Lincoln Electric IM526 User Manual
INVERTEC V300-PRO
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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.
™
For use with machines Code 10256 and 10257.
IM526-B
December,1999
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
WARNING
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can
kill.
1.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
1.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing;
on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire)
Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
1.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically“hot”.
1.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should
be as close as possible to the area being welded.
1.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
1.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
1.g. Never dip the electrode in water for cooling.
1.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
1.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
1.j. Also see Items 4.c. and 6.
ARC RAYS can burn.
2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
2.c. Protect other nearby personnel with suitable non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
3.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these
fumes and gases.When welding, keep your
head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
with electrodes which require special ventilation such
as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and
other metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and below
Threshold Limit Values (TLV) using local exhaust or
mechanical ventilation. In confined spaces or in some
circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
3.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating products.
3.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
3.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your
welding distributor or from the manufacturer.
3.e. Also see item 7b.
WELDING SPARKS can
cause fire or explosion.
4.a..Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
4.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the equipment being used.
4.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
4.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned.” For information purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
4.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Apr. ‘93
– 2 –
4.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a welding area.
4.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until
they fail.
4.h. Also see item 7c.
CYLINDER may explode
if damaged.
5.a. Use only compressed gas cylinders containing the correct shielding gas for the process
used and properly operating regulators
designed for the gas and pressure used. All
hoses, fittings, etc. should be suitable for the application and
maintained in good condition.
5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
5.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
5.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
5.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,”available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
6.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s recommendations.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
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.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes outdoors.
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.
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 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.
---------------------------------------------------------------------------------------
7.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC
FIELDS
may be dangerous
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.
---------------------------------------------------------------------------------------
– 3 –
Mar. ‘93
PRÉCAUTIONS DE SÛRETÉ
zones où l’on pique le laitier.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue ou
les vétements mouillés. Porter des gants secs et sans trous
pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher
à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
– 4 –
Mar. ‘93
TABLE OF CONTENTS
Page
Safety Precautions .............................................................................................................2-4
Introductory Information .......................................................................................................6
Product Description..............................................................................................................7
Specifications.......................................................................................................................7
Installation .........................................................................................................................7-10
Safety Precautions ........................................................................................................7
Location .........................................................................................................................7
Electrical Installation......................................................................................................7
Input Voltage Setup.......................................................................................................8
Power Cord Connection ................................................................................................8
Connection of Wire Feeders to Invertec .....................................................................8-10
Output Cables & Plugs .................................................................................................10
Operating Instructions ......................................................................................................11-13
Safety Precautions .......................................................................................................11
Controls Description and Function.............................................................................11-13
Maintenance.....................................................................................................................13-14
Capacitor Discharge Procedure ...................................................................................13
Routine Maintenance....................................................................................................13
Periodic Maintenance ...................................................................................................14
Troubleshooting Guide .....................................................................................................14-20
Matched Parts.....................................................................................................................20
Switch P.C. Board Replacement Procedure .......................................................................20
Replacement of Power Modules and Output Diodes .......................................................20-21
Connection Diagrams.......................................................................................................22-31
Wiring Diagrams...............................................................................................................32-33
Parts Lists......................................................................................................................appendix
– 5 –
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
– 6 –
PRODUCT DESCRIPTION
The Invertec V300-PRO is a 300 amp arc welding
power source that utilizes single or three phase input
power to produce either constant voltage or constant
current outputs. The V300-PRO is designed for 60 Hz
supply systems. The welding response of the Invertec
has been optimized for GMAW, SMAW, TIG and
FCAW processes. It is designed to be used with the
LN-25 and LN-7 semiautomatic wire feeders.
