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.
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.
importantly, think before you act
and be careful.
And, most
DO
®
RACKS
Covers Rack codes 10038 thru 10045
IM512
May,2000
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 •
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
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.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
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.d. Keep all equipment safety guards, coversand devices in posi-
tion 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.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 weld-
ing 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.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.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
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.
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
i
Page 3
SAFETY
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.
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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
ii
Page 4
SAFETY
FOR ENGINE
powered equipment.
7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
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.
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.
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
8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
8.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
8d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
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.
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.
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.
Mar. ‘93
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.
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.
7.g. To p revent 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.
7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
iii
Page 5
SAFETY
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 suiv-
antes:
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-é
soudage.
lectrode s’applicuent aussi au pistolet de
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un 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
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
, voir
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 é mises 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 branchéà 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 sûretéà leur place.
iv
Mar. ‘93
Page 6
for selecting a QUALITY product by Lincoln Electric.
We want you to take pride in operating this Lincoln
Thank You
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.
Code Number _____________________________________
Serial Number _____________________________________
Model Name _____________________________________
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.
Read entire installation section before starting
installation.
Step 3 Attach K898-3, -4 Slave Unit to K898-1, -2
Primary Unit
Safety Precautions
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this installation.
• Turn the input power OFF at the
disconnect switch or fuse box or by
unplugging power cable before
working on this equipment.
• Do not touch electrically hot
parts.
MECHANICAL INSTALLATION
K898 Series of Aluminum Racks (4)
Step 1 Unpack Carton
Remove four pack cartons. Unpack skids and set
aside. Remove hardware mounting rack to pallet.
Remove screws that fasten hood down. For racks
with main disconnect, the switch must be in the “OFF”
position before the hood can be removed. Remove
hood from rack and take out parts bag and check
against the list provided.
Attach slave unit to primary unit only after skids or
casters have been installed to both the primary and
slave units.
Remove hood from both racks. Remove 2.00” knockouts on primary and slave units. Place both racks in
upright position, side-by-side with slave unit to the
right when viewed from the front. Align units so that
the 2.00” holes are concentric. Clamp racks together.
Drill six .313” diameter clearance holes for a 1/4 - 20
bolt using the slave unit as a guide. Remove clamp.
Join slave unit to primary unit using close nipple with
two steel lock washers and two neoprene lock washers as shown below. Do not tighten. Assemble slave
unit to primary unit with two 1/4 - 20 x 2.00” bolts, 4
flat washers and a rod coupling in six places as shown
below. Tighten lock nuts on close nipple. Cap close
nipple on each end with plastic bushing.
Neoprene
Lock Washer
Steel
Plastic Bushing
Lock Washer
Step 2 Attach Skids
Skids can be installed by hoisting rack one foot above
ground level. If hoist is not available, place rack skids
on level surface near rack approximately 27” apart
from outside edges. Two-man lift the four pack off
pallet and place onto skids with rack front perpendicular to skids as shown below. Align holes. Place flat
washer on 1/4 - 20 x 2.25” bolt. Insert bolt from the
top side. Place 1/4 - 20 lock nut on bolt from bottom
side. Fasten four bolts and nuts per skid, securely.
The rack is ready for mounting products supported.
Mounting
Holes
(8 Places)
Bolt
CLOSE NIPPLE
CONNECTION
Bolt
Connections
Rod Coupling
Washer
FRONT
INVERTEC RACKS
- 3 -
Page 11
INSTALLATION
L-BOLT
POWER SOURCE
BASE
RACK
SHELF
WING NUT
WASHER
K912 Series of Steel Racks (8)
Step 1 Unpack Carton
Remove eight pack carton. Hoist rack 1 ft. above
ground level to remove pallet from rack. With rack on
level surface, remove screws that fasten hood down.
For racks with main disconnect, the switch must be in
the “OFF” position before the hood can be removed.
Remove hood from rack and take out parts bag and
check against the list provided. K912 series of racks
come with skids and do not require any assembly.
The rack is ready for mounting products supported.
MOUNTING PRODUCTS SUPPORTED
WARNING
Always check for proper and secure mounting of
equipment before hoisting the rack to high or low elevations.
Place power source in rack with controls toward the
front of rack. Align unit with mounting holes. Insert
four #10-24 x .75” L-bolts from the top side and
secure each L-bolt as follows:
Mounting K900-1 DC TIG Starter
The Invertec power source handles must be removed
in order to slide the Invertec/TIG unit into the rack.
WARNING
Follow safety instructions and capacitor discharge
procedure as outlined in owner’s manual before servicing inverter power source.
