Lincoln Electric SVM199-A User Manual

INVERTEC® V450-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.

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SVM199-A

July, 2010

For use with machine code number: 11212

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Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

SERVICE MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i i

SAFETY

WARNING

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 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.

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1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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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.

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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.

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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.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.

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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.

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SAFETY

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.

3.i. When working above floor level, use a safety belt to protect 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 within applicable OSHA PEL and ACGIH TLV limits 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.

5.c.

Do not weld in locations near chlorinated hydrocarbon 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 products.

vapors

to

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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.

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’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

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SAFETY

WELDING and CUTTING SPARKS can cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

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 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.

the welding sparks from starting a fire.

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.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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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 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:

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.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

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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.

INVERTEC® V450-PRO

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.

v v

SAFETY

Electromagnetic Compatibility (EMC)

Conformance

Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national

codes. Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the

welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment being

used in the environment is compatible. This may require additional protection measures;

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h) the time of day that welding or other activities are to be carried out.

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vi vi

SAFETY

Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applica-

1

tions.

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1

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.”

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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -

Page

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-525

INVERTEC® V450-PRO

A-1 A-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Lifting, Stacking & Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

High Frequency Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Input Fuse and Supply Wire Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Negative Electrode Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

TABLE OF CONTENTS - INSTALLATION SECTION

Connections of Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Parallel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

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INVERTEC® V450-PRO

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS -

INVERTEC® V450-PRO

INPUT AT RATED OUTPUT - THREE PHASE ONLY

INPUT VOLTS-

FREQUENCY

208/230/460/575V - 60HZ.

200/220/440/575V - 50HZ.

OUTPUT

CONDITIONS

AMPS / VOLTS / DUTY CYCLE

450A@38V.100%

570A@43V. 60%

400A@36V.100%

500A@40V. 60%

INPUT

CURRENT

AMPS

58/53/25/22 82/78/37/31

49/45/23/18 67/61/31/25

IDLE

POWER

400 Watts

Max.

POWER FACTOR

@ RATED OUTPUT

.95 MIN.

EFFICIENCY

@ RATED

OUTPUT

88%

OUTPUT

PULSE

FREQUENCY

0.15 - 1000 Hz

PULSE

VOLTAGE

RANGE

5 - 55 VDC

PULSE AND

BACKGROUND

TIME RANGE

100 MICRO SEC. -3.3

SEC.

(CIRCUIT BREAKER PROTECTED)

AUXILIARY POWER

24VAC

42VAC AT

10 AMPS

115VAC AT

15* AMPS

OPEN CIRCUIT VOLTAGE PROCESS CURRENT RANGE (DC) CURRENT

30-76

76 76

18-76

76

MIG/MAG

FCAW

SMAW

GTAW

Pulse

50-570 Average Amps 40-570 Average Amps 55-570 Average Amps

5-570 Average Amps

5-750 Peak Amps

RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT

INPUT

VOLTAGE /

FREQUENCY

208/50/60HZ 230/50/60HZ 460/50/60HZ 575/50/60HZ

TYPE 75°C

COPPER WIRE IN

CONDUIT AWG(MM2)

SIZES

4(25) 4(25) 8(10) 10(6)

TYPE 75°C

GROUND WIRE IN

CONDUIT AWG(MM2)

SIZES

8(10) 8(10) 10(6) 10(6)

TYPE 75°C

(SUPER LAG)

OR BREAKER

SIZE (AMPS)

100 100

50 40

PHYSICAL DIMENSIONS

HEIGHT

26.10 in 663 mm

WIDTH

19.86 in 505 mm

DEPTH

32.88 in 835 mm

WEIGHT

293 lbs.

133 kg.

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

-20°C to +40°C

* Earlier models used 10 amps circuit breaker.

STORAGE TEMPERATURE RANGE

-40°C to +40°C

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INVERTEC® V450-PRO

A-3 A-3

INSTALLATION

SAFETY PRECAUTIONS Read

start installation.

this entire installation section before you

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• Turn the input power OFF at the

disconnect switch or fuse box before working on this equipment. Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on the equipment.

• Do not touch electrically hot parts.

• Always connect the V450-PRO grounding lug

(located inside the reconnect input access door) to a proper safety (Earth) ground.

--- -- --- - ---- -- --- - ---- -- --- - ---- -- --- - ---- -- --- - ---- -- ---

SELECT SUITABLE LOCATION

Do not use the Invertec® in outdoor environments without appropriate protection. The V450-PRO power source should not be subjected to falling water, nor should any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice is to keep the machine in a dry, sheltered area.

LIFTING

Lift the machine by the lift bail only. The lift bail is designed to lift the power source only. Do not attempt to lift the V450-PRO with accessories attached to it.

STACKING

V450-PRO machines can be stacked to a maximum of 3 high.

CAUTION

The bottom machine must always be placed on a firm, secure, level surface. There is a danger of machines toppling over if this precaution is not taken.

MACHINE GROUNDING

The frame of the welder must be grounded. A ground terminal marked with the symbol is located inside the reconnect/input access door for this purpose. See your local and national electrical codes for proper grounding methods.

HIGH FREQUENCY PROTECTION

Locate the V450-PRO away from radio controlled machinery.

WARNING

Do not mount the V450-PRO over combustible surfaces. Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least .060" (1.6mm) thick, which shall extend not less than 5.90" (150mm) beyond the equipment on all sides.

------------------------------------------------------------------------

Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the case sides and bottom. Water, Dirt, dust, or any foreign material that can be drawn into the welder should be kept at a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns.

Machines are equipped with F.A.N. (fan as needed) circuitry. The fan runs whenever the output is enabled, whether under loaded or open circuit conditions. The fan also runs for a period of time (approximately 5 minutes) after the output is disabled, to ensure all components are properly cooled.

If desired, the F.A.N. feature can be disabled (causing the fan to run whenever the power source is on). To disable F.A.N., connect leads 444 and X3A together at the output of the solid state fan control relay, located on the back of the Control PC board enclosure. (See Wiring Diagram)

CAUTION

The normal operation of the V450-PRO may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

INPUT CONNECTION

WARNING

Only a qualified electrician should connect the input leads to the V450-PRO. Connections should be made in accordance with all local and national electrical codes and the connection diagram located on the inside of the reconnect/input access door of the machine. Failure to do so may result in bodily injury or death.

------------------------------------------------------------------------

Use a three-phase supply line. A 1.75 inch (45 mm) diameter access hole for the input supply is located on the upper left case back next to the input access door. Connect L1, L2, L3 and ground according to the Input Supply Connection Diagram decal located on the inside of the input access door or refer to Figure A.1 on the following page.

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INVERTEC® V450-PRO

A-4 A-4

200-208V

220-230V

440-460V

550-575V

200-208V

220-230V

=

220-230V

200-208V

220-230V

440-460V

550-575V

200-208V

U / L1

550-575V

440-460V

'A'

= 440-460V

'A'

S25198

VOLTAGEVOLTAGE

VOLTAGE

=

200-208V

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

XA

'A'

= 550-575V

C

R1

W / L

3

V / L

2

440-460V

550-575V

.

inspecting or servicing machine.

Do not operate with covers

.

r

emoved.

Do not touch electrically live parts.

.

Only qualied persons should install,

use or service this equipment.

.

Disconnect input power before

INPUT SUPPLY CONNECTION DIAGRAM

WARNING

ELECTRIC

SHOCK

CAN KILL

200-208V

220-230V

440-460V

550-575V

200-208V

220-230V

=

220-230V

200-208V

220-230V

440-460V

550-575V

200-208V

U / L1

550-575V

440-460V

'A'

= 440-460V

'A'

S25198

VOLTAGEVOLTAGE

VOLTAGE

=

200-208V

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

XA

'A'

= 550-575V

C

R1

W / L

3

V / L

2

440-460V

550-575V

.

inspecting or servicing machine.

Do not operate with covers

.

r

emoved.

Do not touch electrically live parts.

.

Only qualied persons should install, use or service this equipment.

.

Disconnect input power before

INPUT SUPPLY CONNECTION DIAGRAM

WARNING

ELECTRIC SHOCK CAN KILL

INSTALLATION

FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to do

so will result in damage to the machine.

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS

Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and wire sizes. Fuse the input circuit with the recommended super lag fuse or delay type breakers (also called “inverse time” or “thermal/magnetic” circuit breakers). Choose an input and grounding wire size according to local or national electrical codes. Using fuses or circuit breakers smaller than recommended may result in “nuisance” shut-offs from welder inrush currents, even if the machine is not being used at high currents.

INPUT VOLTAGE CHANGE OVER (FOR MULTIPLE INPUT VOLTAGE MACHINES ONLY)

Welders are shipped connected for the highest input voltage listed on the rating plate. To move this connection to a different input voltage, see the diagram located on the inside of the input access door. If the main reconnect switch or link position is placed in the wrong position, the welder will not produce output power.

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If the Auxiliary (A) lead is placed in the wrong position, there are two possible results. If the lead is placed in a position higher than the applied line voltage, the welder may not come on at all. If the Auxiliary (A) lead is placed in a position lower than the applied line voltage, the welder will not come on, and the two circuit breakers or fuses in the reconnect area will open. If this occurs, turn off the input voltage, properly connect the (A) lead, reset the breakers, and try again. For machines equipped with a fuse in the reconnect area, turn off the input voltage and replace the fuse with the spare fuse that is attached to the reconnect switch pin.

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INVERTEC® V450-PRO

ELECTRODE AND WORK CABLE CONNECTIONS

Connect a work lead of sufficient size and length (Per Table 1) between the proper output terminal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly to the work and wire feeder. Avoid excessive lengths and do not coil excess cable.

Minimum work and electrode cable sizes are as follows:

TABLE A.1

(Current (60% Duty Cycle)

400 Amps 2/0 (67 mm2) 500 Amps 3/0 (85 mm2) 600 Amps 3/0 (85 mm2)

NOTE: K1796 coaxial welding cable is recommended to reduce the cable inductance in long cable lengths. This is especially important when Pulse welding up to 350 amps.

When using inverter type power sources like the V450-PRO, use the largest welding (electrode and work) cables that are practical. At least 2/0 (67

2

) copper wire - even if the average output cur-

mm

CAUTION

rent would not normally require it. When pulsing, the pulse current can reach very high levels. Voltage drops can become excessive, leading to poor welding characteristics, if undersized welding cables are used.

------------------------------------------------------------------------

MINIMUM COPPER

WORK CABLE SIZE AWG

Up To-100 Ft. Length (30 m)

A-5 A-5

B

A

C

FIGURE A.2

WORK

V450-PRO

A

C

B

FIGURE A.3

K1796 COAXIAL CABLE

MEASURE FROM END

OF OUTER JACKET OF

CABLE

C

A

B

WORK

SLIDING

WORK

V

450-PRO

A

C

B

FIGURE A.3

K1796 COAXIAL CABLE

MEASURE FROM END OF OUTER JACKET OF CABLE

C

A

B

WORK

SLIDING

WORK

V

450-PRO

CABLE INDUCTANCE, AND ITS EFFECTS ON PULSE WELDING

For Pulse Welding processes, cable inductance will cause the welding performance to degrade. For the total welding loop length less than tional welding cables may be used without any effects on welding performance. For the total welding loop length greater than

50 ft. (15.24m), the K1796 Coaxial

Welding Cables are recommended. The welding loop length is defined as the total of electrode cable length (A) + work cable length (B) + work length (C) (See Figure A.2).

50 ft.(15.24m), tradi-

INSTALLATION

For additional Safety information regarding the electrode and work cable set-up, See the standard "SAFETY INFORMATION" located in the front of the Instruction Manuals.

CAUTION

Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding performance.

------------------------------------------------------------------------

NEGATIVE ELECTRODE POLARITY

When negative electrode polarity is required, such as in some Innershield applications, switch the output connections at the power source (electrode cable to the negative (-) stud, and work cable to the positive (+) stud.

For long work piece lengths, a sliding ground should be considered to keep the total welding loop length less

50 ft.(15.24m). (See Figure A.3.)

than

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Output connections on some V450-PRO are made via 1/2-13 threaded output studs located beneath the spring-loaded output cover at the bottom of the case front.

Most welding applications run with the electrode being positive (+). For those applications, connect the electrode cable between the wire feeder and the positive (+) output stud on the power source (located beneath the spring loaded output cover near the bottom of the case front). Connect the other end of the electrode cable to the wire drive feed plate. The electrode cable lug must be against the feed plate. Be sure the connection to the feed plate makes tight metal-to-metal electrical contact. The electrode cable should be sized according to the specifications given in the work cable connections section. Connect a work lead from the negative (-) power source output stud to the work piece. The work piece connection must be firm and secure, especially if pulse welding is planned.

INVERTEC® V450-PRO

A-6 A-6

14-PIN

STUD

WORK CLAMP

ELECTRODE CABLE

V450-PRO

ACROSS THE ARC MODEL

CONROL CABLE MODEL

OUTPUT TERMINALS

ALWAYS HOT.

POWER SOURCE CONTACTOR

SWITCH MUST BE IN THE

“ON” POSITION OR USE A

K848 JUMPER PLUG KIT.

MAGNUM GUN

AND CABLE

ASSEMBLY LN-15

SEMIAUTOMATIC

WIRE FEEDER

K1870-1

14-PIN

STUD

ELECTRODE CABLE

V450-PRO

K1819-10

CONTROL CABLE

MAGNUM GUN

AND CABLE

ASSEMBLY LN-15

SEMIAUTOMATIC

WIRE FEEDER

K1871-1 MODEL

14-PIN

STUD

WORK CLAMP

ELECTRODE CABLE

V450-PRO

ACROSS THE ARC MODEL

CONROL CABLE MODEL

OUTPUT TERMINALS ALWAYS HOT.

POWER SOURCE CONTACTOR SWITCH MUST BE IN THE “ON” POSITION OR USE A K848 JUMPER PLUG KIT.

MAGNUM GUN AND CABLE ASSEMBLY

LN-15 SEMIAUTOMATIC WIRE FEEDER K1870-1

14-PIN

STUD

ELECTRODE CABLE

V450-PRO

K1819-10 CONTROL CABLE

MAGNUM GUN AND CABLE ASSEMBLY

LN-15 SEMIAUTOMATIC WIRE FEEDER K1871-1 MODEL

INSTALLATION

CONNECTIONS OF WIRE FEEDERS TO V450-PRO

LF-72, 74 Connection Instructions

• Turn the Invertec® power switch "off".

• Connect the K1797-[ ] control cable from the LF-72, 74 to the 14-pin MS-style connector.

• Connect the electrode cable to the output terminal of the polarity required by electrode. Connect the work lead to the other terminal.

• If a remote control such as K857 is to be used with the LF-72, 74 the remote can be connected directly to the 6pin MS-style connector on the front of the Invertec® or use a K864 adapter to connect the LF-72, 74 and the remote to the 14-pin MS-style connector.

LN-10, DH-10 Connection Instructions

• Turn the Invertec® power switch "off"

• Connect the K1505 control cable from the LN-10 to the 14-pin MS-style connector.

• Connect the electrode cable to the output terminal of polarity required by the electrode. Connect the work lead to the other terminal.

• Set the meter polarity switch on the front of the Invertec® to coincide with wire feeder polarity used.

• See the LN-10 manual for details on accessing Control DIP Switch. Dip Switches for the V350 and the same settings may be used for the V450.

LN-15 Connection Instructions (See Figure A.4)

• Turn the Invertec® power switch "off".

