFIER 1 4
POWER SWITCH 1 5
HEAT SINK FINS 2 6
MAIN TRANSFORMER 1 8
OUTPUT STUDS 1 9
INPUT FILTER CAPACITORS 2 11
1
6
2
7
3
8
4
9
5
10
11
Section E-1 Section E-1
1ø OR 3ø DETETCTION (H5)
LINE
SWITCH
INPUT
RECTIFIER
AC1
AC2
AC3
A-LEAD
AUXILIARY
TRANSFORMER
TO
WIREFEEDER
18VAC
24VAC
POWERBOARD
24VDC
PULSE
TRAIN
DRIVER
BOARD
P
RE-CHARGE
PRE-CHARGE
2ND STEP PWM
1ST STEP PWM VOLTAGE
15VDC-CONTROL BOARD FUNCTION VOLTAGE
24VAC-THERMOSTATS-GUN TRIGGERING
LOCAL
REMOTE
METER
MODE
POT
POT
PROTECTION
BOARD
<1 VDC
RIGHT SWITCH BOARD
FET MODULES
CAP
FET MODULES
FAN
1
2
3
CONTROL
BOARD
Y-Y FEEDBACK
CR1
CR2
3A
POWER SWITCH
SECTIONS
20KHZ
LEFT SWITCH BOARD
FET MODULES
CAP
FET MODULES
CURRENT
TRANSFORMER
M
AIN
TRANSFORMER
CHOKE
RECTIFIER
HEATSINK
BOTTOM
1 DIODE
5 DIODES
5 DIODES
TOP
TOP
1 DIODE
CHOKE
CHOKE
SHUNT
CURRENT FEEDBACK-PROTECTION
VOLTAGE FEEDBACK
TABLE OF CONTENTS
- THEORY OF OPERATION SECTION -
Theory of Operation ...............................................................................................Section E
Power Supply Operation ......................................................................................E-2
Pre Charge and Protection Circuitry ....................................................................E-3
Switch Board and Main Transformer ...................................................................E-4
Control and Output Circuitry ................................................................................E-5
Field Effect Transistor (FET) Operation ...............................................................E-6
Pulse Width Modulation .......................................................................................E-7
Protective Circuits ................................................................................................E-8
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FIGURE E.1 – V300-I BLOCK LOGIC DIAGRAM
V300-I
V300-I
THEORY OF OPERATION
INPUT LINE VOLTAGE & AUXILIARY
TRANSFORMER
The V300-I can be connected for a variety of three
phase or single phase input voltages. Power is applied
through the Line Switch to the Input Rectifier and the
Auxiliary Transformer.
The Reconnect Panel has switches to select high or
low operating voltage. The “A” lead must then be set for
the proper input voltage. It is important to set the
switches and “A” lead to the proper positions before
applying input power. Changing the switch position
with the power applied will result in major damage
to the machine
The auxiliary transformer provides 18v.a.c. and
24v.a.c. supplies to the Control and Power Boards. It
also provides 115v.a.c., 42v.a.c. and 24v.a.c. supplies
to the wirefeeder amphenol. (CE machines do not have
115v.a.c. supply)
The Power Board provides a 15v.d.c. supply to the
Control Board and a 24v.d.c.supply to the Driver Board
to operate the Pre-charge Relays.
E-2 E-2
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1ø OR 3ø DETETCTION (H5)
LINE
SWITCH
INPUT
RECTIFIER
AC1
AC2
AC3
A-LEAD
AUXILIARY
TRANSFORMER
TO
WIREFEEDER
18VAC
24VAC
POWERBOARD
24VDC
PULSE
TRAIN
DRIVER
BOARD
PRE-CHARGE
PRE-CHARGE
2ND STEP PWM
1ST STEP PWM VOLTAGE
15VDC-CONTROL BOARD FUNCTION VOLTAGE
24VAC-THERMOSTATS-GUN TRIGGERING
LOCA L
REMOTE
METER
MODE
POT
POT
PROTECTION
BOARD
<1 VDC
RIGHT SWITCH BOARD
FET MODULES
CAP
FET MODULES
FAN
1
2
3
CONTROL
BOARD
Y-Y FEEDBACK
CR1
CR2
3A
POWER SWITCH
SECTIONS
20KHZ
LEFT SWITCH BOARD
FET MODULES
CAP
FET MODULES
CURRENT
TRANSFORMER
MAIN
TRANSFORMER
CHOKE
RECTIFIER
HEATSINK
BOTTOM
1 DIODE
5 DIODES
5 DIODES
TOP
TOP
1 DIODE
CHOKE
CHOKE
SHUNT
CURRENT FEEDBACK-PROTECTION
VOLTA GE FEEDBACK
FIGURE E-2 --- INPUT CIRCUITS
NOTE: Unshaded areas of block logic diagram are the subject of discussion
V300-I
THEORY OF OPERATION
PRECHARGE & PROTECTION CIRCUITS
The DC voltage from the Input Rectifier is applied to the
Driver Board to begin charging the Switch Board
capacitors at a slow rate. When the pre-charge level is
achieved, the input relays close, applying the full DC
voltage to the capacitors. Depending on the Code
Number of the machine, there will be either two or four
relays and they may or may not be mounted on the
Driver Board.