SPECIFICATIONS
Product Ordering Input AC Rated DC Output Input Amps at Rated DC Output Output Weight Dimensions
Name Information Voltage Amps/Volts/Duty Cycle
208 230 460 575
Range with Gun HxWxD
(continuous) (net)
208/230/460 300A / 32V / 60%
3 Phase 250A / 30V / 100%
60 Hz
Invertec K1349-3 22.2”
V300- 208/230/460 250A / 30V / 60%
PRO 1 Phase 160A / 28V / 100%
60 Hz
575 300A / 32V / 60%
K1349-4 3 Phase 250A / 30V / 100%
60 Hz 300A / 36V / 60%
(1 )
NEMA Class I Rated Output / Based on a 10 min. Period .
(2 )
Lincoln plus rating.
* Overall Height Including Handle, (16.4” (417mm without handle).
300A / 35/39/41V /60%
250A / 37/41/43V / 60%
(1)
(1)
(2)
(1)
(1)
(1)
(1)
(2)
48 43 24
37 33 19
49 48 28
69 62 38 AMPS 64 lbs. (475x274x
53 47 29 5-350 (29 kg) 564 mm)
(2)
75 67 42
20 handle
16
22
18.7*x10.8x
* Includes
INSTALLATION
WARNING
ELECTRICAL INSTALLATION
ELECTRIC SHOCK can kill.
• Have an electrician install and service
this equipment.
• Turn the input power off at the fuse
box before working on equipment.
• Do not touch electrically hot parts.
---------------------------------------------------------------------
LOCATION
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.
1. The Invertec should be connected only by a qualified electrician. Installation should be made in
accordance with the U.S. National Electrical Code,
all local codes and the information detailed below.
2. Single voltage, 575 VAC machines, can only be
connected to 575 VAC. No internal reconnection
for other input voltages is possible.
3. 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.
• Keep machine dry. Shelter from rain and snow. Do
not place on wet ground or in puddles.
– 7 –
INPUT VOLTAGE SETUP
CAUTION
DO NOT ATTEMPT TO POWER THIS UNIT
FROM THE AUXILIARY POWER SUPPLY
OF AN ENGINE WELDER.
• Special protection circuits may operate, causing
loss of output.
• The supply from engine welders often has excessive voltage peaks because the voltage waveform
is usually triangular shaped instead of sinusoidal.
• If voltage peaks from the engine welder exceed
380V, the input circuits of this machine protecting
the filter capacitors, FETS and other components
from damage will not
---------------------------------------------------------------------
RECONNECT PROCEDURE
1. BE SURE POWER SWITCH IS OFF.
2. CONNECT LEAD ’A’ TO DESIRED
INPUT VOLTAGE RANGE.
440-460V
380-415V
220-230V
200-208V
3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.
be energized .
.
Disconnect input power before
inspecting or servicing machine.
.
Do not operate with wraparound
removed.
.
Do not touch electrically live parts.
.
Only qualified persons should install,
’A’
IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)
AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;
REPLACE WITH A 3 AMP SLOW BLOW ONLY.
use or service this equipment.
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)
3 phase 208 60
50/60 Hz 230 60
460 40
1 phase 208
50/60 Hz 230
(2)
(2)
85
80
460 50
3 phase 575 30
60 Hz
(1)
Input voltage must be within ±10% of rated value.
(2)
When operating on these inputs, at outputs exceeding 200A/60%
or 165A/100%, the input line cord should be changed to an input
conductor of 6 AWG or larger.
CONNECTION OF WIRE FEEDERS TO THE
INVERTEC
(Note: IEC units do not have 110 VAC auxiliary
power).
LN-25 Connection Instructions
1. Turn the Invertec power switch “off”.
VOLTAGE=380-460V
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
9-11-92
VOLTAGE=200-230V
S20324
POWER CORD CONNECTION
A 10 ft. (3.0m) power cord is provided and wired into
the machine. Follow the power cord connection
instructions. Incorrect connection may result in equipment damage.
BLACK
GREEN
RED
WHITE
Single Phase Input
1. Connect green lead to ground per U.S. National
Electrical Code.
2. Connect black and white leads to power.
3. Wrap red lead with tape to provide 600V insula-
tion.