• Connect the electrode cable to the output terminal of polarity required by electrode. (See Figures below)

• Set the meter polarity switch on the front of the Invertec® to coincide with wire feeder polarity used.

LN-25 Connection Instructions

• Turn the Invertec® power switch "off".

• Connect the electrode cable to the output terminal of polarity required by electrode. Connect the work lead to the other terminal.

• LN-25 with Remote Control 6-Pin (K444-1) and 14-pin (K444-2) remotes can be connected directly to the 6-pin & 14-pin MS-style connectors. The 42 Volt Remote Voltage and Output Control (K624-1) Kit can be connected to the V450’s 14-pin MS-style connector using Remote Control Cable assembly K627- [ ]. LN-25s with a K431-1 remote kit can be connected to the V450’s 14-pin MS-style connector using a K432 cable and K876 adapter. (See connection diagram S19899). Or the K432 cable could be modified with a K867 Universal Adapter Plug (See connection diagram S19405) to connect it to the V450’s 14-pin MS-style connector.

FIGURE A.4

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INVERTEC® V450-PRO

A-7 A-7

INSTALLATION

LN-742 Connection Instructions

• Turn the Invertec® power switch "off"

• A K1819-1 Input cable assembly is required to connect the LN-742 to the Invertec®.

• Connect the control cable from the LN-742 to the 14-pin MS-style connector.

• Connect the electrode cable to the output terminal of the polarity required by electrode. Connect the work lead to the other terminal.

• Set the meter polarity switch on the front of the Invertec® to coincide with wire feeder polarity used. The wire feeder will now display the welding voltage.

• If a remote control such as K857 is to be used with the LN-742, the remote can be connected directly to the 6-pin MS-style connector on the front of the Invertec® or use a K864 adapter to connect the LN-742 and the remote to the 14-pin MS-style connector.

Cobramatic Connection Instructions

• Turn the Invertec® power switch "off"

• Connect the control cable from the Cobramatic to the 14-pin MS-style connector.

• Connect the electrode cable to the output terminal of the polarity required by electrode. Connect the work lead to the other terminal.

• Set the meter polarity switch on the front of the Invertec® to coincide with wire feeder polarity used.

• If a remote control such as K857 is to be used with the Cobramatic, the remote can be connected directly to the 6-pin MS-style connector on the front of the Invertec® or use a K864 adapter to connect the cobramatic and the remote to the 14-pin MSstyle connector.

General Instructions for Connection of Wire Feeders to V450-Pro

Wire feeders other than those listed above may be used provided that the auxiliary power supply rating of the V450-Pro is not exceeded and the V450-PRO output is not actively controlled by the wire feeder. (Like an LN-9). K867 universal adapter plug is required. See connection diagram S24985 in Operator Manual.

REMOTE CONTROL OF INVERTEC®

Remote Control K857, Hand Amptrol K963 and Foot Amptrol K870 may be used.

PARALLEL OPERATION

The V450-Pro are operable in parallel in CC mode. For best results, the currents of each machine should be reasonably equally balanced. As an example, with two machines set up in parallel for a 800 amps procedure, each machine should be set to deliver approximately 400 amps, not 450 amps from one and 350 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 control pots in identical positions. Use the output control pots to balance the currents and maintain the desired current. The arc control pots should be kept identical on the two machines.

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TIG Module K930-2

The TIG Module connects to the Factory and Advanced Process control cable. Connect the K936-1 to the 14-Pin MSstyle connector.

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V450-Pro versions with a K936-1 (9-14 pin)

INVERTEC® V450-PRO

A-8 A-8

NOTES

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INVERTEC® V450-PRO

B-1 B-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Case Front Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Hidden Middle Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

TIG GTAW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

CV-Innershield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Weld Mode Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Memory Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

TABLE OF CONTENTS - OPERATION SECTION

Weld Mode Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Pulse Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Remote Control Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10

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INVERTEC® V450-PRO

B-2 B-2

SAFETY PRECAUTIONS

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 closed containers.

OPERATION

• After welding, the meter holds the actual current value for 5 seconds. Output adjustment while in the "hold" period results in the "prior to operation" characteristics stated above. The displays blink indicating that the machine is in the "Hold" period.

3. VOLT METER

• Prior to CV operation (current flow), the meter displays desired preset voltage value (+/- .5V).

• Prior to STICK or TIG operation, the meter displays the Open Circuit Voltage of the Power Source or four dashes if the output has not been turned on.

• During welding, this meter displays actual average volts.

• After welding, the meter holds the actual voltage value for 5 seconds. The displays blink indicating that the machine is in the "Hold" period.

• Output adjustment while in the "hold" period results in the "prior to operation" characteristics stated above.

------------------------------------------------------------------------

ARC RAYS can burn eyes and skin.

• Wear eye, ear and body protection.

------------------------------------------------------------

See additional warning information at

front of this operator’s manual.

-----------------------------------------------------------

GENERAL DESCRIPTION

The Invertec® V450-Pro offers multi-process CV, CC, and DC welding and is rated 570 amps, 43 volts at a 60% duty cycle.

DUTY CYCLE

The V450-Pro is rated at 570 amps, 60% duty cycle (based on a 10 minute cycle). It is also rated at 450 amps, 100% duty cycle.

OPERATIONAL FEATURES and CONTROLS:

UPPER CONTROL PANEL

1. ON, OFF- SWITCH

4. OUTPUT CONTROL

• Output control is conducted via a single turn potentiometer.

• Adjustment is indicated by the meters as stated above.

• When in TIG modes, this control sets the maximum welding current. Full depression of a foot or hand Amptrol results in the preset level of current.

5. WELD TERMINALS-REMOTE / ON

• Two status lights indicate the location of trigger control as determined by the "WELD TERMINALS" push button.

• If trigger control is local "weld terminals on", the ON display will be lit.

• If trigger control is remote "weld terminals remotely controlled", the REMOTE display will be lit.

• The unit will power up in "pre-determined preferred" trigger modes.

STICK = ON

CV = REMOTE

TIG = REMOTE if remote output controls are attached

to the machine.

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2. AMPS Meter

• Prior to STICK or TIG operation (current flow), the meter displays preset current value (either +/- 2 amps or +/- 3% (e.g. 3 amps on 100), whichever is greater).

• Prior to CV operation, the meter displays four dashes indicating AMPS unable to be preset.

• During welding, this meter displays actual average amps.

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TIG = ON if remote output controls are not attached to

the machine.

For all versions, these trigger modes can be over-ridden (switched) with the WELD TERMINALS push button. When changed, the unit will power up in the configuration it was in

INVERTEC® V450-PRO

B-3 B-3

OUTPUTOUTPUT

MPSMPS

AA

O

LTSOLTS

VV

REMOTEREMOTE

LOCALLOCAL

CONTROLCONTROL

SELECTSELECT

SOFT

C

RIP

HI-FREQ

TIG

TOUCH

S

TART

TIG

OUTPUTOUTPUT

MPSMPS

AA

O

LTSOLTS

VV

REMOTEREMOTE

LOCALLOCAL

CONTROLCONTROL

SELECTSELECT

SOFT

C

RIP

HI-FREQ TIG

TOUCH S

TART

TIG

6.

THERMAL

• This status light indicates when the power source has been driven into thermal overload. If the output terminals were

OPERATION

CC-STICK SOFT: The Stick Soft process features contin-

uous control ranging from 5 to 570 amps. This mode was

intended for most SMAW applications, and Arc Gouging. "ON", the "ON" light will blink indicating that the output will be turned back on once the unit cools down to an acceptable temperature level. If the unit was operating in the "REMOTE" mode, the trigger will need to be opened before or after the thermal has cleared and closed after the machine has cooled down to an acceptable temperature to establish output.

• Arc Gouging: Setting the output of the Stick Soft mode to 570 amps or setting the arc control to maximum will enable the arc-gouging mode. The actual output current will depend on the size of carbon used. The recommended maximum size carbon is 3/8"(9.5mm).

• The Hot Start control regulates the starting current at arc initiation. Hot Start can be adjusted from minimum

7.

CONTROL-REMOTE / LOCAL

• Two status lights indicate the location of output control as pre-determined by the power sources auto-configure system.

• The LOCAL display will be lit when control is at the power

source.

• The REMOTE display will be lit when a remote pot/control

is detected. These Output Control configurations can be overridden (switched) with the CONTROL push button. When changed, the unit will power up in the configuration it was in when it was last powered down.

(0), with no additional current added at arc start, to maximum (10), with double the preset current or 570 amps (max of machine) added for the first second after arc initiation.

• The Arc Control regulates the Arc Force to adjust the short circuit current. The minimum setting (-10) will produce a "soft" arc and will produce minimal spatter. The maximum setting (+10) will produce a "crisp" arc and will minimize electrode sticking.

CC-STICK CRISP:The Stick Crisp mode features continuous control from 5 to 570 amps with a crisp shorting response optimized for E6010 type electrodes.

Hidden Middle Control Panel – Process Set Up Panel

The middle control panel is removable to allow for upgrades (see Field Installed Options/Accessories).

Additionally, this panel is hidden by an access door to provide protection to the controls.

8. WELD MODE SELECT - STANDARD (See Figure B.1)

The Mode Control button selects from the following welding modes.

2

6

7

8

9

• Arc Gouging: Setting the output of the Crisp mode to 570 amps or setting the arc control to maximum will enable the arc-gouging mode. The actual output current will depend on the size of carbon used. The recommended maximum size carbon is 3/8"(9.5mm).

• The Hot Start control regulates the starting current at arc initiation. Hot Start can adjust starting current up or down by 25% of the preset value. The recommended setting for Hot Start is 5 where the initial current is equal to the preset current.

FIGURE B.1

3

4

1

5

10

13

14

12

11

15

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INVERTEC® V450-PRO

B-4 B-4

• The Arc Control regulates the Arc Force to adjust the short circuit current. The minimum setting (-10) will produce a "soft" arc and will produce minimal spatter. The maximum setting (+10) will produce a "crisp" arc and will minimize electrode sticking.

TIG GTAW: The TIG mode features continuous control from 5 to 570 amps. The TIG mode can be run in either the TIG touch start or high frequency (optional equipment required) assisted start mode.

• The Hot Start control selects the starting mode desired. A setting of less than 5, the TIG lift start mode is selected. The OCV is controlled below 10v and the short circuit "TIG touch" current is maintained at 25 amps independent of the preset current.

When the tungsten is lifted, an arc is initiated and the output is regulated at the preset value. Hot start settings between 0 and 5 regulate the arc initiation current. A setting of 5 results in the most positive arc initiation. A setting of 0 reduces hot start.

• Hot Start settings between 5 and 10, select high frequency assisted starting TIG mode. In this range, the OCV of the machine is controlled between 50 and 70 volts. If using the Lincoln K930-1 TIG Module, set the Hot start to 10 for maximum OCV.

• The Arc Control is not used in the TIG mode.

OPERATION

CV-WIRE: The CV-WIRE mode features continuous

control from 10 to 40 volts. This mode was intended for most GMAW, FCAW, and MCAW applications.

• The Hot Start control is not used in the CV-WIRE mode.

• The Arc Control regulates pinch effect. At the minimum setting (-10), minimizes pinch and results in a soft arc. Low pinch settings are preferable for welding with gas mixes containing mostly inert gases. At the maximum setting (+10), maximizes pinch effect and results in a crisp arc. High pinch settings are preferable for welding FCAW and GMAW with CO

CV-INNERSHIELD: The CV-INNERSHIELD mode features continuous control from 10 to 45 volts. This mode was designed for self-shielded flux cored wires that require tight voltage control.

• The Hot Start control is not used in the CV-INNERSHIELD mode.

• The Arc Control regulates pinch effect. At the minimum setting (-10), minimizes pinch and results in a soft arc. At the maximum setting (+10), maximizes pinch effect and results in a crisp arc. Most selfed wires work well at an Arc Control setting of 5.

2.

shield-

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INVERTEC® V450-PRO

B-5 B-5

OUTPUT KNOBOUTPUT KNOB

REMOTEREMOTE

ONON REMOTEREMOTE

LOCALLOCAL

WELD TERMINALSWELD TERMINALS

CONTROLCONTROL

SELECTSELECT SELECTSELECT

MPSMPS

AA

OLTSOLTS

VV

ADVANCE PROCESS PANEL- MIDDLE SECTION OF WELDER (OPTIONAL)

MEMORYMEMORY

MEMORY BUTTON MEMORY BUTTON

(M1 THRU M8)(M1 THRU M8)

SELECT BUTTONSELECT BUTTON

(HOT START OR ARC CONTROL)(HOT START OR ARC CONTROL)

ADJUST KNOB ADJUST KNOB

(0 THRU +10 HOT START) (0 THRU +10 HOT START)

(-10 THRU 0 AND 0 THRU +10 ARC CONTROL)(-10 THRU 0 AND 0 THRU +10 ARC CONTROL)

SELECT KNOB SELECT KNOB

(SCOLLS WELDING PROCESSES)(SCOLLS WELDING PROCESSES)

SELECTSELECT

ADJUST ADJUST

SELECTSELECT

OUTPUT KNOBOUTPUT KNOB

REMOTEREMOTE

ONON

REMOTEREMOTE

LOCALLOCAL

WELD TERMINALSWELD TERMINALS

CONTROLCONTROL

SELECTSELECT

MPSMPS

AA

OLTSOLTS

VV

ADVANCE PROCESS PANEL- MIDDLE SECTION OF WELDER (OPTIONAL)

MEMORYMEMORY

MEMORY BUTTON MEMORY BUTTON

(M1 THRU M8)(M1 THRU M8)

SELECT BUTTONSELECT BUTTON (HOT START OR ARC CONTROL)(HOT START OR ARC CONTROL)

ADJUST KNOB AD JUS T K N OB

(0 THRU +10 HOT START) (0 THRU +10 HOT START)

(-10 THRU 0 AND 0 THRU +10 ARC CONTROL)(-10 THRU 0 AND 0 THRU +10 ARC CONTROL)

SELECT KNOB SELECT KNOB

(SCOLLS WELDING PROCESSES)(SCOLLS WELDING PROCESSES)

SELECTSELECT

ADJUST ADJUST

SELECTSELECT

OPERATION

8A. WELD MODE SELECT-FOR MACHINES EQUIPPED WITH OPTIONAL ADVANCED PROCESS PANEL

(See Figure B.2 UPPER AND MIDDLE SECTION)

See (WELD MODE DETAILS) in this section.

To program welding modes, the SELECT knob is used to Scroll through all welding modes. The MEMORY button is used to store and access welding modes into locations M1 thru M8.

Modes: In addition to the 5 welding modes described in SECTION 7, the Advance Process Panel allows you to

select the Following additional modes.

• Constant Power mode

In the Power Mode; The work point will be in the Volts window. The Amp window will have CP displayed indicating Constant Power. Once current starts flowing and during the 5 second “Hold” feature the displays will show Volts and Amps respectively.

• Gouge Mode

The gouging mode is specifically designed for carbon arc gouging with electrodes up to 3/8”.

• Pulsed Modes

In Pulse Modes; The work point will be in the Amps window and should be set close to the wire feed speed of the wire feeder in inches per minute. The Volts window will have SPd displayed indicating Wire Feed Speed. Once current starts flowing and during the 5 second “Hold” feature the displays will show amps and volts.