Remove handles from Invertec case. Use handle
hardware and flange nuts provided with rack to plug
the holes in the Invertec case, as shown below. A
quantity of eight and sixteen 3/8” flange nuts are supplied with four pack and eight pack racks respectively.
Note: Earlier code machines may have insulation
held in place by handle hardware. If so, do not
remove it.
SCREW
Once the handles are removed, follow the instructions
in the TIG Starter Owner’s Manual to mount the
Invertec on top of the DC TIG Starter.
Place the Invertec/TIG unit into the rack with controls
toward front of rack. Align unit with mounting holes.
Secure Invertec/TIG unit to shelf as follows:
TIG BASE
W/O RIVNUTS
WASHER
FLANGE NUT
RACK
SHELF
RIVNUT
INSULATION
(IF PRESENT)
TIG BASE
W/O RIVNUTS
RACK
SHELF
Note:
Earlier code power sources may not have all four or
any mounting holes on the bottom of the base. If
hoisting the rack to high or low elevations is required,
provisions for the use of all four mounting screws
must be made. Use the following dimensions for hole
locations.
9.65
.22 DIA
(4 PLACES)
BACK
BOTTOM
VIEW
FRONT
4.50
13.50
SCREW
WASHER
#10-32
SCREW
ELECTRICAL INSTALLATION
Racks 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:
Input Connection
A 2.88” hole is provided for input lines for low voltage
operation (208/230V). All racks except K898-3, -4 are
provided with reducing washers for input lines for high
voltage operation (460/575V). Strain relief connectors
for input cables are not supplied with racks. Make sure
connections are secure and water tight. Ground lead
for rack must accompany input lines.
- 4 -
INVERTEC RACKS
WASHER
Page 12
INSTALLATION
Wiring K898-3, -4 Slave Units
The input cables to the slave unit are pre-wired from
the factory for minimal installation. Remove tie-wrap
and uncoil the cables. Feed cables through the close
nipple that connects slave unit to primary unit.
Connect cables to main fuse block in primary unit.
Secure all connections. Connect ground lead
between ground bar of primary and slave units.
The slave unit can be used as a stand alone unit
where the customer is required to supply the racks
main fusing and disconnect. If so, simply remove the
feed through cables in the slave unit and connect the
main input lines. Strain relief connectors and reducing
washers are not supplied with slave units.
Fusing
All racks are shipped without fuses which are sold
separately. All racks accommodate the following
types of fuses.
Qty./Rack Available Fuse Manufacturers
ProductK898 K912 Littelfuse Bussman Gould
Power Source 12* 24*JTD LPJ AJT
Rack3 3JLLS JJS A6T
* Maximum quantity based on a full rack for 3 phase operation.
Fusing of Products Supported
See Operator’s Manual for each type of power source
for recommended fusing. A 35 amp and 50 amp fuse
is available from the factory, to meet the input requirements for all of the Lincoln power sources. See Fuses
in Parts List Section for replacement part numbers.
Products Supported
Rack Main Fusing
The fuse protection for all racks must not exceed 200
amps. The following table shows the recommended
fusing for racks based on the applied input voltage
and a full rack of Invertec V300-PRO power sources.
Aluminum (4)
Input Voltage OperationFusing Fusing
Single Phase 208VAC or 230VAC 200A 200A*
Three Phase 208VAC or 230VAC 150A 200A
Single Phase 460VAC or 575VAC 150A 200A
Three Phase 460VAC or 575VAC 110A 200A
*When Steel Racks are used on single phase low voltage (208/230V) only, the Invertec V300-PRO power
sources have reduced output capability at high duty
cycles and maximum output currents. The maximum
number of power sources that can be used at one
time for the most common welding applications is 5 -
6. Exceeding this number may cause the main input
fuses to open.
Fuses listed above are available from the factory.
See Fuses in Parts List Section.
Steel (8)
ELECTRICAL
K898 and K912 series of racks are designed to operate any combination of single phase or three phase
power sources, on 208V, 230V, 460V or 575V operation. The main disconnect switch is the limiting factor
for maximum input power to the rack, which is 200
amps of service. K898 and K912 series of racks are
designed for the domestic market. For proper fusing
of racks and products supported see above.
The products that may be placed into the racks are
listed with approximate weights.