The Driver Board is also responsible for gating the
Field Effect Transistors (FETs) on the Switch Boards,
as directed by the pulse width modulated (PWM) signal
from the Control Board.
The Protection Board monitors the capacitors for proper balance and voltage level. If an imbalance or overvoltage condition is detected, the Protection Circuit will
de-energize the relays, removing the power from the
switch circuits. The machine output will also be disabled.
Another function of the Protection Board is to detect
whether the input voltage is single phase or three
phase and pass that information to the Control Board.
The maximum output of the machine will be limited to
approximately 250 amps with single phase input and
360 amps with 3 phase input.
E-3 E-3
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FIGURE E-3 ---PRECHARGE & PROTECTION CIRCUITS
1ø OR 3ø DETETCTION (H5)
LINE
SWITCH
INPUT
RECTIFIER
AC1
AC2
AC3
A-LEAD
AUXILIARY
TRANSFORMER
TO
WIREFEEDER
18VAC
24VAC
POWERBOARD
24VDC
PRE-CHARGE
2ND STEP PWM
1ST STEP PWM VOLTAGE
15VDC-CONTROL BOARD FUNCTION VOLTAGE
24VAC-THERMOSTATS-GUN TRIGGERING
LOCA L
REMOTE
METER
MODE
POT
POT
<1 VDC
FAN
1
2
3
CONTROL
BOARD
Y-Y FEEDBACK
3A
POWER SWITCH
SECTIONS
20KHZ
CURRENT
TRANSFORMER
MAIN
TRANSFORMER
CHOKE
RECTIFIER
HEATSINK
BOTTOM
1 DIODE
5 DIODES
5 DIODES
TOP
TOP
1 DIODE
CHOKE
CHOKE
SHUNT
CURRENT FEEDBACK-PROTECTION
VOLTA GE FEEDBACK
PULSE
TRAIN
DRIVER
BOARD
PRE-CHARGE
CR1
CR2
LEFT SWITCH BOARD
FET MODULES
CAP
FET MODULES
RIGHT SWITCH BOARD
FET MODULES
CAP
FET MODULES
PROTECTION
BOARD
NOTE: Unshaded areas of block logic diagram are the subject of discussion
E-4 E-4
1
ø OR 3ø DETETCTION (H5)
LINE
SWITCH
INPUT
RECTIFIER
AC1
AC2
AC3
A-LEAD
AUXILIARY
TRANSFORMER
TO
WIREFEEDER
18VAC
24VAC
POWERBOARD
2
4VDC
PRE-CHARGE
2ND STEP PWM
1ST STEP PWM VOLTAGE
15VDC-CONTROL BOARD FUNCTION VOLTAGE
24VAC-THERMOSTATS-GUN TRIGGERING
LOCAL
REMOTE
METER
MODE
POT
POT
<1 VDC
FAN
1
2
3
CONTROL
BOARD
Y-Y FEEDBACK
3A
POWER SWITCH
SECTIONS
20KHZ
CHOKE
RECTIFIER
HEATSINK
1 DIODE
5
DIODES
5 DIODES
1
DIODE
CHOKE
CHOKE
SHUNT
CURRENT FEEDBACK-PROTECTION
VOLTAGE FEEDBACK
PULSE
TRAIN
DRIVER
BOARD
PRE-CHARGE
CR1
CR2
PROTECTION
BOARD
TOP
T
OP
CURRENT
TRANSFORMER
LEFT SWITCH BOARD
FET MODULES
CAP
FET MODULES
MAIN
T
RANSFORMER
RIGHT SWITCH BOARD
FET MODULES
CAP
FET MODULES
BOTTOM
THEORY OF OPERATION
FIGURE E-4 ---SWITCH CIRCUITS & TRANSFORMER
SWITCH BOARDS
The Switch Boards contain the the Field Effect
Transistors (FETs) which, when switched ON, supply
power to the primary windings of the main transformer
Each Switch Board powers a separate, oppositely
wound primary winding. The opposite direction of cur
rent flow in those windings and a slight of
FET switching produces a square wave AC signal in
the secondary of the transformer.