Pulse Mode features that are displayed while selecting a Welding pulse mode are listed below: Steel - .030”, .035”, .045”, .052”, 1/16” – Argon Blends Stainless Steel - .030”, .035”, .045” – Argon Blends &

Helium/Argon Blends Aluminum - .035”, 3/64”, 1/16” – 4043 & 5356 Metal Core - .045”, .052”, 1/16” – Argon Blends Nickel - .035”, .045” – Argon/Helium blends

FIGURE B.2

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INVERTEC® V450-PRO

B-6 B-6

OPERATION

MEMORY SELECTIONS:

(See Figure B.2 for location of controls)

The MEMORY button and SELECT knob are used

together to select a welding process and store it in memory (M1 thru M8). The SELECT knob scrolls through the welding process modes and memory M1 thru M8. The MEMORY button stores the welding process in memory.

• SELECT button" (The right button) selects between

the "Hot Start" or "Arc Control". The < will indicate the active feature shown below.

Right Digital Window "Hot Start" (-10 to 0 +10) "Arc Control" (0 to 10) <

• The ADJUST knob adjusts the desired settings for

the Hot Start or Arc Control feature that is active.

WELDING PROCESS MODES AVAILABLE

Stick SMAW, TIG GTAW Gouge CAG, CV MIG GMAW CV Flux Core, Pulse MIG

ELECTRODE MATERIAL

Steel, Metal Core, Stainless, Aluminum, Nickel

EXAMPLE OF SAVING WELDING MODES TO MEMORY

The following example is how to select Pulse MIG using .035 steel and store it into memory.

1. Turn the SELECT knob until welding process is dis-

played.

RIGHT WINDOW LEFT WINDOW

Pulse MIG Argon Blends

Steel .035

2. Wait two seconds and the right window will display Arc Control on the second line on the right side.

Pulse MIG Argon Blends

Steel .035 Arc Cntrl ### <

3. SPd is displayed in the upper right Volts window. The left Amps window matches the desired wire feed speed that is set on the wire feeder. Adjust the OUTPUT knob until desired number is displayed.

4. Start welding. If the arc length is too short, turn the

Output knob up. If the arc length is too long, turn the Output knob down.

The Arc Control, which is displayed in the right digital window, can be used to fine-tune the arc length and characteristics.

5. After all adjustments have been made press and

hold the MEMORY button until the display changes. The right and the left window will display a memory position, for example M1 (or turn knob to select memory of your choice). To store in M1, push the MEMORY button again to save the Pulse Mig mode to memory M1.

6. The display in the digital windows read as follows: M1 Pulse MIG Argon Blends

Steel .035 Arc Cntrl 1.2

7. To save a second welding mode to a memory position of your choice, turn the SELECT knob until the desired welding process mode is displayed in right digital window. Then follow steps 2 thru 6.

8. Adjust the output control to the correct wire feed setting and the V450-PRO is ready to weld again. (NOTE: The wire feed speed setting is not stored in memory and will need to be reset.)

9. Adjust the Arc Control and note that the M1 goes away indicating that the V450-PRO settings no longer match what is stored in memory. Going back to the original settings will not bring the M1 back. You will need to push the MEMORY button to recall the original settings in M1.

NOTE: After all memory; M1 thru M8, are used and the welder needs to store another welding process, a new welding process will overwrite what was originally in the memory and will read:

Save to MEM

M1 Overwrite M1, which previously stored Pulse Mig, is now overwritten with the new welding process.

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INVERTEC® V450-PRO

B-7 B-7

OPERATION

WELD MODE DETAILS:

Mode Range Comments

Stick Soft 55 - 570 amps The stick soft mode is the best selection for general stick

applications. Arc Control = Arc Force Hot Start = Initial hot start current (min = start a match set amps, Max.

= greatest hot start current) During hot start, arc force is set at high and is fast response.

For gouging applications: Turn current up to 570 amps.

Stick Crisp 55 - 570 amps The stick crisp mode features an aggressive arc force routine well suit-

ed for Exx10, Exx11 series electrodes. Arc Control = Arc Force Hot Start = Initial hot start current (Mid range = welding current and will

vary up and down with knob control.) During hot start, arc force is set at high and is fast response.

For gouging applications: Turn current up to 570 amps.

GTAW (Tig mode) 5 - 570 amps The tig mode produces a soft, steady constant current waveform for

either touch start or high frequency assisted start DC GTAW applications. Hot Start = Min to Mid range = Touch start with low OCV Mid to Max range = High frequency assisted starting with adjustable OCV up to 70 volts.

GMAW - CV 10 - 45 volts The GMAW - CV mode is the best selection for general MIG welding,

Metal core, and gas shielded applications. Arc Control = Pinch (Min = min pinch, softest arc),

(Max = max pinch, crispest arc)

FCAW-SS 10 - 45 volts The FCAW-SS mode is designed for Self Shielded Innershield products

that require tight voltage control. For example; the NR 203 series or NR

207) Arc Control = Pinch (Min = min pinch, softest arc),

(Max = max pinch, crispest arc)

ADVANCED PULSE PANEL WELDING PROGRAMS

Gouging 60 - 570 amps The gouging mode is specifically designed for carbon arc gouging with

electrodes up to 3/8”.

GMAW - Power 0.1 - 20 KW The GMAW - power mode is similar in operation to other GMAW

modes. The power mode features a very stable short arc performance, which is especially good when welding small diameter (.025 and .030 steel and stainless) wires for low procedures. The short arc steel and stainless applications, a fast response for spray applications, and a drooper type spray mode characteristic for Aluminum.

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INVERTEC® V450-PRO

B-8 B-8

OPERATION

PULSE PROGRAMS:

MODE IPM*

.030 Steel 75 - 800 .035 Steel 50 - 800 .045 Steel 60 - 800 .052 Steel 60 - 750 1/16 Steel 60 - 600 .045 Metal Core 60 - 700 .052 Metal Core 60 - 500 1/16 Metal Core 60 - 500 .030 Stainless Ar Blends 100 - 800 .030 Stainless He Ar CO

2

100 - 800

.035 Stainless Ar Blends 70 - 800 .035 Stainless He Ar CO

2

70 - 700

.045 Stainless Ar Blends 50 - 700 .045 Stainless He Ar CO

2

60 - 700

.035 Aluminum 4043 125 - 700 .035 Aluminum 5356 130 - 750 3/64 Aluminum 4043 85 - 600 3/64 Aluminum 5356 85 - 700 1/16 Aluminum 4043 55 - 300 1/16 Aluminum 5356 65 - 400

The V450 pulse programs are non-synergic and allow independent control of the wire feed speed and the arc length. The Output Control Knob on the V450, adjusts an "SPD" value. Similar to trim, the "SPD" value indicates the relative arc length setting. The value of "SPD" is meant to be a starting point at which to set the arc length relative to the wire feed speed. Depending on the application, the "SPD" value can be adjusted to obtain the desired arc length.

The "SPD" value displayed on the V450 may not match the actual wire feed speed!

The operation of the Arc Control knob on the V450 is similar to the Power Wave series. As Arc Control is increased, the frequency is increased and the background reduced. Decreasing Arc Control will reduce frequency and increase background current. Arc Control acts to fine tune the arc plasma to the specific application. Preferred gas selections:

Steel Argon Blends = Argon with CO % or Oxygen additions from 2 to 5%.

COMMENTS

additions from 2 to 20

2

.035 Nickel Alloys .045 Nickel Alloys

(Non Adaptive) (Non Adaptive)

60 - 700 60 - 600

.035 4043 (4x Pulse on Pulse) 125 - 600 3/64 4043 (4x Pulse on Pulse) 85 - 400 1/16 4043 (4x Pulse on Pulse) 65 - 315 .035 5356 (5x Pulse on Pulse) 140 - 700 3/64 5356 (5x Pulse on Pulse) 100 - 550 1/16 5356 (5x Pulse on Pulse) 75 - 360

*IPM (INCHES PER MINUTE)

Stainless Argon Blends = Argon with Oxygen additions up to 2%.

Stainless Argon Blends = Argon with Oxygen additions up to 2%

Stainless He Ar CO2= ~ 90% Helium, 7 1/2 % Argon 2 1/2 CO Aluminum 100% Argon

The Nickel Alloy pulse programs are non adaptive. The operator sets the output control knob to deliver the correct arc length at the desired wire feed speed and stick out. While welding, the operator manipulates the stick out to maintain the correct arc length. This method of operation produces very stable arc performance considering the nature of nickel alloys.

Preferred gas: Argon/Helium Blends = for the best results add helium to the argon base from 0-25%.

PULSE ON PULSE

Arc Control = Pulse on Pulse frequency. For faster travel speed welds, the arc control should be increased. For larger puddle, slower travel speeds, the arc control should be decreased.

2

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INVERTEC® V450-PRO

B-9 B-9

OPERATION

LN-10/DH-10 Wire Feeder Compatibility Note:

The LN-10 and DH-10 feeders can be used to pulse weld and in the power mode with the panel. The displays on the LN-10 & DH-10 do not show the wire feed speed or power.

9. SERIAL PORT FOR SOFTWARE UPDATES

10. HOT START and ARC CONTROL features have different

functions depending on the welding Mode that is active. Each feature is described under the welding mode heading. (See

Item 8 or 8A for specified Mode Operations) (See Figure B.1 or B.2)

LOWER CASE PANEL

The output studs, Meter Polarity switch and remote connector are located on the lower case front.

11. Both Output terminals are "STUD" connectors.

12. The METER POLARITY switch is located above the out-

put connectors. 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.

13. 6-pin MS-style connector for remote control.

14. 14-PIN MS-style connector for wire and remote control.

(See Figure B.1)

TIG Mode

• The remote will default to the 6-pin MS-style if a remote control is connected to the 6-pin MS-style and to the 14-pin MS-style connector. If a remote is not connected to the 6-pin MS-style connector, then the remote will default to the 14-pin MS-style connector if a remote is connected.

• If a remote control is connected to any of the MSstyle connectors, the WELD TERMINAL control will default to REMOTE. If there are not any remote control devices attached, the WELD TERMINAL control will default to ON.

CC-Stick Modes

• The remote will default to only the 6-pin MS-style connector if a remote is connected to it.

• The WELD TERMINAL control will default to ON with or without a remote connected.

Types of Remote OUTPUT CONTROL

• The Invertec® V450-Pro’s Output Control can be controlled by either a potentiometer connected between 77 & 75 with the wiper connected to 76 or a 0V to 10V DC supply connected between 76 & 75. (76 needs to be positive)

• 14-Pin Ms-style connector lead 75 is pin G, lead 76 is pin F and lead 77 is pin E.

• 6-Pin Ms-style connector lead 75 is pin C, lead 76 is pin B and lead 77 is pin A.

15. AUXILIARY POWER

• 115VAC, 42VAC and 24VAC power is available from the 14-pin MS-style connector.

• 42 VAC supply is rated at 10 amps.

• 24 VAC supply is rated at 10 amps.

• 115VAC outlet rated at 15* amps.

* Earlier models used a 10 amp circuit breaker.

REMOTE CONTROL SELECTION

The Invertec® V450-Pro has auto sensing of remote output controls. If after connecting or removing a remote, the Invertec® V450-Pro did not configure the way you would like the local or remote control settings can be changed by pushing the OUTPUT CONTROL or WELD TERMINAL button. (A user cannot select between the 6 and 14 pin MS-style connectors.)

CV modes

• The remote will default to the 14-pin MS-style connector if a remote is connected. If no remote is connected to the 14-pin MS-style connector, then the remote will default to the 6-pin MS-style connector if a remote is connected to it.

• In all of the CV modes, the WELD TERMINAL control will default to REMOTE.

Potentiometer Control

• The total resistance should be between 2,000 ohms (2K) and 10,000 ohms (10K)

• The machine output will be at minimum when lead 76 (wiper) is at the end of the potentiometer that is connected to 75. The machine’s output will increase as the wiper of the potentiometer is moved to the end that is connected to 77. (Note: In TIG mode, moving the lead 76 (wiper) to lead 77 would produce the current that has been set by the Invertec® V450-Pro’s front panel Output Control.)

• Remotes of this type offered by Lincoln Electric are the K857, K812 and K870.

Voltage Control

• The supply should be an isolated supply. (Not referenced to earth ground, any auxiliary power from the Invertec® V450-Pro or the welding output) The supply should be capable of supplying at least 20mA.

• 0 volts supplied to 76 will set the Invertec® V450-Pro to minimum output for the mode that has been selected while 10 volts supplied to 76 will set the Invertec® V450-Pro to the maximum output for the mode. (NOTE: In TIG mode, 10 volts supplied to lead 76 would produce the current that has been set by the Invertec® V450-Pro’s front panel Output Control.)

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INVERTEC® V450-PRO

B-10 B-10

OPERATION

Types of Remote WELD TERMINAL Control

• The Invertec® V450-Pro’s Weld Terminals can be controlled from each of the MS-style connectors. The circuit has a nominal OCV of 15VDC and requires a dry contact closure (less than 100 ohms) to activate the output of the Invertec® V450-Pro.

• 14-Pin MS-style connector, the Weld Terminals are controlled from pin C (lead 2) and pin D (lead 4). Pin C is positive.

• 6-Pin MS-style connector, the Weld Terminals are controlled from pin D (lead 2) and pin E (lead 4). In the 6-pin MS-style connector pin D is positive.

LIMITATIONS

• The V450-Pro is not recommended for processes other than those listed.

• The V450-Pro can only be used with the recommended equipment and options.

RECOMMENDED PROCESSES

Properly equipped, the Invertec® V450-Pro supports GMAW-P, FCAW, SMAW, GTAW and CAC-A processes for a variety of materials, including mild steel, stainless steel, cored wires, and aluminum.

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INVERTEC® V450-PRO

C-1 C-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

TABLE OF CONTENTS - ACCESSORIES SECTION

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INVERTEC® V450-PRO

C-2 C-2

OPTIONS / ACCESSORIES

K857 Remote Output Control K814 Arc Start Switch K812 Hand Operated Amptrol K870 Foot Operated Amptrol

NOTE: All of the above remote controls connect direct-

ly to the 6-pin MS-style connector, with either a K864 or K876 adapter and connect it to the 14 pin wire feeder MS-style connector. (See Diagram in Operator Manual)

K930-[ ] TIG Module K428, K446, K449 LN-25 * K617 (-1 or -2) K618 (-1 or -2) LN-742 K2327-[ ] LF-72 K2426-[ ] LF-74 K1559-1, K1564-1 LN-10 K1499-1, K1521-1 DH-10 K1587-1 Cobramatic

*Not recommended for pulse welding

ACCESSORIES

FIELD INSTALLED OPTION (ALL VERSIONS)

• K1763-1 Advanced Process Panel

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INVERTEC® V450-PRO

D-1 D-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

TABLE OF CONTENTS - MAINTENANCE SECTION

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INVERTEC® V450-PRO

D-2 D-2

CAPACITOR

TERMINALS

RESISTOR

CAPACITOR

TERMINALS

RESISTOR

CAPACITOR TERMINALS

RESISTOR

CAPACITOR TERMINALS

RESISTOR

SAFETY PRECAUTIONS

MAINTENANCE

VISUAL INSPECTION

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourse lf fr om work an d

ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

EXPLODING PARTS can cause injury.

•

Failed parts can explode or cause other parts to explode when power is applied.

Always wear a face shield and long

•

sleeves when servicing.

------------------------------------------------------------------------

See additional warning information throughout this Operator’s Manual

-----------------------------------------------------------

CAPACITOR DISCHARGE PROCEDURE

1. Obtain a power resistor (25 ohms, 25 watts).

2. Hold resistor body with electrically insulated glove. DO NOT TOUCH TERMINALS. tor terminals across the two studs in the position shown. Hold in each position for 1 second. Repeat for all three capacitors.