*Invertec V250S 36 lbs/17.0 kg
Pro-Cut® 40 (25 ft. torch)88 lbs/ 39.9 kg
Pro-Cut 40 (50 ft. torch)96 lbs/ 43.5 kg
DC TIG Starter20 lbs/ 9.10 kg
*Requires K934-1 Bracket Kit
INVERTEC RACKS
LIMITATIONS
When Steel Racks (8) are used on single phase low
voltage (208/230V) only, the Invertec V300-PRO
power sources have reduced output capability at high
duty cycles and maximum output currents. The maximum number of power sources that can be used at
one time for the most common welding applications is
5 - 6. Exceeding this number may cause the main
input fuses to open.
- 5 -
Page 13
OPERATION
OPERATING INSTRUCTIONS
General Warnings
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts
or electrode with skin or wet
clothing.
• Insulate yourself from work and
ground.
• Always wear dry insulating
gloves.
FUMES AND GASES
can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
WELDING SPARKS
can cause fire or
explosion
• Keep flammable material away.
• Do not weld on containers that
have held combustibles.
ARC RAYS
can burn.
• Wear eye, ear and body
protection.
Observe all Safety Guidelines detailed throughout
this manual. Do not attempt to use this equipment
until you have throughly read this manual and the
manuals for any Lincoln Equipment installed in
this equipment.
- 6 -
INVERTEC RACKS
Page 14
OPERATION
GENERAL DESCRIPTION
K898 Series Aluminum Racks (4)
The K898 series of Invertec racks are compact power
source racks. Up to four or eight power sources can
be powered from a single external power supply
source. K898 series of racks accommodates the
Lincoln family of portable Invertec power sources and
portable Pro-Cut plasma cutters.
The frame is designed with 1/8” wall tubular aluminum
for a rugged lightweight construction. The lightweight
design makes the rack ideal where the number of
power sources required for the job fluctuates and
where portability is important.
The Aluminum Rack (4) is a versatile rack which may
be easily expanded or reduced to meet the requirements on the job site.
K898 Series Aluminum Racks (4)
K912 Series Steel Rack (8)
The steel racks are economically designed for job
sites where 5 to 8 machines need to be available on
demand. with the optional disconnect and power
pack, electrical hookups and versatility are greatly
enhanced. The steel racks (8) are designed for job
sites where easy portability is not a major concern.
K912 series of racks accommodates the Lincoln family of portable Invertec power sources and portable
Pro-Cut plasma cutters.
K912 Series Steel Racks (8)
With MainWith Factory
Productand Main Fusing*Power Pack
Disconnect
K912-1YesYes
K912-2YesNo
K912-3NoYes
K912-4NoNo
* All units are shipped without fuses which are ordered
separately.
Installed 115 V
With MainWith Factory
Disconnect
Productand Main Fusing*Power Pack
K898-1YesYes
K898-2YesNo
K898-3NoYes
K898-4NoNo
* All units are shipped without fuses which are ordered
separately.
Installed 115 V
K898-1, -2 Primary Aluminum Rack (4)
with Disconnect
K898-1, -2 are basic aluminum racks with main fusing
and disconnect capability.
K898-3, -4 Aluminum Slave Unit (4)
K898-3, -4 slave units mechanically and electrically
connect with primary racks K898-1, -2 to expand them
into a unit that accommodates up to eight power
sources. Slave units have main disconnect capability
provided by the primary rack (K898-1, -2).
The more economical slave units are also stand alone
racks where the customer is required to provide main
fusing and disconnect for the rack.
K912-1, -2 Steel Rack (8) with Disconnect
K912-1, -2 are steel racks with main fusing and disconnect capability.
K912-3, -4 Steel Rack (8) without
Disconnect
K912-3, -4 are more economical units where the customer is required to provide main fusing and disconnect for the rack.
POWER UP PROCEDURE
Recommended procedure for the first time setup at a
job site. Power up the rack in the following sequence.
Step 1
With racks main disconnect “OFF”, turn “OFF” all
power source control switches located on the front of
the rack.
Step 2
Turn “ON” all power sources switches located at the
back or front of each power source.
Step 3
Turn “ON” the rack’s main disconnect located on top
of the rack.
Step 4
Turn “ON” one power source control switch located
INVERTEC RACKS
- 7 -
Page 15
OPERATION
on the front of the rack. Verify operation of the power
source by listening for fan operation. Turn “OFF” the
power source control switch located on the front of the
rack. Verify operation of remaining power sources in
the same manner.
With all power sources operational, the aluminum rack
or steel rack is ready for use. Each operator independently controls their power source with the power
source control switch located on the front of the rack.
See Operating Optional Accessories Section if
you will be using K907-1 Quick Connect Plugs.