Three Phase Input
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 at
the back 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
1. Turn the Invertec power switch “off”.
2. Connect the K480 control cable from the LN-7 to
the Invertec control cable connector. The control
cable connector is located at the rear of the
Invertec.
1. Connect green lead to ground per U.S. National
Electrical Code.
2. Connect black, red and white leads to power.
Install in accordance with all local and national electric
codes.
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
–– 8 –
remote control adapter and K857 remote control
are required for remote output control).
5. Set the meter polarity switch on the rear of the
Invertec to coincide with wire feeder polarity used.
The wire feeder will now display the welding voltage.
6. If K480 is not available, see connection diagram
S19404 for modification of K291 or K404 LN-7
input cable with K867 universal adapter plug.
General Instructions for Connection of Wire
Feeders to Invertec
Wire feeders other than LN-7 and LN-25 may be used
provided that the auxiliary power supply capacity of
the Invertec is not exceeded. K867 universal adapter
plug is required. See connection diagram S19406 and
S19386 at the back of this manual for more information.
Remote Control of Invertec
Remote control K857, hand amptrol K963 and foot
amptrol K870 require K864 remote control adapter.
See 19309 instruction at the back of this manual for
connection information.
K954-1 MIG PULSER
Parallel Operation
The Invertec’s are operable in parallel in both CC and
CV modes. For best results, the currents of each
machine should be reasonably well shared. As an
example, with two machines set up in parallel for a
400 amp procedure, each machine should be set to
deliver approximately 200 amps, not 300 amps from
one and 100 amps from the other. This will minimize
nuisance shutdown conditions. In general, more than
two machines in parallel will not be effective due to
the voltage requirements of procedures in that power
range.
To set machine outputs, start with output control pots
and arc force/pinch pots in identical positions. If running in a CC mode, adjust outputs and arc forces to
maintain current sharing while establishing the proper
output current. In CV modes, the pots in identical
positions. Then switch the machine meters to amps
and adjust one of the output control pots for current
balance. Check the voltage and if readjustment is
necessary, repeat the current balancing step. Pinch
settings should also be kept identical on the
machines.
K900-1 DC TIG Starter Connection
This versatile new kit was made to mate with the
Invertec.
The MIG Pulser is a hand-held “pendant” type GMAW
Pulsing option for the V300 Power Source. Refer to
the Mig Pulser’s IM manual (IM555) for connection
information.
A control cable assembly is supplied with the kit to
connect the kit to an Invertec. The cable can be connected, either end, at the DC TIG Starter kit and at
the Invertec by attaching to the 14-pin Amphenols on
the backs of each unit. Refer to diagram S20405 at
the back of this manual.
A negative output cable assembly is also supplied
with the DC TIG Starter kit to connect the kit with the
Invertec’s negative output terminal.
All Magnum™ one and two piece water-cooled torches with 7/8 left-hand threads and gas-cooled torches
with 7/8 and 5/16 right-hand threads can be connected to the starter kit.
To secure the DC TIG Starter kit to the bottom of the
Invertec and for more detailed instructions, refer to
the K900-1 manual.
– 9 –– 9 –
MAR97
LN-9 GMA Connection Instructions
25 mm
1 in.
WELDING CABLE
BOOT
TRIM
SET SCREW
BRASS PLUG
COPPER TUBE
1. Turn the Invertec power switch “off”.
2. Connect the K596 control cable assembly from the
LN-9 GMA to the Invertec control cable connector.
The control cable connector is located at the rear
of the Invertec.
3. Connect the electrode cable to the output terminal
of polarity required by electrode. Connect the work
lead to the other terminal.
4. Place the local-remote switch in the “remote” position to allow output control at the LN-9 GMA.
5. Set the meter polarity switch on the rear of the
Invertec to coincide with wire feeder polarity used.
The wire feeder will now display the welding voltage.
6. K608-1 adapter is required in LN-9 GMA for LN-9
type control. K608-1 is installed in line with P10
connection at the LN-9 GMA voltage board. See
diagram S20607 at the back of this manual.