Connect the resis-

Clean interior of machine with a low-pressure air stream. Make a thorough inspection of all components. Look for signs of overheating, broken leads or other obvious problems. Many problems can be uncovered with a good visual inspection.

ROUTINE MAINTENANCE

1. Every 6 months or so, the machine should be cleaned with a low pressure airstream. Keeping the machine clean will result in cooler operation and higher reliability. Be sure to clean these areas:

• All printed circuit boards

• Power switch

• Main transformer

• Input rectifier

• Auxiliary Transformer

• Reconnect Switch Area

• Fan (Blow air through the rear louvers)

2. Examine the sheet metal case for dents or breakage. Repair the case as required. Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained. All external sheet metal screws must be in place to insure case strength and electrical ground continuity.

3. Use a DC voltmeter to check that voltage is not present across the terminals on three capacitors.

OVERLOAD PROTECTION

The machine is electrically protected from producing high output currents. Should the output current exceed 570A, an electronic protection circuit will reduce the current to approximately 100A. 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.

Thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the Power Switch may be left on and the reset should occur within a 15 minute period.

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See Voltage Current Calibration Procedure.

INVERTEC® V450-PRO

D-3 D-3

55

11

77

44

33

66

22

55

11

77

44

33

66

22

MAINTENANCE

1. Case Front Assembly

2. Control Box & Horizontal Plate

3. Base, Lift Bale & Fan Assembly

4. Input Assembly

5. Transformer & Output Assembly

6. Switch Board Heatsink Assembly

7. Covers Assembly

Figure D.1 - Major Component Location

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INVERTEC® V450-PRO

D-4 D-4

NOTES

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INVERTEC® V450-PRO

E-1 E-1

INPUT

CONTACTOR INPUT

RECTIFIER

R

E

C

O

N

E

C

T

CONTROL BOARD

RIGHT

SWITCH

BOARD

LEFT

SWITCH

BOARD

MAIN

TRANSFORMER

CURRENT

SENSOR

CHOKE

OUTPUT

TERMINAL

OUTPUT

TERMINAL

POWER

BOARD

115VAC

RECEPTACLE

P

O

W

E

R

S

W

I

T

C

H I

N

P

U

T

B

O

A

R

D

FAN

MOTOR

AUX.

TRANS.

AUX.

TRANS.

RECTIFIER

AUX.

RECONNECT

PRIMARY

CURRENT

SENSOR

WIRE FEEDER

RECEPTACLE RS232

CONN.

THERMOSTATS

STATUS

LIGHT

THERMAL

LIGHT

CURRENT FEEDBACK

VOLTAGE FEEDBACK

65VDC

40VDC

CONTROL SIGNALS

PWM

CAPACITOR

VOLTAGE

FEEDBACK

PWM

DRIVE

VOLTAGE

SENSE

RECEPTACLE

#1

#2

S

W

I

T

C

H

DRIVE

FEEDBACK VOLTAGE CAPACITOR

INPUT

CONTACTOR

INPUT

RECTIFIER

R E C O N N E C T

CONTROL BOARD

RIGHT SWITCH BOARD

LEFT SWITCH BOARD

MAIN

TRANSFORMER

CURRENT

SENSOR

CHOKE

OUTPUT

TERMINAL

OUTPUT

TERMINAL

POWER BOARD

115VAC

RECEPTACLE

P O W E R

S W

I T C H

I N P U T

B O A R D

FAN

MOTOR

AUX.

TRANS.

AUX.

TRANS.

RECTIFIER

AUX.

RECONNECT

PRIMARY

CURRENT

SENSOR

WIRE FEEDER RECEPTACLE

RS232

CONN.

THERMOSTATS

STATUS

LIGHT

THERMAL

LIGHT

CURRENT FEEDBACK

VOLTAGE FEEDBACK

65VDC

40VDC

CONTROL SIGNALS

PWM

CAPACITOR VOLTAGE FEEDBACK

PWM

DRIVE

VOLTAGE

SENSE

RECEPTACLE

#1

#2

S

W

I

T

C

H

DRIVE

FEEDBACK

VOLTAGE

CAPACITOR

TABLE OF CONTENTS-THEORY OF OPERATION SECTION

Theory of Operation ................................................................................................................................. Section E

Block Logic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

General Description, Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Switch Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

Output Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6

IGBT Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7

Typical IGBT Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8

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FIGURE E.1 BLOCK LOGIC DIAGRAM

INVERTEC® V450-PRO

E-2 E-2

INPUT

CONTACTOR INPUT

RECTIFIER

R

E

C

O

N

E

C

T

CONTROL BOARD

R

IGHT

SWITCH

BOARD

L

EFT

SWITCH

BOARD

M

AIN

TRANSFORMER

CURRENT

S

ENSOR

CHOKE

OUTPUT

TERMINAL

O

UTPUT

TERMINAL

POWER

BOARD

115VAC

RECEPTACLE

P

O

W

E

R

S

W

I

T

C

H I

N

P

U

T

B

O

A

R

D

FAN

MOTOR

A

UX.

TRANS.

AUX.

TRANS.

RECTIFIER

AUX.

RECONNECT

PRIMARY

CURRENT

SENSOR

WIRE FEEDER

RECEPTACLE RS232

CONN.

THERMOSTATS

STATUS

LIGHT

THERMAL

LIGHT

CURRENT FEEDBACK

VOLTAGE FEEDBACK

65VDC

40VDC

CONTROL SIGNALS

P

WM

CAPACITOR

VOLTAGE

FEEDBACK

PWM

DRIVE

VOLTAGE

SENSE

RECEPTACLE

#1

#2

S

W

I

T

C

H

DRIVE

FEEDBACK VOLTAGE CAPACITOR

INPUT

CONTACTOR

INPUT

RECTIFIER

R E C O N N E C T

CONTROL BOARD

R

IGHT SWITCH BOARD

L

EFT SWITCH BOARD

M

AIN

TRANSFORMER

CURRENT

S

ENSOR

CHOKE

OUTPUT

TERMINAL

O

UTPUT

TERMINAL

POWER BOARD

115VAC

RECEPTACLE

P O W E R

S W

I T C H

I N P U T

B O A R D

FAN

MOTOR

A

UX.

TRANS.

AUX.

TRANS.

RECTIFIER

AUX.

RECONNECT

PRIMARY

CURRENT

SENSOR

WIRE FEEDER RECEPTACLE

RS232

CONN.

THERMOSTATS

STATUS

LIGHT

THERMAL

LIGHT

CURRENT FEEDBACK

VOLTAGE FEEDBACK

65VDC

40VDC

CONTROL SIGNALS

P

WM

CAPACITOR VOLTAGE FEEDBACK

PWM DRIVE

VOLTAGE

SENSE

RECEPTACLE

#1

#2

S

W

I

T

C

H

DRIVE

FEEDBACK

VOLTAGE

CAPACITOR

THEORY OF OPERATION

FIGURE E.2 - INPUT VOLTAGE AND PRECHARGE.

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POWER SOURCE GENERAL DESCRIPTION

The INVERTEC® V450-PRO is an inverter based welding power source that is designed to be a multiprocess welding system. It is a high performance, digitally controlled inverter capable of complex, highspeed waveform control. With the appropriate modular components it can support constant current, constant voltage and pulse welding processes. The output rating is 450 amps at 36 volts with a 100% duty cycle.

INPUT VOLTAGE AND PRECHARGE

The INVERTEC® V450-PRO can be connected for a variety of three phase voltages. Refer to Figure E.2. The initial input power is applied to the INVERTEC® V450-PRO through a line switch located on the front of the machine. Two phases of the three-phase input power is applied to the input board and both auxiliary transformers. The various secondary voltages developed by the #1 auxiliary transformer are applied to the input board, the power board rectifier and the fan motor. The 115 VAC secondary voltage developed by the No. 2 auxiliary transformer is applied to the 115 VAC receptacle.

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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

The 65 VDC produced from the power board rectifier is utilized by the power board to provide various DC voltages for the control board and wire feeder.

The two phases, which are connected to the input board through the power switch, are connected to the input rectifier. During precharge or “soft start” these two phases are current limited by the input board. This AC input voltage is rectified, and the resultant DC voltage is applied through the reconnect switches to the input capacitors located on the switch boards. The control board monitors the voltage across the capacitors. When the capacitors have charged to an acceptable level, the control board signals the input board to energize the main input contactor making all three phases of input power, without current limiting, available to the input capacitors. At this point, the INVERTEC® V450-PRO is in the “Run Mode” of operation. If the capacitors become under or overvoltage, the control board will signal the input board to deenergize the main input contactor, and the INVERTEC® V450-PRO will be disabled.

INVERTEC® V450-PRO

E-3 E-3

INPUT

C

ONTACTOR INPUT

R

ECTIFIER

R

E

C

O

N

E

C

T

CONTROL BOARD

RIGHT

S

WITCH

BOARD

L

EFT

SWITCH

BOARD

M

AIN

TRANSFORMER

CURRENT

SENSOR

C

HOKE

OUTPUT

TERMINAL

OUTPUT

T

ERMINAL

POWER

B

OARD

1

15VAC

RECEPTACLE

P

O

W

E

R

S

W

I

T

C

H I

N

P

U

T

B

O

A

R

D

FAN

M

OTOR

A

UX.

TRANS.

A

UX.

TRANS.

R

ECTIFIER

AUX.

RECONNECT

PRIMARY

CURRENT

SENSOR

WIRE FEEDER

RECEPTACLE RS232

CONN.

T

HERMOSTATS

STATUS

LIGHT

T

HERMAL

LIGHT

CURRENT FEEDBACK

VOLTAGE FEEDBACK

65VDC

4

0VDC

C

ONTROL SIGNALS

P

WM

DRIVE

C

APACITOR

VOLTAGE

FEEDBACK

CAPACITOR

VOLTAGE

F

EEDBACK

P

WM

DRIVE

VOLTAGE

SENSE

R

ECEPTACLE

#1

#2

S

W

I

T

C

H

INPUT

C

ONTACTOR

INPUT

R

ECTIFIER

R E C O N N E C T

CONTROL BOARD

RIGHT S

WITCH

BOARD

L

EFT SWITCH BOARD

M

AIN

TRANSFORMER

CURRENT

SENSOR

C

HOKE

OUTPUT

TERMINAL

OUTPUT

T

ERMINAL

POWER B

OARD

1

15VAC

RECEPTACLE

P O W E R

S W

I T C H

I N P U T

B O A R D

FAN

M

OTOR

A

UX.

TRANS.

A

UX.

TRANS.

R

ECTIFIER

AUX.

RECONNECT

PRIMARY

CURRENT

SENSOR

WIRE FEEDER

RECEPTACLE

RS232

CONN.

T

HERMOSTATS

STATUS

LIGHT

T

HERMAL LIGHT

CURRENT FEEDBACK

VOLTAGE FEEDBACK

65VDC

4

0VDC

C

ONTROL SIGNALS

P

WM

DRIVE

C

APACITOR VOLTAGE FEEDBACK

CAPACITOR VOLTAGE F

EEDBACK

P

WM

DRIVE

VOLTAGE

SENSE

R

ECEPTACLE

#1

#2

S

W

I

T

C

H

THEORY OF OPERATION

FIGURE E.3 — SWITCH BOARDS AND MAIN TRANSFORMER

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SWITCH BOARDS AND MAIN TRANSFORMER

There are two switch boards in the INVERTEC® V450PRO, each containing an input capacitor and insulated gate bipolar transistor (IGBT) switching circuitry. Refer to Figure E.3. When the machine reconnect switches are configured for a lower input voltage (below 300 VAC) the input capacitors are connected in parallel. When the machine is configured for higher input voltages (300 VAC and above) the input capacitors are connected in series.

When the input capacitors are fully charged they act as power supplies for the IGBT switching circuit. The Insulated Gate Bipolar Transistors switch the DC power, from the input capacitors, “on and off” thus supplying pulsed DC current to the main transformer primary windings. See IGBT Operation Discussion and Diagrams in this section.

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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

Each switch board feeds current to a separate, oppositely wound primary winding of the main transformer. The reverse directions of current flow through the main transformer primaries and the offset timing of the IGBT switch boards induce an AC square wave output signal at the secondary of the main transformer. These primary currents are monitored by the current transformer (CT). If the primary currents become abnormally high, the control board will shut off the IGBTs, thus disabling machine output. The DC current flow through each primary winding is clamped back to each respective input capacitor when the IGBTs are turned off. This is needed due to the inductance of the transformer primary winding. The firing of the two switch boards occurs during halves of a 50 microsecond interval, creating a constant 20 kHz output.

INVERTEC® V450-PRO

E-4 E-4

I

NPUT

CONTACTOR I

NPUT

RECTIFIER

R

E

C

O

N

E

C

T

CONTROL BOARD

RIGHT

SWITCH

BOARD

LEFT

SWITCH

BOARD

MAIN

TRANSFORMER

CURRENT

SENSOR

C

HOKE

O

UTPUT

TERMINAL

OUTPUT

TERMINAL

POWER

B

OARD

1

15VAC

RECEPTACLE

P

O

W

E

R

S

W

I

T

C

H I

N

P

U

T

B

O

A

R

D

FAN

M

OTOR

AUX.

TRANS.

AUX.

TRANS.

RECTIFIER

AUX.

RECONNECT

PRIMARY

CURRENT

SENSOR

WIRE FEEDER

RECEPTACLE RS232

CONN.

T

HERMOSTATS

THERMAL

LIGHT

CURRENT FEEDBACK

VOLTAGE FEEDBACK

65VDC

40VDC

C

ONTROL SIGNALS

PWM

DRIVE

CAPACITOR

VOLTAGE

FEEDBACK

CAPACITOR

VOLTAGE

FEEDBACK

PWM

DRIVE

VOLTAGE

SENSE

R

ECEPTACLE

#1

#

2

S

W

I

T

C

H

S

TATUS

MODE BOARD OR

ADVANCED MODE

BOARD

LIGHT

I

NPUT

CONTACTOR

I

NPUT

RECTIFIER

R E C O N N E C T

CONTROL BOARD

RIGHT SWITCH BOARD

LEFT SWITCH BOARD

MAIN

TRANSFORMER

CURRENT

SENSOR

C

HOKE

O

UTPUT

TERMINAL

OUTPUT

TERMINAL

POWER B

OARD

1

15VAC

RECEPTACLE

P O W E R

S W

I T C H

I N P U T

B O A R D

FAN

M

OTOR

AUX.

TRANS.

AUX.

TRANS.

RECTIFIER

AUX.

RECONNECT

PRIMARY

CURRENT

SENSOR

WIRE FEEDER RECEPTACLE

RS232

CONN.

T

HERMOSTATS

THERMAL

LIGHT

CURRENT FEEDBACK

VOLTAGE FEEDBACK

65VDC

40VDC

C

ONTROL SIGNALS

PWM

DRIVE

CAPACITOR VOLTAGE FEEDBACK

PWM DRIVE

VOLTAGE

SENSE

R

ECEPTACLE

#1

#

2

S

W

I

T

C

H

S

TATUS

MODE BOARD OR ADVANCED MODE BOARD

LIGHT

THEORY OF OPERATION

FIGURE E.4 - CONTROL BOARD & MODE SELECTION BOARD

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CONTROL BOARD & MODE SELECTION

The control board performs the primary interfacing functions to establish and maintain output control of the INVERTEC® V450-PRO. Refer to Figure E.4. The control board sends and receives digital command information through the wire feeder receptacle and or the RS232 connector. The software that is contained within the control board processes and compares these commands with the voltage and current feedback information it receives from the current sensor and voltage sensing leads. The appropriate pulse width modulation (PWM) signal (See Pulse Width Modulation in this section) is sent to the switch board IGBTs. In this manner, the digitally controlled highspeed welding waveform is created.