TRANSPORTING OR HOISTING RACKS
If the rack needs to be transported in a vehicle or
hoisted to high or low elevations, all power sources
must be firmly secured to the rack per MountingProducts Supported Section. If hoisting, disconnect
main input lines to rack and output cables of power
sources.
OPERATING OPTIONAL ACCESSORIES
Operating Rack with K907-1 Quick
Connect Plugs
WARNING
Turn the input power “OFF” at the rack’s power
source control switch, and the power source switch
before attempting to connect or disconnect K907-1
quick connect plugs for that power source.
Do not lay unused quick connect plugs in puddles,
quick connects must be free of dirt and moisture
before the connection is to be made.
Before operating the rack, turn “OFF” the racks
power source control switch for all unused quick connect receptacles.
Options are available on all racks unless otherwise
specified.
K905-1 115V Power Pack
K906-1 Caster Wheel Kit*
K907-1 Quick Connect Plug Kit
K908-1 50 Ft. Primary Cord Extension
* Available on K898 series of aluminum racks (4) only.
K905-1 115V Power Pack
If not purchased already installed, a 115V power pack
is available as a field installed option. The 115V power
pack consist of a step-down transformer delivering
1KVA (10 amps) of power through a weather proof
GFI duplex receptacle. This supplemental power
source is useful for powering additional tools and
equipment.
K906-1 Caster Wheel Kit
K906-1 caster wheel kit is a field installed option.
Caster wheels offer mobility for convenient in-shop
use. K906-1 is available for K898 series of aluminum
racks (4) only.
K907-1 Quick Connect Plug Kit
K907-1 quick connect plugs are a field installed
option. The kit comes with fur sets of quick connect
plugs which makes power source-to-rack power connection quick and easy for four power sources. Two
kits are needed for a steel rack (8). A power source
can be disconnected from the rack for relocation without interrupting the productivity of other operators.
K943-1 Invertec Mounting Bracket Kit
K934-1 is a field installed option. This kit allows up to
four Invertec V250S machines to be mounted into any
K898 or K912 series of racks.
Weights
ModelTypeWeight
K905-1 115V Power Pack31 lbs / 14.0 kg
K906-1 Caster Wheel Kit13 lbs / 5.9 kg
K907-1 Quick Connect Plug Kit 14 lbs / 6.4 kg
K908-1
K934-1
50 ft. Primary Cord Extension
Invertec Rack Mounting
Bracket Kit
24 lbs / 10.9 kg
4.5 lbs / 2.1 kg
Electrical
K905-1 115V Power Pack
K905-1 115 v power pack provides 1KVA (10 amps)
of auxiliary power and is protected by a 10A circuit
breaker. The power pack is powered by the same
main power supply source that feeds the rack, therefore, reconnection of the power pack may be necessary depending on the input voltage applied. When
factory installed, K905-1 is connected for the highest
available input voltage connection. See rack wiring
diagram for reconnection.
K907-1 Quick Connect Plug Kit
Maximum ratings for quick connects are 600V @ 50
amps of service. Fuse power sources for 50A maximum for low voltage operation when using quick connect plugs.
Receptacles mount and hang by a short line cord from
underneath the fuse box. Each mating plug mounts to
a power source line cord. The quick connect plugs
are 3 pole/4 wire plugs, weather sealed for outdoor
use, and mate with a twist lock action.
K908-1 50 ft. Primary Cord Extension
K908-1 is a 50 ft. line cord terminated at each end
with a quick connect to be used in conjunction with
K907-1 quick connect plug kit. K908-1 allows a power
source to be relocated around the job site and still
draw power from one central location.