The DC current of the primaries is clamped back to the
respective capacitors through diodes on the board
when the FET
voltage spikes due to the inductance of the windings
and also helps maintain capacitor balance.
The boards are fired during a 50 microsecond interval
with respect to a Pulse Width Modulated (PWM) signal
from the Control Board through the Driver Board. This
creates a constant 20Khz output in the secondary
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s turn off. This protects against inductive
NOTE: Unshaded areas of block logic diagram are the subject of discussion
fset in of the
.
.
-
V300-I
Along with ease of control, the 20Khz operating frequency allows for a much smaller and lighter transformer
Signals from the Current Transformer insure that one
switch circuit is turned off before the other is gated on.
Field Ef
Modulation are discussed in more detail later in this
fect Transistor operation and Pulse Width
section.
V300-I
THEORY OF OPERATION
OUTPUT AND CONTROL CIRCUITS
The AC output of the transformer is changed to DC by
the Output Rectifier. The Output Choke between the
negative side of the rectifier and the negative output
stud provides the necessary filtering for DC welding.
The two smaller chokes and their series diodes are the
OCV boost circuit used to help provide good weld
starts.
Current feedback to the Control Board is provided by
the shunt in the negative output circuit. It is used for
weld control, overcurrent protection and actual ammeter readings. The Voltage feedback lead at the positive
output stud also provides information for weld control
and actual voltmeter readings.
The Control Board monitors input from the front panel
controls (output, arc control, mode switch, etc..). The
software on the board processes these inputs, sets up
the proper weld information and sends the “set” parameter information to the meter.
When weld output is requested, the Control Board
compares the input information to the feedback signals
and provides the correct PWM signals to the Switch
Boards for optimum welding. The Mode Switch setting
determines which feedback signal (voltage or current)
will have the most relevance. However, both signals
are used in all modes.
The Control Board also monitors signals from the thermostats and the Protection Board and if necessary,
shuts off the weld output. The protection circuit information is discussed in more detail later in this section.
E-5 E-5
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1˘ OR 3˘ DETETCTION (H5)
LINE
SWITCH
INPUT
RECTIFIER
AC1
AC2
AC3
A-LEAD
AUXILIARY
TRANSFORMER
TO
WIREFEEDER
18VAC
24VAC
POWERBOARD
24VDC
PRE-CHARGE
2ND STEP PWM
1ST STEP PWM VOLTAGE
15VDC-CONTROL BOARD FUNCTION VOLTAGE
24VAC-THERMOSTATS-GUN TRIGGERING
<1 VDC
FAN
1
2
3
3A
POWER SWITCH
SECTIONS
20KHZ
PULSE
TRAIN
DRIVER
BOARD
PRE-CHARGE
CR1
CR2
PROTECTION
BOARD
TOP
TOP
LEFT SWITCH BOARD
FET MODULES
CAP
FET MODULES
MAIN
TRANSFORMER
RIGHT SWITCH BOARD
FET MODULES
CAP
FET MODULES
BOTTOM
1 DIODE
5 DIODES
5 DIODES
1 DIODE
CHOKE
SHUNT
RECTIFIER
HEATSINK
CHOKE
CHOKE
CURRENT
TRANSFORMER
VOLTA GE FEEDBACK
CURRENT FEEDBACK-PROTECTION
CONTROL
BOARD
Y-Y FEEDBACK
LOCA L
REMOTE
METER
MODE
POT
POT
FIGURE E-5 --OUTPUT & CONTROL CIRCUITS
NOTE: Unshaded areas of block logic diagram are the subject of discussion
V300-I
THEORY OF OPERATION
An FET is a type of transistor. FETs are semiconductors well suited for high-frequency switching because
they are capable of going from full off to full on much
more quicklfy than other types of semi-conductors.