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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

The control board also monitors the thermostats, main transformer primary current, and capacitor voltage, and activates either the thermal light and/or the status light. Dependent upon the fault situation, the control board will either disable or reduce machine output, or de-energize the main input contactor.

INVERTEC® V450-PRO

E-5 E-5

INPUT

CONTACTOR INPUT

RECTIFIER

R

E

C

O

N

E

C

T

CONTROL BOARD

RIGHT

S

WITCH

BOARD

LEFT

S

WITCH

BOARD

MAIN

TRANSFORMER

C

URRENT

SENSOR

CHOKE

OUTPUT

TERMINAL

OUTPUT

T

ERMINAL

POWER

BOARD

115VAC

RECEPTACLE

P

O

W

E

R

S

W

I

T

C

H I

N

P

U

T

B

O

A

R

D

FAN

MOTOR

AUX.

TRANS.

AUX.

TRANS.

R

ECTIFIER

A

UX.

RECONNECT

PRIMARY

CURRENT

SENSOR

WIRE FEEDER

R

ECEPTACLE RS232

C

ONN.

THERMOSTATS

STATUS

LIGHT

THERMAL

LIGHT

CURRENT FEEDBACK

VOLTAGE FEEDBACK

65VDC

40VDC

CONTROL SIGNALS

PWM

DRIVE

CAPACITOR

VOLTAGE

FEEDBACK

CAPACITOR

V

OLTAGE

F

EEDBACK

PWM

DRIVE

VOLTAGE

S

ENSE

RECEPTACLE

#

1

#2

S

W

I

T

C

H

INPUT

CONTACTOR

INPUT

RECTIFIER

R E C O N N E C T

CONTROL BOARD

RIGHT S

WITCH

BOARD

LEFT S

WITCH

BOARD

MAIN

TRANSFORMER

C

URRENT

SENSOR

CHOKE

OUTPUT

TERMINAL

OUTPUT

T

ERMINAL

POWER BOARD

115VAC

RECEPTACLE

P O W E R

S W

I T C H

I N P U T

B O A R D

FAN

MOTOR

AUX.

TRANS.

AUX.

TRANS.

R

ECTIFIER

A

UX.

RECONNECT

PRIMARY

CURRENT

SENSOR

WIRE FEEDER R

ECEPTACLE

RS232

C

ONN.

THERMOSTATS

STATUS

LIGHT

THERMAL

LIGHT

CURRENT FEEDBACK

VOLTAGE FEEDBACK

65VDC

40VDC

CONTROL SIGNALS

PWM

DRIVE

CAPACITOR VOLTAGE FEEDBACK

CAPACITOR V

OLTAGE

F

EEDBACK

PWM DRIVE

VOLTAGE

S

ENSE

RECEPTACLE

#

1

#2

S

W

I

T

C

H

THEORY OF OPERATION

FIGURE E.5 - OUTPUT RECTIFIER AND CHOKE

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OUTPUT RECTIFIER AND CHOKE

The output rectifier receives the AC output from the main transformer secondary and rectifies it to a DC voltage level. Since the output choke is in series with the negative leg of the output rectifier and also in series with the welding load, a filtered DC output is applied to the machine output terminals. See Figure E.5.

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

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INVERTEC® V450-PRO

E-6 E-6

THEORY OF OPERATION

THERMAL PROTECTION

Two normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are connected to the control board. One of the thermostats is located on the heat sink of the output rectifier and the other is located near the fan. (On later production machines this thermostat is located on the output choke) Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond its duty cycle or output rating. If excessive operating temperatures should occur, the thermostats will prevent output from the machine. The yellow thermal light, located on the front of the machine, will be illuminated. The thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the power switch may be left on and the reset should occur within a 15-minute period. If the fan is not turning or the air intake louvers are obstructed, then the power must be removed from the machine, and the fan problem or air obstruction corrected. The F.A.N. (fan as needed) system is controlled by the control board via a solid-state relay.

OVER CURRENT PROTECTION

If the average current exceeds 590 amps, then the peak current will be limited to 100 amps until the average current decreases to fewer than 50 amps.

UNDER/OVER VOLTAGE PROTECTION

A protective circuit is included on the control board to monitor the voltage across the input capacitors. In the event that a capacitor voltage is too high, or too low, the protection circuit will de-energize the input contactor. Machine output will be disabled and the “soft start” mode will be repeated. The protection circuit will prevent output if any of the following circumstances occur.

1. Capacitor conditioning is required. (May be required if machine has been off for a long period of time and is connected for high input voltage operation.)

PROTECTIVE CIRCUITS

Protective circuits are designed into the INVERTEC® V450-PRO to sense trouble and shut down the machine before damage occurs to the machine's internal components.

2. Voltage across a capacitor exceeds 390 volts. (High line surges or improper input voltage connections.)

3. Voltage across a capacitor is under 70 volts. (Due to improper input voltage connections.)

4. Internal component damage.

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INVERTEC® V450-PRO

E-7 E-7

DRAIN

SOURCE

GATE

A. PASSIVE

B. ACTIVE

BODY REGION

DRAIN DRIFT REGION

BUFFER LAYER

INJECTING LAYER

DRAIN

SOURCE

G

ATE

B

ODY REGION

DRAIN DRIFT REGION

BUFFER LAYER

INJECTING LAYER

n+n+

P

n

-

n+

P+

n

+n+

P

n-

n+

P+

POSITIVE

V

OLTAGE

A

PPLIED

DRAIN

SOURCE

GATE

A. PASSIVE

B. ACTIVE

BODY REGION

DRAIN DRIFT REGION BUFFER LAYER

INJECTING LAYER

DRAIN

SOURCE

G

ATE

B

ODY REGION

DRAIN DRIFT REGION BUFFER LAYER

INJECTING LAYER

n+ n+

P

n

-

n+

P+

n

+ n+

P

n-

n+ P+

POSITIVE V

OLTAGE

A

PPLIED

THEORY OF OPERATION

FIGURE E.6 - IGBT OPERATION

INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION

An IGBT is a type of transistor. IGBT are semiconductors well suited for high frequency switching and high current applications.

Example A in Figure E.6 shows an IGBT in passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow. The drain terminal of the IGBT may be connected to a voltage supply; but since there is no conduction, the circuit will not supply current to components connected to the source. The circuit is turned OFF like a light switch.

Example B shows the IGBT in an active mode. When the gate signals a positive DC voltage relative to the source, is applied to the gate terminal of the IGBT, it is capable of conducting current. A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to the circuit components coupled to the source. Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present. This is similar to turning ON a light switch.

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INVERTEC® V450-PRO

E-8 E-8

(+)

1 μsec

48 μsec

50 μsec

1 μsec

(-)

(+)

(-)

2 μsec

24 μsec

50 μsec

24 μsec

MINIMUM OUTPUT

MAXIMUM OUTPUT

(+)

1 μsec

48 μsec

50 μsec

1 μsec

(-)

(+)

(-)

2 μsec

24 μsec

50 μsec

24 μsec

MINIMUM OUTPUT

MAXIMUM OUTPUT

THEORY OF OPERATION

FIGURE E.7 - TYPICAL IGBT OUTPUTS

PULSE WIDTH MODULATION

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 IGBT is turned on and off for different durations during the cycle. The top drawing in Figure E.7 shows the minimum output signal possible over a 50-microsecond time period.

The positive portion of the signal represents one IGBT

1

group

conducting for one microsecond.

The negative portion is the other IGBT group1. The dwell time (off time) is 48 microseconds (both IGBT groups off). Since only two microseconds of the 50microsecond time period is devoted to conducting, the output power is minimized.

MAXIMUM OUTPUT

By holding the gate signal on for 24 microseconds each, and allowing only two 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 that is under the curve indicates that more power is present.

1

An IGBT group consists of two IGBT modules feeding one transformer primary winding.

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INVERTEC® V450-PRO

F-1 F-1

TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4

Input Filter Capacitor Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13

Voltage and Current Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19

Main Switch Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19

Input Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-21

Input Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25

Input Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29

Aux. Transformer No.2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33

Aux. Transformer No.1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-35

Power Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-39

Current Transducer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-43

Thermostat Test - Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47

Fan Control and Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-49

Output Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-51

Choke Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-53

Control Board Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-55

SPI Cable Resistance and Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-57

Removal and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-59

Control or Power Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-59

Input Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-63

Input Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-65

Aux. Transformer No.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-67

Aux. Transformer No.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-71

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Control, Remote, Mode or Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-75

Current Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-77

Switch Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-81

Retest and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-84

INVERTEC® V450-PRO

F-2 F-2

TROUBLESHOOTING AND REPAIR

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

---------------------------------------------------------------------------------------------------------------------------

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into the following categories: output problems and welding problems.

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)” lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap-around cover.

Step 3. RECOMMENDED COURSE OF ACTION

The last column labeled “Recommended Course of Action” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed one possibility at a time until you locate the cause of your problem.

All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the specified test points, components, terminal strips, etc. can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram.

to eliminate

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

-----------------------------------------------------------------------------------------------------------------------------------

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INVERTEC® V450-PRO

F-3 F-3

TROUBLESHOOTING AND REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

ELECTRIC SHOCK can kill.

•

Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electricall y hot par ts.

CAUTION

Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure:

1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2. Check for loose connections at the PC board to a ss ur e th a t the PC boar d is p roper l y connected.

3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:

PC board can be damaged by static electricity.

- Rem o ve y o ur b o dy ’s s t at ic charge before opening the staticshielding bag. Wear an anti-static wris t strap. For sa f e t y, use a 1 Meg ohm resistive cord connected

ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations

to a g ro un de d p ar t of th e equipment frame.

- If you don’t have a wrist strap, touch an un-painted, grounded, part of the equipment frame. Keep touc h in g t h e fram e to pr ev en t stat i c bui l d- up . Be su r e not to touch any electrically live parts at the same time.

- Remove the PC board from the static-shielding bag and place it directly into the equipment. Don’t set the PC board on or near paper, plastic or cloth which could have a static charge. If the PC board can’t be installed immediately, put it back in the static-shielding bag.

- If the PC board uses protective shorting jumpers, don’t remove them until installation is complete.

- If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.

4. Test the machine to determ ine if the failure

symp t om has b een c o rrect e d by t he replacement PC board.

NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

NOTE: Allow the machine to heat up so that all electrica l components can reach their operating temperature.

5. Rem o ve the r e pl ac em ent P C b oa rd an d

subs t it ute it wi t h the ori g in al PC boa r d to recreate the original problem.

a. If the original problem does not reappear by

substituting the original board, then the PC board was not the problem. Continue to look fo r bad connect ions in the control wiring harness, junction blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then the PC boar d wa s the pr ob le m. Rei n st all the replacement PC board and test the machine.

6. Alw a ys in d ic at e th a t thi s pro c edure wa s

foll o we d whe n warra n ty re p or ts are to b e submitted.

NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

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- Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.

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INVERTEC® V450-PRO

F-4 F-4

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Major physical or electrical damage is evident when the sheet metal covers are removed.

The input fuses repeatedly fail or the input circuit breakers keep tripping.

The input fuses fail or input breakers trip after the CR-1 contactor closes

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Input fuses or breakers may be improperly sized.

2. The reconnect panel may not be configured properly for the applied voltage.

1. Input fuses or breakers may be improperly sized.

2. The reconnect panel may not be configured properly for the applied voltage.

3. A component in the input circuitry has failed.

RECOMMENDED

COURSE OF ACTION

Contact the Lincoln Electric Service Department at 1-888935-3877.

1. Check the reconnect panel connections and associated wiring. See the Wiring Diagram and Input Information in Section A for the proper input voltage. Check the input voltage and make sure it is correct.

1. Check the re-connect panel connections and associated wiring. See the Wiring Diagram and Input Information in Section A.

2. Perform the Input Rectifier Test. If the Input Rectifier is defective, perform tests 3 and

4.

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3. Perform the IGBT Switch

Board Test.

4. Perform the Input Board Test

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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INVERTEC® V450-PRO

F-5 F-5

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

The machine is dead - - no lights

- - no output - - the machine appears to have no power.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Make sure the input power switch SW1 is in the ON position.

2. Check the main input fuses or breakers and make sure all three phases are present.

3. Check the CB3 breaker (located in the reconnect area). Reset if tripped.

RECOMMENDED

COURSE OF ACTION

1. Check the input power switch SW1 for proper operation. Also check the associated leads for loose or faulty connections. See the Wiring Diagram or Machine Diagram for the welder in Section G.

2. Replace or reset input fuses or breaker.

3. If CB-3 opens repeatedly, perform the Auxiliary

Transformer Test.

4. The power board rectifier may be faulty. Check the rectifier and associated wiring. See the Wiring Diagram or Machine Diagram for the welder in Section G.

The Auxiliary Receptacle is “dead”. No 120VAC present.

1. Check CB-2 on the case front. Reset if necessary.

2. Check CB-3 in the reconnect area. Reset if necessary.

3. Make sure all three input phases are present

5. Perform the Power Board

Test.

6. Perform the Control Board Check. The Control Board

may be faulty.

1. Check the receptacle and asso-

ciated wiring. See the Wiring Diagram or Machine Diagram in

Section G.

2. Perform the Auxiliary

Transformer Test #2.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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INVERTEC® V450-PRO

F-6 F-6

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

The INVE RTE C® V45 0 -P RO does not have we l d in g o u tp u t. The main input contactor (CR1) is not activating.

NOTE: Th i s prob l em wi ll

normally be accompanied by an error code.

The D i ag nosti c Utili t y i s also avai l ab le on t he Se rv ic e Navigator.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. The input voltage may be too high or too low or reconnect panel may be incorrectly connected

2. May be a thermal shutdown. Check to see if the Thermal LED is ON

3. The primary current limit has been exceeded (CR1 drops out when the output is initiated).

4. The power source (upper section) has failed. If nothing is evident from a visual inspection, perform tests as shown.

NOTE: Error codes as indicated

by LED 9 and 10 on the Control Board.

RECOMMENDED

COURSE OF ACTION

1. Make certain that the input voltage is proper, according to the Rating Plate located on the rear of the machine. See Installation Section of this manual.

2. See “Thermal LED is ON” in this section.

3. Possible short in output circuit. Turn machine off. Remove all leads from the output of the machine.

4. Perform the Input Contactor Test.

5. Perform the Input Board Test.

6. Perform the Auxiliary Transformer test for T-1

7. Preform the Input Rectifier

test.

CAUTION

8. Perform the IGBT Switch Board Test.

9. Perform the Power Board Test.

10. Perform the Control Board

Check. The Control Board

may be faulty.

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If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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INVERTEC® V450-PRO

F-7 F-7

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Thermal light is ON. The machine regularly “overheats.”

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. The welding application may be exceeding the recommended duty cycle and/or limits of the machine.

2. Dirt and dust may have clogged the cooling channels inside the machine. Refer to the Maintenance Section of this manual.

3. Air intake and exhaust louvers may be blocked due to inadequate clearance around the machine. Check the upper section of the machine and AC/DC switch lower section intakes.