INVERTEC RACKS
- 9 -
Page 17
NOTES
- 10 -
INVERTEC RACKS
Page 18
GENERAL ASSEMBLY
K898 SERIES ALUMINUM RACKS (4)
15
111222444333
FB1
11
MAIN
FUSE BLOCK
PARTS
GND BAR
T1
X1
SEC
PRI
X2 X3
H3H4H5
FB2
115V
H1H2
LIFT
BALE
MAIN
SWITCH
FB3
12
FB4
6
13
DISTRIBUTION
BLOCK
SW1SW2
PL1
GFI
SW3SW4
CB1
17
4
7
18
INVERTEC RACK
2
ON
OFF
O
1
ON
OO
OFF
2
ON
10
OFF
115V
O
3
R
21
WARNING
ON
OFF
4
5
3
1
K898-1,2
RIGHT SIDE VIEW
INVERTEC RACKS
9
K898-1
FRONT VIEW
10
K898-3,4
LEFT SIDE VIEW
- 11 -
Page 19
PARTS
GENERAL ASSEMBLY
K898 SERIES ALUMINUM RACKS (4)
Qty Per Pack
Item # Part DescriptionPart No.K898-1 K898-2 K898-3 K898-4
WIRING DIAGRAM FOR K898 SERIES OF ALUMINUM RACKS (4)
M17175
X2 - 110V
X3 - 115V
X1 - COMMON
"A"
TRANSFORMER (T1)
GND
PRIMARY UNIT INPUT LINE
ROUTING TO SLAVE UNIT
MAIN INPUT - PRIMARY UNIT
GND
T1
GND BAR
INV1INV2INV3INV4
X1
SEC
"A"
FB4
FB3
X2 X3
115V
PRI
H3H4H5
FB2
111222444333
FB1
PRIMARYSECONDARY
H1 - START
H2 - 208V
H3 - 230V
H4 - 460V
H5 - 575V
MAIN
SWITCH
LIFT
BALE
H1H2
MAIN
FUSE BLOCK
RECONNECT "A" LEAD FOR PROPER
PRIMARY INPUT VOLTAGE
3333
SW3SW4
H1
"A"
NUT HOT
CB1
GFI
PL1
SW1SW2
RED
BLUE
BLK
DISTRIBUTION
BLOCK
X3
10
X1
CLEVELAND, OHIO U.S.A.
R
GND
SLAVE UNIT
INPUT LINE ROUTING
AND MAIN DISCONNECT FOR
PROPER PRIMARY INPUT VOLTAGE
FUSE INVERTER POWER SOURCES
IMPORTANT !
IMPORTANT !IMPORTANT !
- 18 -
3333
SOME UNITS DO NOT HAVE 115 V POWER PACK OPTION SHOWN (T1, GF1, PL1, CB1)
SLAVE UNITS DO NOT HAVE MAIN FUSE BLOCK & MAIN SWITCH
RECONNECT INVERTER POWER
INPUT VOLTAGE
SOURCES FOR PROPER PRIMARY
INVERTEC RACKS
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..
Page 26
WIRING DIAGRAM
WIRING DIAGRAM FOR K912 SERIES OF STEEL RACKS (8)
MAIN INPUT LINES
GND
FB6
555666
FB5
777888
FB8
3333
FB7
X2 - 110V
X3 - 115V
X1 - COMMON
"A"
TRANSFORMER (T1)
PRIMARYSECONDARY
H1 - START
H2 - 208V
H3 - 230V
H4 - 460V
M17175
H5 - 575V
RECONNECT "A" LEAD FOR PROPER
PRIMARY INPUT VOLTAGE
IMPORTANT !
INV5INV6INV7INV8
GND BAR
INV1INV2INV3INV4
222111
X2 X3
X1
FB2
FB1
115V
SEC
MAIN
SWITCH
LIFT
T1
PRI
333444
BALE
MAIN FUSE BLOCK
H1H2
H3H4H5
"A"
DISTRIBUTION
FB4
FB3
BLU
RED
BLK
3333
SW5SW6SW7SW8
NUT
CB1
HOT
GFI
PL1
SW1SW2SW3SW4
X3
10
X1
BLOCK
3333
3333
CLEVELAND, OHIO U.S.A.
R
SOME UNITS DO NOT HAVE 115 V POWER PACK OPTION SHOWN (T1, GF1, PL1, CB1)
SLAVE UNITS DO NOT HAVE MAIN FUSE BLOCK & MAIN SWITCH. MAIN INPUT LINES
WILL CONNECT TO THE DISTRIBUTION BLOCK.
INVERTEC RACKS
- 19 -
RECONNECT INVERTER POWER
FUSE INVERTER POWER SOURCE
AND MAIN DISCONNECT FOR
IMPORTANT !
PROPER PRIMARY INPUT VOLTAGE
SOURCE FOR PROPER PRIMARY
IMPORTANT !
INPUT VOLTAGE
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..
Page 27
NOTES
- 20 -
INVERTEC RACKS
Page 28
NOTES
INVERTEC RACKS
- 21 -
Page 29
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SUB TOTAL
TOTAL COST
INVERTEC RACKS
Page 30
WARNING
Spanish
AVISO DE
PRECAUCION
● Do not touch electrically live parts or
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.
● Keep flammable materials away.
● Mantenga el material combustible
fuera del área de trabajo.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
● 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.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-
dos.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Use proteção para a vista, ouvido e
corpo.
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.
INVERTEC RACKS
- 23 -
Page 31
● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
● 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-
teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von
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.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.