Drawing A above shows an FET in a passive mode.
There is no gate signal, zero volts relative to the source
and, therefore, no current flow. The drain terminal of
the FET may be connected to a voltage supply; but
since there is no conduction, the circuit will not supply
current to downstream components connected to the
source. The circuit is turned off like a light switch in the
OFF position.
Drawing B above shows the FET in an active mode.
When the gate signal, a positive DC voltage relative to
the source, is applied to the gate terminal of the FET, it
is capable of conducting current. A voltage supply connected to the drain terminal will allow the FET to conduct and henceforth supply current to downstream
components. Current will flow through the conducting
FET to downstream components as long as the gate
signal is present. This is similar to turning on a light
switch
E-6 E-6
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SOURCE
TERMINAL
GATE
TERMINAL
DRAIN
TERMINAL
DRAIN (N)
N CHANNELSUBSTRATE (P)
SOURCE (N)
(0 VOLTS)
GATE
TERMINAL
(+ 6 VOLTS)
DRAIN (N)
ELECTRONS
SOURCE (N)
B. ACTIVE
A. PASSIVE
FIELD EFFECT TRANSISTOR OPERATION
V300-I
THEORY OF OPERATION
E-7 E-7
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Since only 2 microseconds of the 50-microsecond
time period is devoted to conducting, the output
power is minimized.
MAXIMUM OUTPUT
By holding the gate signals on for 24 microseconds
each and allowing only 2 microseconds of dwell time
(off time) during the 50-microsecond cycle, the output
is maximized. The darkened area under the top
curve can be compared to the area under the bottom
curve. The more dark area under the curve, the
more power is present.
The term PULSE WIDTH MODULATION is used to
describe how much time is devoted to conduction in
the positive and negative portions of the cycle.
Changing the pulse width is known as MODULATION. Pulse Width Modulation (PWM) is the varying
of the pulse width over the allowed range of a cycle
to affect the output of the machine.
MINIMUM OUTPUT
By controlling the duration of the gate signal, the FET
is turned on and off for different durations during a
cycle. The top drawing above shows the minimum
output signal possible over a 50-microsecond time
period.
The positive portion of the signal represents one FET
group1conducting for 1 microsecond. The negative
portion is the other FET group1. The dwell time (off
time) is 48 microseconds (both FET groups off).
FIGURE E.6 — TYPICAL FET OUTPUTS.
MINIMUM OUTPUT
MAXIMUM OUTPUT
24
50
24
2
48
50
sec
sec
sec
sec
sec
sec
sec
sec
PULSE WIDTH MODULATION
1
An FET group consists of the sets of FET modules grouped
onto one switch board.
V300-I
THEORY OF OPERATION
E-8 E-8
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THERMAL PROTECTION
Thermostats protect the machine from excessive
operating temperatures. Excessive temperatures
may be caused by a lack of cooling air or by operating the machine beyond it’s duty cycle or output rating. If excessive operating temperature should occur,
the thermostat will open and prevent output. The
meter will remain on during this time. Thermostats
will normally self-reset once the machine cools sufficiently.
If the thermal shutdown was caused by excessive
output or duty cycle and the fan is operating normally, the Power Switch may be left on and the reset
should occur within a 15-minute period. If the fan is
not turning or the air intake louvers were obstructed,
then the power must be switched off for 15 minutes
in order to reset. The fan problem or air obstruction
must also be corrected.
PROTECTIVE CIRCUITS
Protective circuits are designed into the Invertec
machine to sense trouble and shut down the machine
before the trouble damages the internal machine
components. Both overload and thermal protection
circuits are included.
OVERLOAD PROTECTION
The machine is electronically protected from producing excessive output current. Should the output current exceed 340 to 360 amps, an electronic protection circuit will reduce the current to approximately
150 amps. Lincoln Electric refers to this current
reduction as “Fold Back.” The machine will continue
to produce this low current until the protection circuit
is reset by removing the load.
Another protection circuit is included to monitor the
voltage across input filter capacitors. In the event
that the capacitor voltage is too high, the protection
circuit will signal the Control Board to prevent output.
The protection circuit may prevent output, if any of
these circumstances occur:
1. Capacitor conditioning is required
(Required if machine has been off for prolonged
periods of time.)
2. Line surges over 500 VAC
3. Internal Component damage
4. Improper connections
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