4. Make sure the fan is functioning correctly. Machines are equipped with F.A.N. (fan as needed) circuitry. The fans run whenever the output is enabled and will continue running for a period of time (approximately 5 minutes) after the output is disabled.

RECOMMENDED

COURSE OF ACTION

1. One of the thermostats may be faulty. Also check associated wiring for loose or faulty connections. See the Wiring Diagram or the Machine Diagram in Section G. There are a total of 2 thermostats in the system.

2. Temporarily jumper out the thermostat circuit at the Control Board. See the Machine Diagram in this manual to jump this circuit function for test only. If the machine does not reset, the Control Board is defective. If it does reset, perform the Thermostat Test.

3. Temporarily jump around the fan relay contacts to test fan relay function. See the Machine Diagram in Section G to test the fan relay function.

CAUTION to run the fan.

: 120VAC is used

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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INVERTEC® V450-PRO

F-8 F-8

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

General degradation of weld performance.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

WELD AND ARC QUALITY PROBLEMS

1. Wire feed problem.

2. Cabling problems.

3. Verify weld mode is correct for process.

4. Machine calibration.

RECOMMENDED

COURSE OF ACTION

1. Check for proper wire speed and consistent feeding.

2. Check for poor connections and/or excessive loops in the weld cables.

NOTE: The presence of heat in

external welding circuits indicates poor connections or undersized weld cables.

3. Select the correct weld mode for the application. Refer to the Instruction Manual.

4. Perform Choke Test.

5. Perform Current Transducer Test and Check Sense Lead Routing.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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INVERTEC® V450-PRO

F-9 F-9

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Machine shuts down during a weld.

NOTE: The Diagnostic Utility can

be used to check the ‘event log’ to determine cause of shut-down.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

WELD AND ARC QUALITY PROBLEMS

1. Secondary over-current occurred.

RECOMMENDED

COURSE OF ACTION

1. Adjust parameters to minimize momentary shorting of the arc.

2. Check for single phase input, (loss of L2) which will reduce the secondary current limit. Check input fuses or current in all three phases for balance (+/5 amps).

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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INVERTEC® V450-PRO

F-10 F-10

STATUS LIGHTS ARE LED’S 9 AND 10 ON CENTER TOP OF CONTROL BOARD

TROUBLESHOOTING AND REPAIR

Observe Safety Guidelines detailed in the beginning of this manual.

Fault Codes

Code Description Corrective Action 31 Primary over current. If condition persists The machine needs to

contact an authorized be turned off and back Lincoln Field Service

on to reset the machine.

Shop 32 CAP bank A under voltage. Check input power Self-clearing as 33 CAP bank B under voltage. reconnect to make sure condition ceases. 34 CAP bank A over voltage. the machine 35 CAP bank B over voltage. is connected for the input 37 Soft start Failed. power being supplied. Cycle power. 39 Glitch on the primary over Check the machine Self-clearing as

current fault interrupt; possibly ground. condition ceases. caused by noise or a signal level If problem persists (misc. hardware fault #1) contact an authorized

Lincoln Field Service

Shop 43 CAP delta; CAP A and B are out Check input power

of balance. reconnect to make sure

the machine is

connected for the input

power being supplied. 44 Main CPU problem. The DSP Check the machine

has detected a problem with the ground. CPU.

47 Possible erroneous electrical If problem persists

noise on Voltage/Frequence contact an authorized capacitor feed back circuit. Lincoln Field Service

Shop

(misc. hardware fault #2)

48 The main contactor opened If condition persist Self-clearing

unexpectedly. (misc. hardware contact an authorized fault #3) Lincoln Field Service

Shop "bad The selected weld mode does If condition persists Press the Mode node’ not exist in the weld table that is contact an authorized Select button to “####”

presently loaded in the machine. Lincoln Field Service select a different

Shop mode

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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INVERTEC® V450-PRO

F-11 F-11

TROUBLESHOOTING AND REPAIR

Observe Safety Guidelines detailed in the beginning of this manual.

Displays Description

Scrolling dash

Appears at power up while the machine is going through its self configuration

"Err" "####" Fault code display. The first fault to occur will be displayed for

three seconds. The display will cycle through fault codes for all faults that persist after the initial three-second period are displayed for 1 second each.

"----" "----" Weld mode is changing

"----" "####" A constant voltage weld mode is selected, machine output is off.

The numeric value in the right display is the work point.

"####" "----" A constant current weld mode is selected, machine output is off.

The numeric value in the left display is either the work point or a work point limit, depending on the weld mode and remote configuration.

"####" "####"(on steady) Machine output is on. Left display is current, right display is volt-

age. If actively welding, the displays are arc current and arc voltage. If not actively welding, the display will show work point.

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"####" "####" (blinking) Weld just finished – the average arc voltage and current will be

blinked for 5 seconds following a weld. If the work point changes during this 5 second period, the display will revert to the above mode.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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INVERTEC® V450-PRO

F-12 F-12

NOTES

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INVERTEC® V450-PRO

F-13 F-13

TROUBLESHOOTING AND REPAIR

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This procedure will drain off any charge stored in the four large capacitors that are part of the switch board assembly. This procedure MUST be performed as a safety precau-

tion before conducting any test or repair procedure that requires you to touch internal components of the machine.

MATERIALS NEEDED

5/16” Nut Driver

Insulated Pliers Insulated Gloves High Wattage Resistor (25-1000 ohms and 25 watts minimum) DC Volt Meter

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INVERTEC® V450-PRO

CAPACITOR

TERMINALS

RESISTOR

CAPACITOR

TERMINALS

RESISTOR

CAPACITOR TERMINALS

RESISTOR

CAPACITOR TERMINALS

RESISTOR

F-14 F-14

TROUBLESHOOTING AND REPAIR

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)

FIGURE F.1 – CAPACITOR TERMINAL LOCATION

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PROCEDURE

1. Remove input power to the INVERTEC® V450PRO.

2. Using the 3/8” nut driver, remove the left and right case sides.

3. Be careful not to make contact with the capacitor terminals that are located in the bottom center of the left and right side switch boards. See Figure F.1.

4. Carefully check for a DC voltage at the capacitor terminals on both boards. Note the polarity is marked on the PC board and also lead #19 is positive.

5. If any voltage is present, proceed to Step #6. If no voltage is present, the capacitors are discharged.

NOTE: Normally the capacitors discharge in about

two minutes after input power is removed.

INVERTEC® V450-PRO

6. Using the high wattage resistor (25-1000 ohms @ 25 watts (minimum), electrically insulated gloves and pliers, connect the resistor across the two capacitor terminals. Hold the resistor in place for 10 seconds. DO NOT TOUCH THE CAPACITOR TERMI-NALS WITH YOUR BARE HANDS. NEVER USE A SOLID CONDUCTOR

W/LESS THAN 25 OHM RESISTANCE FOR THIS PROCEDURE.

7. Repeat procedure for the other capacitor.

8. Recheck the voltage across the capacitor terminals. The voltage should be zero. If any voltage remains, repeat the discharge procedure.

F-15 F-15

TROUBLESHOOTING AND REPAIR

VOLTAGE AND CURRENT CALIBRATION PROCEDURE

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the machine is capable of producing welding output and to check and adjust, if necessary, the voltage and or current calibration.

MATERIALS NEEDED

Resistive Load Bank Calibrated Test Voltmeter Calibrated Test Ammeter

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INVERTEC® V450-PRO

F-16 F-16

TROUBLESHOOTING AND REPAIR

VOLTAGE AND CURRENT CALIBRATION PROCEDURE (continued)

CALIBRATION CHECK

The calibration of the V450-PRO can be checked using a resistive load bank with the V450-PRO in mode 200. Mode 200 is a constant current test mode.

NOTE: Before attempting to calibrate the voltage

or current setting of the V450-PRO, be sure to read the entire voltage or current calibration section. If the steps are not completed quickly, the machine will automatically leave the calibration mode without changing the calibration settings. The voltage and current calibration settings of the V450-PRO are completely independent of each other. Adjusting one will not affect the other.

1. Press and hold in the Mode SELECT button.

2. Turn on the V450-PRO.

3. Rotate the Output Knob, while still holding the mode select button in, until the displays read “mode 200”.

VOLTAGE CALIBRATION

NOTE: If the Mode SELECT/MEMORY button is

not pressed within 30 seconds after adjusting the Output Control knob the machine will leave the calibration mode

and use the previous calibration settings.

1. Connect the resistive load band (approximately .087 ohms) and test voltmeter to the welding output terminals.

2. Press and hold in the Mode SELECT/MEMO- RY button.

3. Turn on the V450-PRO.

4. Rotate the Output Control knob until the display reads “vol cAL”.

5. Release the Mode SELECT/MEMORY but- ton.

6. Adjust the Output Control knob until the actu- al output voltage reading on the test voltmeter is 20volts +/- .5 volts.

NOTE: Machines with an Advanced Process

Panels do not have a mode select button. Use the same procedure except hold in the Memory button on the advanced process panel instead of the mode select button.

4. Release the Mode SELECT/MEMORY but- ton and the machine will be in mode 200.

5. With the machine in mode 200 apply a resistive load to the welding output terminals (approximately .087 ohms) set the machine output to 300 amps and enable the Weld Terminals. (Weld Terminals Select ON).

6. Using the test meters note the output voltage and current.

7. The V450-PRO voltmeter must match the test meter reading to within +/- 1 volt.

8. The V450-PRO ammeter must match the test meter within +/- 5 amps.

9. If the voltmeter does not meet the specification then proceed to the Voltage Calibration

Procedure.

7. Wait for the machine’s output to be automatically turned off and then back on.

8. Adjust the Output Control knob again if necessary to make the actual voltage output 20 volts +/- .5 volts.

9. Wait for the machine’s output to be automatically turned off and then back on.

10. Repeat the above two steps if necessary.

11. Press and release the Mode SELECT/MEM- ORY button to save the calibration.

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10. If the ammeter does not meet the specification then proceed to the Current Calibration

Procedure.

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INVERTEC® V450-PRO

F-17 F-17

TROUBLESHOOTING AND REPAIR

VOLTAGE AND CURRENT CALIBRATION PROCEDURE (continued)

CURRENT CALIBRATION PROCEDURE

NOTE: If the Mode SELECT/MEMORY button is

not pressed within 30 seconds after adjusting the Output Control knob the machine will leave the calibration mode

and use the previous calibration settings.

1. Connect the resistive load band (approximately .087 ohms) and test ammeter to the welding output terminals.

2. Press and hold in the Mode SELECT/MEMO- RY button.

3. Turn on the V450-PRO.

4. Rotate the Output Control knob until the display reads “cur cAL”.

5. Release the Mode SELECT/MEMORY but- ton.

6. The left display will change to “IcAL” to indicate that current calibration is in progress.

7. The right display will scroll the following message: Adj oCP SorEAL cur-300A.

8. Adjust the Output Control knob until the actual output current reading on the test ammeter is 300amps +/-2A.

9. Wait for the machine’s output to be automatically turned off and then back on.

10. Adjust the Output Control knob again if necessary to make the actual output current reading on the test ammeter 300 amps +/-2A.

11. Wait for the machine’s output to be automatically turned off and then back on.

12. Repeat the above two steps if necessary.

13. Press and release the Mode SELECT/MEM- ORY button to save the calibration.

14. The left display will scroll the message IcAL SAVEd.

15. The machine will reset to normal operation.

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INVERTEC® V450-PRO

F-18 F-18

NOTES

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INVERTEC® V450-PRO

F-19 F-19

TROUBLESHOOTING AND REPAIR

MAIN SWITCH BOARD TEST PROCEDURE

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the “power section” of the switch boards are functioning correctly. This test will NOT indicate if the entire PC board is functional. This resistance test is preferable to a voltage test with the machine energized because this board can be damaged easily. In addition, it is dangerous to work on this board with the machine energized.

MATERIALS NEEDED

Analog Volt/Ohmmeter

5/16 in. Wrench

7/16 in. Wrench

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INVERTEC® V450-PRO

CAPACITOR

TERMINALS

RESISTOR

CAPACITOR

TERMINALS

RESISTOR

CAPACITOR TERMINALS

RESISTOR

CAPACITOR TERMINALS

RESISTOR

F-20 F-20

TROUBLESHOOTING AND REPAIR

MAIN SWITCH BOARD TEST PROCEDURE (continued)

FIGURE F.2 - CAPACITOR TERMINAL LOCATIONS

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TEST PROCEDURE

1. Remove input power to the INVERTEC® V450-PRO.

2. Perform the Capacitor Discharge Procedure.

3. Use a DC voltmeter to check that the voltage is not present across the terminals on three capacitors.

4. Locate label and remove leads 19C and 19D from the reconnect switches with the 3/8” wrench. Note lead placement for reassembly. Clear leads. See Figure F.2.

5. Using the Analog ohmmeter, perform the following

resistance tests. See Figure F.2 for the test points. Any readings below 100 ohms can be considered a short circuit. However, readings usually are below 30 ohms. A short on any of the following points indicates a possible failed switch board.

INVERTEC® V450-PRO

Check 11/12 to -20 and 11/12 to +19

Check 15/16 to -20 and 15/16 to +19

Check 13/14 to -20 and +19 to 13/14

Check 17/18 to -20 and +19 to 17/18

6. If any test fails (measures a short) isolate the PC board and retest, if board still fails, replace switch board. See Switch Board Removal

and Replacement.

7. If the switch board tests are OK, check the molex pin connections and associated wiring from the switch boards to the control board. See the Wiring Diagram.

8. Reconnect leads 19C and 19D to the reconnect switches. Ensure that the leads are installed in the same location they were removed from.

9. Install the right and left case sides and top using the 3/8” nut driver.

F-21 F-21

TROUBLESHOOTING AND REPAIR

INPUT RECTIFIER TEST PROCEDURE

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the input rectifier has “shorted” or “open” diodes.

MATERIALS NEEDED

Analog Voltmeter/Ohmmeter (Multimeter)

5/16” Nut Driver

Phillips Head Screwdriver

Wiring Diagram

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INVERTEC® V450-PRO

F-22 F-22

NEG (-)

P

OS (+)

A B

C

I

NPUT

RECTIFIER

NEG (-)

P

OS (+)

A

B

C

I

NPUT

RECTIFIER

TROUBLESHOOTING AND REPAIR

INPUT RECTIFIER TEST PROCEDURE (continued)

FIGURE F.3 - INPUT RECTIFIER

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PROCEDURE

1. Remove input power to the INVERTEC® V450-PRO.

2. Using the 3/8” nut driver, remove the case top.

3. Perform the Capacitor Discharge Procedure.

4. Locate the Input Rectifier and lead locations. Refer to Figure F.3.

INVERTEC® V450-PRO

NOTE: Some RTV sealant may have to be

removed from the input rectifier terminals. The RTV should be replaced when test is complete.

5. With the Phillips head screwdriver remove the positive and negative leads from the rectifier.

F-23 F-23

TROUBLESHOOTING AND REPAIR

INPUT RECTIFIER TEST PROCEDURE (continued)

6. Use the analog ohmmeter to perform the tests detailed in Table F.1.

7. If the input rectifier does not meet the acceptable readings outlined in the table, the component may be faulty. Replace.

NOTE: Before replacing the input rectifier, perform

the Switch Board Test and the Input Contactor Test.

8. When installing a new input rectifier, see Input Rectifier Removal and Replacement proce-

dure.

9. If the input rectifier is good, be sure to reconnect the positive and negative leads to the correct terminals and torque to 31 in.-lbs. See the Wiring Diagram.