7. K442-1 Pulse Power Filter Board is also required
for GMAW, but should be disconnected for FCAW.
8. If K596 is not available, see connection diagram
S20608 at the back of this manual for modification
of K196 LN-9 GMA input cable with K867 universal
adapter plug.
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.
3. Slide the copper tube into the brass plug.
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.
Output Cables
Select the output cable size based upon the following
chart.
Cable sizes for Combined Length of Electrode and
Work Cable (Copper) 75° rated:
Duty Length Up 61-76m
Cycle Current 61m (200 ft.) (200-250 ft.)
100% 250 1/0 1/0
60% 300 1/0 2/0
Quick Disconnect Plugs
A quick disconnect system is used for the welding
cable connections. The welding plug included with the
machine is designed to accept a welding cable size of
1/0 to 2/0.
1. Remote 25mm (1 in.) of welding cable insulation.
– 10 –
OPERATING INSTRUCTIONS
Output Control - This controls the output voltage in
the CV modes and output current in the CC modes.
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 danger-
ous.
• 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.
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.
OUTPUT
Local/Remote Switch - Place in the “LOCAL” position to allow output adjustment at the machine. Place
in the “REMOTE” position to allow output adjustment
at the wire feeder or with a remote control option
package.
REMOTE
------------------------------------------------------------
See additional warning information at
front of this operator’s manual.
-----------------------------------------------------------
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.
OFF
Digital Meter Switch - Select either “A” for amps or
“V” for volts to display welding current or voltage on
the meter.
When welding current is not present, the meter will
display the set current for the CC modes or the set
voltage for the CV modes. This set reading is an indication of machine control setting. For a more precise
process reading, read meter during actual welding.
Mode Switch
GTAW Optimized for both scratch start and Hi-
Freq kit use.
CC SOFT Best for EXX18 thru EXX28 stick elec-
trodes.
– 11 –
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
GMAW
FCAW
SMAW
CRISP
SMAW
SOFT
GTAW
OUTPUT
TERMINALS
ON
REMOTE
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 17V, may operate better in the
FCAW mode. Voltage in the GMAW
mode can become erratic when
welding is attempted using voltages
equal to or less than 17V DC+.
Output Terminals Switch
Arc Force / Inductance Control
This control functions in all modes except GTAW. For
CC modes, this control acts as an Arc Force adjustment. The arc is soft at the minimum settings and
more forceful or driving at the maximum settings.
Higher spatter levels may be present at the maximum
settings.
For CV modes, this control will set the degree of
“pinch effect” which predominantly affects short circuit
transfer. In FCAW, the maximum setting is generally
preferred. With GMAW, the upper half of the range is
preferred with CO2or high content CO2mixed. The
lower half is for inert gas mixes.
For processes and equipment that require energized
machine terminals (stick, TIG, air-carbon arc cutting or
hot tip LN-25), set the Output Terminals Switch to
“ON” position.
Set to the REMOTE (OFF) position when using LN-25
with K431 and K432 options or LN-7 which will allow
the gun trigger to energize the welding terminals.
– 12 –
Recommended Arc Force / Inductance Settings
For Selected Applications
Full Range Is 1-10,
1 Is Very Soft, 10 Is Very Crisp
Nominal Recommended
Mode Process Setting Adjustment Range
CC SMAW 1 EXX18 thru 5 1 (gentle, may stick) to 9
EXX28 stick (forceful, more spatter)
CC SMAW 2 EXX10 thru 6 3 to 10
EXX14 stick
Air Carbon Arc 1 None
Cutting
CV FCAW Innershield or 10 None
Outershield
Air Carbon Arc 1 None
Cutting
CV GMAW* CO2or 25% CO27.5 5 to 10
or similar
gas mixes
98% Ar-2% O2Ar, 5 1 to 10
90% He-7.5% Ar
2.5% CO2and
other
predominantly
inert gases
* 1 = Lowest pinch, highest inductance and least spatter.
10 = Highest pinch, lowest inductance and most spatter.
–
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