10. Replace any RTV sealant previously removed.

11. Install the case top.

TABLE F.1 – INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS

TEST POINT TERMINALS

+ Probe - Probe

A B C

NEG NEG NEG

POS POS POS

NEG NEG NEG

POS POS POS

A B C

ANALOG METER X100

RANGE

Acceptable Meter Readings

Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms

Approx. 500 ohms Approx. 500 ohms Approx. 500 ohms

Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms

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INVERTEC® V450-PRO

F-24 F-24

NOTES

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INVERTEC® V450-PRO

F-25 F-25

TROUBLESHOOTING AND REPAIR

INPUT CONTACTOR TEST PROCEDURE

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the input contactor is functional and if the contacts are functioning correctly.

MATERIALS NEEDED

3/8” Nut Driver Volt-Ohmmeter External 24 VAC supply

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INVERTEC® V450-PRO

F-26 F-26

INPUT

C

ONTACTOR

601

X4

INPUT C

ONTACTOR

601

X4

TROUBLESHOOTING AND REPAIR

INPUT CONTACTOR TEST PROCEDURE (continued)

FIGURE F.4 – INPUT CONTACTOR COIL

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PROCEDURE

1. Remove input power to the INVERTEC® V450-PRO.

2. Using the 3/8” nut driver, remove the input access panel and case top.

3. Locate, mark, and remove the two leads (601, X4) that are connected to the input contactor coil. See Figure F.4.

INVERTEC® V450-PRO

4. Using the external 24 VAC supply, apply 24 VAC to the terminals of the input contactor coil. If the contactor does NOT activate, the input contactor is faulty. Replace.

F-27 F-27

L3

L2

L1

T3

T2

T1

L3

L2

L1

T3

T2

T1

TROUBLESHOOTING AND REPAIR

INPUT CONTACTOR TEST PROCEDURE (continued)

FIGURE F.5 – INPUT CONTACTOR TEST POINTS

5. With the input contactor activated, check the continuity across the three sets of contacts. (Zero ohms or very low resistance is normal.) See Figure F.5. If the resistance is high, the input contactor is faulty. Replace the input contactor.

6. When the contactor is NOT activated, the resistance should be infinite or very high across the contacts. If the resistance is low, the input contactor is faulty.

7. Reconnect the two leads (601, X4) to the input contactor coil.

8. Install the input access door and case top using the 3/8” nut driver.

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INVERTEC® V450-PRO

F-28 F-28

NOTES

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INVERTEC® V450-PRO

F-29 F-29

TROUBLESHOOTING AND REPAIR

INPUT BOARD TEST PROCEDURE

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the Input Board is sending the correct voltages, as well as if the Input Board is regulating and producing the correct DC voltages.

MATERIALS NEEDED

3/8” Nut Driver Volt-Ohmmeter Wiring Diagram

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INVERTEC® V450-PRO

F-30 F-30

INPUT

CONTACTOR

601

X4

J

60

J61

6 7 8 9 10

J61

1 2 3 4

5 6 7 8

1 2 3 4 5

J60

INPUT CONTACTOR

601

X4

J

60

J61

6 7 8 9 10

J61

1 2 3 4

5 6 7 8

1 2 3 4 5

J60

TROUBLESHOOTING AND REPAIR

INPUT BOARD TEST PROCEDURE (continued)

FIGURE F.6 – INPUT CONTACTOR CR1

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PROCEDURE

1. Remove input power to the INVERTEC® 450-PRO.

2. Using the 3/8” nut driver, remove the case top.

3. Remove lead X4 from the coil terminal of main input contactor CR1. Insulate lead X4. See Figure F.6.

4. Carefully apply input power to the INVERTEC®

450-PRO.

INVERTEC® V450-PRO

WARNING

ELECTRIC SHOCK can kill.

High voltage is present when input power is applied to the machine.

5. Turn on the INVERTEC® 450-PRO. Carefully

test for the correct voltages according to Table

F.2.

F-31 F-31

TROUBLESHOOTING AND REPAIR

INPUT BOARD TEST PROCEDURE (continued)

6. Remove input power to the INVERTEC® V-

450 PRO. If any of the voltages are low or not present, perform the Input Contactor Test. If that checks out, the Input Board may by faulty.

7. Reconnect lead X4 to the main input contac-

tor CR1 coil terminal.

8. Carefully apply the correct input voltage to

the INVERTEC® V-450 PRO.

WARNING

ELECTRIC SHOCK can kill.

High voltage is present when input power is applied to the machine.

9. Turn on the INVERTEC® V-450 PRO. Check for the presence of 24 VAC from lead X4 to lead 601. See Figure F.6. If the voltage is not present, perform the

Auxiliary Transformer #1 Test.

9. This 24 VAC is the coil voltage for main

input contactor CR1. It will normally be present approximately 12 seconds after input line switch (SW1) is activated.

10. When the test is completed, remove input power from the INVERTEC® V-450 PRO.

11. Install the case top using the 3/8” nut driver.

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INVERTEC® V450-PRO

F-32 F-32

TROUBLESHOOTING AND REPAIR

INPUT BOARD TEST PROCEDURE (continued)

TABLE F.2 – INPUT BOARD VOLTAGE CHECKS

TEST POINTS

PLUG J61 PIN 8 (H1D)

TO

PLUG J61 PIN 2 (612)

PLUG J61 PIN 10 (T3)

TO

PLUG J61 PIN 2 (T1)

PLUG J60 PIN 3 (238)

TO

PLUG J60 PIN 4 (604)

NUMBERS

#612

T1

LEAD

J61

H1D

J61

J60

#238

T3

#604

EXPECTED

VOLTAGE

READINGS

SAME AS

INPUT

VOLTAGE

A LITTLE LESS

THAN INPUT

VOLTAGE

13 – 15 VDC

COMMENTS

Present when Input Switch SW1 is closed.

This is Pre-Charge Voltage and will normally be present 6 seconds after activating Input Switch SW1. The Pre-Charge Voltage should remain for approximately 6 seconds and then be removed.

This is the Coil Voltage for the Pre-Charge Relay. Normally this DC Voltage will be present 6 seconds after Input Switch SW1 is activated. This 13 - 15 VDC will remain for approximately 6 seconds and then be removed. The Relay is controlled by the Control Board. See the Wiring Diagram.

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PLUG J60 PIN 3 (238)

TO

PLUG J60 PIN 5 (232)

#232

J60

13 – 15 VDC

#238

INVERTEC® V450-PRO

This is the DC Coil Voltage for the Control Relay. Normally this DC Voltage will be present approximately 12 seconds after Input Switch SW1 is activated. The Relay is controlled by the Control PC Board. See the Wiring Diagram.

F-33 F-33

TROUBLESHOOTING AND REPAIR

AUXILIARY TRANSFORMER NO. 2 TEST

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if the correct voltage is being applied to the primary of Auxiliary Transformer No. 2, as well as if the correct voltage is being induced on the secondary winding of the transformer.

MATERIALS NEEDED

Volt-Ohmmeter (Multimeter) 3/8 in. Nut Driver Wiring Diagram

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INVERTEC® V450-PRO

TRANSFORMER #2

3/8” MOUNTING

SCREWS (2)

P51

P52

P50

TRANSFORMER #2

3/8” MOUNTING

SCREWS (2)

P51

P52

P50

F-34 F-34

TROUBLESHOOTING AND REPAIR

AUXILIARY TRANSFORMER NO. 2 TEST (continued)

FIGURE F.7 – PLUGS P52 AND P54

PROCEDURE

1. Remove the main input supply power to the INVERTEC® V-450 PRO.

2. Remove any load that may be connected to the 115 VAC receptacle.

3. Using the 3/8 in. nut driver, remove the left and right case sides.

4. Perform the Capacitor Discharge Procedure.

5. Locate plugs P50 and P51 at the Auxiliary Transformer No. 2. See Figure F.7.

6. Carefully apply the correct input power and check for 115 VAC at plug P51 pins #1 and #4.

7. If 115 VAC is present, the Auxiliary Transformer No. 2 is good.

8. If 115 VAC is not present between pins #1 and #4, check the associated leads and plugs for loose or faulty connections.

WARNING

High voltage is present at plug P50.

9. Carefully test for the correct AC input voltage applied to the primary windings at H6 and H1. (P50 Pins 1 and 5) Normal is 550-575 VAC. See wiring diagram.

10. If the correct AC input voltage is applied to the

primary of the Auxiliary Transformer No. 2 and the secondary voltage is NOT correct, the transformer may be faulty. Replace.

11. Install the left and right case sides using the

3/8 in. nut driver.

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INVERTEC® V450-PRO

F-35 F-35

TROUBLESHOOTING AND REPAIR

AUXILIARY TRANSFORMER NO. 1 TEST

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if the correct voltage is being applied to the primary of Auxiliary Transformer No. 1, as well as if the correct voltage is being induced on the secondary windings of the transformer.

MATERIALS NEEDED

Volt-Ohmmeter (Multimeter) 3/8 in. Nut Driver Wiring Diagram

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INVERTEC® V450-PRO

TRANSFORMER #1

3

/8” MOUNTING

SCREWS (2)

PLUG

P59

TRANSFORMER #1

3

/8” MOUNTING

SCREWS (2)

PLUG P59

F-36 F-36

TROUBLESHOOTING AND REPAIR

AUXILIARY TRANSFORMER NO. 1 TEST (continued)

FIGURE F.8 – TEST LEAD LOCATIONS

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1. Remove the main input supply power to the

2. Using the 3/8 in. nut driver, remove the case

3. Perform the Capacitor Discharge Procedure.

4. Locate leads X8 and 41B at Power Board

5. Locate secondary leads X3 and X5 (fan motor

6. Locate secondary lead X4 (at main

7. Carefully apply the correct input voltage to the

PROCEDURE

INVERTEC® V450-PRO.

sides and top.

Bridge.

leads).

contactor).

INVERTEC® V450-PRO and check for the correct secondary voltages per Table F.3.

INVERTEC® V450-PRO

NOTE: The secondary voltages will vary if the

input line volage varies.

8. If the secondary voltages are present, the T1 auxiliary transformer is functioning properly. If any of the secondary voltages are missing or low, check to make certain the primary is configured correctly for the input voltage applied. See Wiring Diagram.

9. If the correct voltage is applied to the primary, and the secondary voltage(s) are not correct, the T2 transformer may be faulty.

10. Install the case sides and top using the 3/8” nut

driver.

F-37 F-37

TROUBLESHOOTING AND REPAIR

AUXILIARY TRANSFORMER NO. 1 TEST (continued)

TABLE F.3

NORMAL EXPECTED

LEAD IDENTIFICATION VOLTAGE

X8 to 41B 28 VAC

X3 to X5 115 VAC

X3 to X4 24 VAC

X6 to X7 24 VAC

X6 to X9 42 VAC

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INVERTEC® V450-PRO

F-38 F-38

NOTES

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INVERTEC® V450-PRO

F-39 F-39

TROUBLESHOOTING AND REPAIR

POWER BOARD TEST

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the power board is receiving the correct voltages as well as if the power board is regulating and producing the correct DC voltages.

MATERIALS NEEDED

3/8 in. Nut Driver Volt-Ohmmeter Wiring Diagram

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INVERTEC® V450-PRO

J42

J41

J43

4 5 6

3 4

7 8 9 10 11 12

J42

J41

J43

1 2 3

1 2

1 2 3 4 5 6

J42

J41

J43

4 5 6

3 4

7 8 9 10 11 12

J42

J41

J43

1 2 3

1 2

1 2 3 4 5 6

F-40 F-40

TROUBLESHOOTING AND REPAIR

POWER BOARD TEST (continued)

FIGURE F.9 – POWER BOARD

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PROCEDURE

1. Remove input power to the INVERTEC® V-450 PRO.

2. Using the 3/8” nut driver, remove the case top.

3. Perform the Capacitor Discharge Procedure.

4. Locate the Power Board and plugs J42 and J43. Do not remove plugs or leads from the Power Board. See Figure F.9.

5. Carefully apply input power to the INVERTEC® V-450 PRO.

WARNING

ELECTRIC SHOCK can kill.

High voltage is present when input power is applied to the machine.

INVERTEC® V450-PRO

6. Turn on the INVERTEC® V-450 PRO. Carefully test for the correct voltages at the Power Board according to Table F.4.

7. If either of the 40 VDC voltages is low or not present at plug J41, check capacitor C3 and the rectifier bridge. See the Wiring Diagram. Also perform the T1 Auxiliary Transformer Test.

8. If any of the DC voltages are low or not present at plugs J42 and/or 43, the Power Board may be faulty.

9. Install the case top using the 3/8” nut driver.

F-41 F-41

TROUBLESHOOTING AND REPAIR

POWER BOARD TEST (continued)

TABLE F.4 – POWER BOARD VOLTAGE CHECKS

CHECK POINT

LOCATION

POWER BOARD

CONNECTOR

PLUG J41

POWER BOARD

CONNECTOR

PLUG J42

POWER BOARD

CONNECTOR

PLUG J42

POWER BOARD

CONNECTOR

PLUG J42

POWER BOARD

CONNECTOR

PLUG J43

POWER BOARD

CONNECTOR

PLUG J43

POWER BOARD

CONNECTOR

PLUG J43

POWER BOARD

CONNECTOR

PLUG J43

TEST

DESCRIPTION

CHECK 40 VDC

INPUT FROM

DC BUS BOARD

CHECK +15

VDC SUPPLY FROM

POWER BOARD

CHECK +5 VDC

SUPPLY FROM

POWER BOARD

CHECK -15 VDC

SUPPLY FROM

POWER BOARD

CHECK +5 VDC

“RS-232” SUPPLY

FROM POWER BOARD

CHECK +15 VDC

SPI SUPPLY FROM

POWER BOARD

CHECK +5 VDC

SPI SUPPLY FROM

POWER BOARD

CHECK +20 VDC STT

SUPPLY FROM

POWER BOARD

CONNECTOR

PLUG PIN NO.

2 (+)

1 (-)

NEG. POS.

1 (+)

5 (-)

225

222

3 (+)

5 (-)

221

222

2 (+)

5 (-)

223

222

4 (+)

9 (-)

228

6 (+)

11 (-)

3 (+)

12 (-)

268A

7 (+)

1 (-)

346

345

226

266

267

262

LEAD NO. OR

IDENTITY

477 (+)

475 (-)

225 (+)

222 (-)

221 (+)

222 (-)

222 (+)

223 (-)

226 (+)

228 (-)

266 (+)

267 (-)

268A (+)

262 (-)

345 (+)

346 (-)

NORMAL

ACCEPTABLE

VOLTAGE READING

38 – 42 VDC

+15 VDC

+5 VDC

-15 VDC

+5 VDC

+15 VDC

+5 VDC

+20 VDC

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INVERTEC® V450-PRO

F-42 F-42

NOTES

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INVERTEC® V450-PRO

F-43 F-43

TROUBLESHOOTING AND REPAIR

CURRENT TRANSDUCER TEST

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the V450-PRO current transducer and associated wiring are functioning correctly.

MATERIALS NEEDED

3/8” Nut Driver Volt-Ohmmeter

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INVERTEC® V450-PRO

F-44 F-44

J8

216

211

212

213

P91

CURRENT

TRANSDUCER

1234

CONTROL BOARD

J8

5 6 7 8

1 2 3 4

J8

216

211

212

213

P91

CURRENT

TRANSDUCER

1 2 3 4

CONTROL BOARD

J8

5 6 7 8

1 2 3 4

TROUBLESHOOTING AND REPAIR

CURRENT TRANSDUCER TEST (continued)

FIGURE F.10 – CURRENT TRANSDUCER TEST

TEST PROCEDURE

1. Remove input power to the V-450 PRO.

2. Using the 3/8” nut driver, remove the case top and the control box cover.

3. Locate the current transducer leads at Control Board plug J8. See Figure F.10.

4. Carefully apply input power to the V-450 PRO.

WARNING

ELECTRIC SHOCK can kill.

High voltage is present when input power is applied to the machine.

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INVERTEC® V450-PRO

F-45 F-45

TROUBLESHOOTING AND REPAIR

CURRENT TRANSDUCER TEST (continued)

5. Turn on the V-450 PRO. Check for the correct DC supply voltage to the current transducer at plug J8. See Figure F.10.

A. Pin 2 (lead 212+) to pin 6 (lead 216-)

should read +15 VDC.

B. Pin 3 (lead 213-) to pin 6 (lead 216+)

should read -15 VDC.

If the DC supply voltages are not present, the control board may be faulty.

6. If both of the supply voltages are low or missing, check the associated leads between plug J8 and current transducer plug P91 and the Control Board.

7. With the V-450 PRO triggered, check the feedback voltage from the current transducer. The current feedback voltage can be read at plug J8 on the Control Board.

A. Pin 1 (lead 211) to pin 6 (lead 216) should

read 2.0 VDC (machine loaded to 250 amps).

8. If for any reason the machine cannot be loaded to 250 amps, Table F.5 shows what feedback voltage is produced at various current loads.

9. If the correct supply voltages are applied to the current transducer, and with the machine loaded, the feedback voltage is missing or not correct, the current transducer may be faulty. Also make certain that lead 211 (plug J8 pin 1) has continuity (zero ohms) between the current transducer and the control board. See the Wiring Diagram.

10. Install the right side case cover using the 3/8”

nut driver.

TABLE F.5 - CURRENT FEEDBACK AT VARIOUS OUTPUT LOADS

OUTPUT LOAD CURRENT

500 450 400 350 300 250 200 150 100

50

EXPECTED TRANSDUCER FEEDBACK

VOLTAGE

4.0

3.6

3.2

2.8

2.4

2.0

1.6

1.2

0.8

0.4

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INVERTEC® V450-PRO

F-46 F-46

NOTES

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INVERTEC® V450-PRO

F-47 F-47

TROUBLESHOOTING AND REPAIR

THERMOSTAT TEST – THERMAL PROTECTION

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

NOTE: The procedures and tests described in this test are written with the under-

standing that the repair technician fully understands the process of locating and accessing (within the welding machine) the specific board or device involved in each procedure or test.

TEST DESCRIPTION

The Thermostats are located in various locations within the welding machine. See Machine Diagram for specific locations.

This test will determine if a thermostat is intermittently opening or is fully open.

MATERIALS NEEDED

Small, gauge (#18) short jumper wire (Wire should be approximately 4 inches in length)

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INVERTEC® V450-PRO

F-48 F-48

J5-2

J5-3

224

220

224

224A

291

224A

O

UTPUT RECTIFIER

THERMOSTAT

(BOLTED CONNECTION)

CHOKE

THERMOSTAT

(CONNECTED W/EPOXY)

J5-2

J5-3

224

220

224

224A

291

224A

O

UTPUT RECTIFIER

THERMOSTAT

(BOLTED CONNECTION)

CHOKE THERMOSTAT

(CONNECTED W/EPOXY)

LED 6

J5

Thermostat

TROUBLESHOOTING AND REPAIR

THERMOSTAT TEST – THERMAL PROTECTION (continued)

FIGURE F.11 – THERMOSTAT CIRCUIT

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SIMPLIFIED TEST PROCEDURE

NOTE: Never run the V-450 PRO under load when

any of the thermostats are bypassed. This is only a means of isolating the inoperative or open thermostat.

1. Tem p o rarily

by p a ss thermosta t circuits with a

shorting jumper as follows:

• All thermostats at the Control Board (2J5 to 3J5)

• Choke thermostat only (224A to 291)

• Output Rectifier thermostat only (220 to 291)

Located on the Output Rectifier Heat Sink

INVERTEC® V450-PRO

All thermostats are normally closed so moving the jumper as indicated and watching the Thermal LED shou l d help dete r mi ne w hi ch ther m os ta t or associated wiring is defective.

Don’t forget to check the incline splice 224 to 224A as a possible open.

F-49 F-49

TROUBLESHOOTING AND REPAIR

FAN CONTROL AND MOTOR TEST

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION

This test will help determine if the fan motor, control board, switch board, and associated leads and connectors are functioning correctly.

MATERIALS NEEDED

Voltmeter 3/8” Nut Driver

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INVERTEC® V450-PRO

F-50 F-50

Fan comes on when

output is enable

3R

FAN CONTROL (+15VDC)

FAN CONTROL (-)

J7-15

J7-16

3W

CR2

+

-

X

3A

4

44

T

P4

F

AN

SOLID STATE

RELAY

Located in Rear of

PowerSource

Fan comes on when output is enable

3R

FAN CONTROL (+15VDC)

FAN CONTROL (-)

J7-15

J7-16

3W

CR2

+

-

X

3A

4

44

T

P4

F

AN

SOLID STATE RELAY

Located in Rear of PowerSource

TROUBLESHOOTING AND REPAIR

FAN CONTROL AND MOTOR TEST (continued)

TEST PROCEDURE

1. Remove the input power to the V450-PRO

machine.

2. Using the 3/8” nut driver, remove the case top

and control box cover.

FIGURE F.12

3. Perform the Capacitor Discharge Procedure.

4. Carefully apply the correct input power to the

machine.

5. Carefully check for 115VAC at X3A and 444.

See Figure F.12.

WARNING

: HIGH VOLTAGE IS PRESENT AT

THE RELAY TERMINALS.

6. If the 115VAC is low or not present, perform the

Auxiliary Transformer Test. Check circuit breaker CB2 and associated leads for loose or

faulty connections. See Wiring Diagram.

7. Energize the weld output terminals (Select

Weld Terminals ON) and carefully check for 115VAC at the fan motor leads. If the 115VAC is present and the fan is not running, the fan

motor may be faulty. See Wiring Diagram.

WARNING

: HIGH VOLTAGE IS PRESENT AT

THE FAN LEADS.

WARNING

ELECTRIC SHOCK can kill.

FAN CONTROL TEST PROCEDURE

1. Locate plug J7 on the control board. Do not remove the plug from the control board. See Figure F.12.

2. Energize the weld output terminals (Select

Weld Terminals ON) and carefully check for +15VDC at plug J7 pins 15 & 16 on the control PC board. If the 15VDC is present and the fan is not running then the relay or fan may be faulty. If the 15VDC is not present when the weld terminals are energized, then the control board may be faulty.

WARNING

HIGH VOLTAGE IS PRESENT AT THE SWITCH BOARD.

High voltage is present when input power is applied to the machine.

INVERTEC® V450-PRO

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F-51 F-51

TROUBLESHOOTING AND REPAIR

OUTPUT RECTIFIER TEST PROCEDURE

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if any of the output rectifiers are shorted.

MATERIALS NEEDED

Analog Volt-Ohmmeter 3/8” Nut driver 5/16” Wrench

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INVERTEC® V450-PRO

OUTPUTOUTPUT

M

PSMPS

AA

OLTSOLTS

VV

R

EMOTEREMOTE

L

OCALLOCAL

CONTROLCONTROL

SELECTSELECT

SOFT

CRIP

HI-FREQ

T

IG

T

OUCH

START

TIG

POSITIVE (+)

OUTPUT

TERMINAL

NEGATIVE (-)

OUTPUT

TERMINAL

OUTPUTOUTPUT

M

PSMPS

AA

OLTSOLTS

VV

R

EMOTEREMOTE

L

OCALLOCAL

CONTROLCONTROL

SELECTSELECT

SOFT

CRIP

HI-FREQ T

IG

T

OUCH START TIG

POSITIVE (+) OUTPUT TERMINAL

NEGATIVE (-) OUTPUT TERMINAL

F-52 F-52

TROUBLESHOOTING AND REPAIR

OUTPUT RECTIFIER TEST PROCEDURE (continued)

FIGURE F.13 - OUTPUT TERMINAL LOCATION

PROCEDURE

1. Remove main input supply power to the V450-

2. Remove any output load that may be connect-

3. With the analog ohmmeter, measure the resis-

Important: The positive (+) meter probe must be attached to the positive output terminal and the negative (-) meter probe must be attached to the negative output terminal.

4. If the reading is approx. 50 ohms, the output

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PRO.

ed to the V450-PRO.

tance between the positive and negative output terminals. Refer to Figure F.13.

rectifier modules are not shorted. If the reading is less than 10 ohms, one or more of the rectifier modules may be shorted. Reverse meter probe and verify low reading.

INVERTEC® V450-PRO

5. Remove the case top perform the Input Filter Capacitor Discharge procedure.

6. Using the 5/16” wrench, remove and insulate lead 202A from the negative output terminal. Repeat step 4 to confirm if it is less than 10 ohms short.

7. Reconnect lead 202A to the negative output terminal.

8. Replace the shorted modules if necessary.

F-53 F-53

TROUBLESHOOTING AND REPAIR

CHOKE TEST PROCEDURE

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The Weld Choke is located down and behind the work stud. This test will help determine whether the Choke is shorted to ground or is open.

MATERIALS NEEDED

Digital Volt/Ohmmeter

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INVERTEC® V450-PRO

CHOKE/IRON

F-54 F-54

TROUBLESHOOTING AND REPAIR

CHOKE TEST PROCEDURE (continued)

FIGURE F.14 – CHOKE ASSEMBLY

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PROCEDURE

1. U s in g an Ohm m et e r, make sure th a t the chok e w in di ng s a r e no t g ro un de d t o t he lamination (> 1megohm).

INVERTEC® V450-PRO

No windings or terminal connections should look burned or over-heated. AC welding may cause choke to buzz slightly.

F-55 F-55

TROUBLESHOOTING AND REPAIR

CONTROL BOARD CHECK

Since the functions of the Control Board are primarily software related, there are not very many tests to be performed that will help in diagnosing a problem with the board itself. Elimination of problems in the areas where loss of function is taking place will help decide by process of elimination if the Control Board is the defective component. As a result, the troubleshooting chart will typically recommend other areas to be tested before the Control Board.

If the Control Board does seem to be the most likely solution, perform the checks outlined below, and then try downloading the latest software into the machine. If a solution is still not evident, use the Diagnostic facility to take a “snapshot” that can then be sent to the Lincoln Service Department via e-mail for assistance in determining where the problem. Contact the Lincoln Service Department at 1-888-935-3877.

TEST PROCEDURE

1. Check the LED’s on the Control Board. Compare

the pattern to Page 3 of the Machine Schematic.

Normal operation will show 8 Green LED’s ON and both Red LED’s OFF.

Green LED’s 1 through 8 indicate the presence of the various DC supplies to the Board.

LED 7 (red) will only be ON in the event of a Primary Over Current. Cycle the Power Switch to reset LED 7.

LED’s 9 (green) & 10 (red) will mimic the Status LED on the front panel in the event of an error. If the Status LED is OFF, these will still indicate the error code.

2. If any of the Green LED’s 1 through 8 are not lit or are dimmer than the others:

Turn the power off and disconnect all of the Control Board Molex connectors except J4 and turn the power back on . If the LED(s) in question stay the same:

3. If LED’s 9 & 10 are flashing an error code and all other LED’s are correct:

Check the Error Code list in this section to determine where the problem may be.

If the Error Code is not listed, contact the Lincoln Service Department for determination.

4. Check the DIP switches. In a single machine setup, switches 1 through 7 should be OFF. Switch 8 should be ON if a remote sense lead is attached.

NOTE: If any switches need to be changed because

the machine was removed from a multi machine application be sure to write down their position before changing them so they can be properly reset when the machine is returned to it’s position.

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Check the DC voltage levels in connector J4. See the Machine Schematic for correct readings.

If voltages are correct, replace the Control Board. If not, replace the Power Board.

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INVERTEC® V450-PRO

F-56 F-56

NOTES

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INVERTEC® V450-PRO

F-57 F-57

TROUBLESHOOTING AND REPAIR

SPI CABLE RESISTANCE AND VOLTAGE TEST PROCEDURE

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if there is a possible “open” in the SPI cable and also if the correct supply voltages are being applied to the boards in the SPI network.

MATERIALS NEEDED

Volt/Ohmmeter 5/16” Nut Driver Phillips Head Screwdriver

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INVERTEC® V450-PRO

J

3

J

3

F-58 F-58

1

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

TROUBLESHOOTING AND REPAIR

SPI CABLE RESISTANCE AND VOLTAGE TEST PROCEDURE (continued)

TEST PROCEDURE

1. Remove the input power to the V450-PRO.

2. Using the #2 Phillips screwdriver, remove the case front panel.

5. Locate and remove plug J33 from the control board. See Figure F.15.

6. Check the resistance and continuity of the SPI cable by testing with the ohmmeter from each pin on plug J33 to the corresponding pins on plug J34. See the Wiring Diagram.

7. The resistance reading pin to corresponding pin should be zero ohms or very low resistance. If the resistance reading is high or “open” check the plug connections to the SPI network PC boards. If the connections are OK and the resistance is high or “open” the SPI cable may be faulty.

10. Turn on the machine.

11. Carefully check for the presence of +15VDC from plug J33 pin -1(+) to plug J33 pin -10(-) at the display board receptacle.

12. Carefully check for the presence of +5VDC from plug J33 pin -2(+) to plug J33 pin -10(-) at the display board receptacle.

13. If either of these voltages are low or not present, the control board may be faulty. Replace.

Also Perform the Power Board Test.

14. Remove the input power to the V450-PRO machine.

15. Replace any cable ties previously removed.

16. Replace the case front.

8. Reconnect the plug into the control board.

9. With plug J33 reinstalled in the control board, carefully apply the correct input power to V450-PRO.

FIGURE F.15 - Plug J33

PLUG J33

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INVERTEC® V450-PRO

F-59 F-59

TROUBLESHOOTING AND REPAIR

CONTROL OR POWER BOARD

REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION

This procedure will aid the technician in the removal and replacement of either the power board or the control board.

MATERIALS NEEDED

3/8 in. Nut Driver Phillips Head Screwdriver Anti-Static Wrist Strap

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INVERTEC® V450-PRO

POWER BOARD

CONTROL BOARD

COMPARTMENT

COVER

POWER BOARD

CONTROL BOARD

COMPARTMENT COVER

F-60 F-60

TROUBLESHOOTING AND REPAIR

CONTROL OR POWER BOARD

REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.16 – BOARD LOCTION

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REMOVAL PROCEDURE

1. Remove input power to the V450-PRO.

2. Remove the case top, sides and front.

3. Perform the Capacitor Discharge

Procedure.

4. Observe all static electricity precautions.

5. Using the 3/8 in. nut driver, remove the PC board compartment cover. Refer to Figure F.16.

6. Remove the molex plugs from the control board.

INVERTEC® V450-PRO

7. Label and remove the two molex plugs and white and black wires with quick connects from the power PC board.

8. Using the 3/8 in. nut driver, remove the two screws holding the rear of the Control Box in place.

9. Clear the lead harnesses from the left and right sides, and carefully remove the power and control PC board assembly.

10. Remove either the power or the control board

from the PC board assembly.