Lincoln Electric V300-PRO User Manual

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INVERTEC V300-PRO

OPERATOR’S MANUAL

For use with machines Code 10256 and 10257.

IM526-B

December,1999

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO

NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most

importantly, think before you act and be careful.

™

Date of Purchase: Serial Number: Code Number: Model: Where Purchased:

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

RETURN TO MAIN INDEX

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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.

WELDING SPARKS can cause fire or explosion.

4.a..Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot

materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

4.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

4.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

4.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned.” For information purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

4.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

ARC RAYS can burn.

2.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

2.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

2.c. Protect other nearby personnel with suitable non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK can kill.

1.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

1.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire)

Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

1.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically“hot”.

1.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

1.e. Ground the work or metal to be welded to a good electrical (earth) ground.

1.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

1.g. Never dip the electrode in water for cooling.

1.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

1.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

1.j. Also see Items 4.c. and 6.

WARNING

ARC WELDING can be hazardous.

FUMES AND GASES can be dangerous.

3.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes

and gases away from the breathing zone. When welding

with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

3.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

3.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

3.d. Read and understand the manufacturer’s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

3.e. Also see item 7b.

Apr. ‘93

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FOR ENGINE powered equipment.

7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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

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FOR ELECTRICALLY powered equipment.

6.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

6.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode if damaged.

5.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All

hoses, fittings, etc. should be suitable for the application and maintained in good condition.

5.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

5.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

5.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

5.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

5.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

5.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,”available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

7.c.Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

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7.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

7.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

7.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

7.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

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7.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

Mar. ‘93

ELECTRIC AND MAGNETIC FIELDS may be dangerous

8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines.

8.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

8.c. Exposure to EMF fields in welding may have other health effects which are now not known.

8d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

8.d.1. Route the electrode and work cables together - Secure them with tape when possible.

8.d.2. Never coil the electrode lead around your body.

8.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

8.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

8.d.5. Do not work next to welding power source.

4.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

4.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

4.h. Also see item 7c.

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PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié ainsi

qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la peau

de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne 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

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

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TABLE OF CONTENTS

Page

Safety Precautions.............................................................................................................2-4

Introductory Information.......................................................................................................6

Product Description..............................................................................................................7

Specifications.......................................................................................................................7

Installation.........................................................................................................................7-10

Safety Precautions ........................................................................................................7

Location.........................................................................................................................7

Electrical Installation......................................................................................................7

Input Voltage Setup.......................................................................................................8

Power Cord Connection ................................................................................................8

Connection of Wire Feeders to Invertec .....................................................................8-10

Output Cables & Plugs.................................................................................................10

Operating Instructions......................................................................................................11-13

Safety Precautions .......................................................................................................11

Controls Description and Function.............................................................................11-13

Maintenance.....................................................................................................................13-14

Capacitor Discharge Procedure ...................................................................................13

Routine Maintenance....................................................................................................13

Periodic Maintenance...................................................................................................14

Troubleshooting Guide.....................................................................................................14-20

Matched Parts.....................................................................................................................20

Switch P.C. Board Replacement Procedure.......................................................................20

Replacement of Power Modules and Output Diodes .......................................................20-21

Connection Diagrams.......................................................................................................22-31

Wiring Diagrams...............................................................................................................32-33

Parts Lists......................................................................................................................appendix

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Thank You

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

CAUTION

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above.

Page 7

PRODUCT DESCRIPTION

The Invertec V300-PRO is a 300 amp arc welding power source that utilizes single or three phase input power to produce either constant voltage or constant current outputs. The V300-PRO is designed for 60 Hz supply systems. The welding response of the Invertec has been optimized for GMAW, SMAW, TIG and FCAW processes. It is designed to be used with the LN-25 and LN-7 semiautomatic wire feeders.

SPECIFICATIONS

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INSTALLATION

ELECTRIC SHOCK can kill.

• Have an electrician install and service this equipment.

• Turn the input power off at the fuse box before working on equipment.

• Do not touch electrically hot parts.

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WARNING

LOCATION

The Invertec has been designed with many features to protect it from harsh environments. Even so, it is important that simple preventative measures are followed in order to assure long life and reliable operation.

• The machine must be located where there is free circulation of clean air such that air movement into the sides and out the bottom and front will not be restricted. Dirt and dust that can be drawn into the machine should be kept to a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown of the Invertec.

• Keep machine dry. Shelter from rain and snow. Do not place on wet ground or in puddles.

ELECTRICAL INSTALLATION

1. The Invertec should be connected only by a qualified electrician. Installation should be made in accordance with the U.S. National Electrical Code, all local codes and the information detailed below.

2. Single voltage, 575 VAC machines, can only be connected to 575 VAC. No internal reconnection for other input voltages is possible.

3. Initial 208 VAC and 230 VAC operation will require a voltage panel setup, as will later reconnection back to 460 VAC:

a. Open the access panel on the right side of

the machine.

b. For 208 or 230: Position the large switch to

200-230. For 460: Position the large switch to 380-460.

c. Move the “A” lead to the appropriate terminal.

Product Ordering Input AC Rated DC Output Input Amps at Rated DC Output Output Weight Dimensions

Name Information Voltage Amps/Volts/Duty Cycle

208 230 460 575

Range with Gun HxWxD

(continuous) (net)

208/230/460 300A / 32V / 60%

(1)

48 43 24

3 Phase 250A / 30V / 100%

(1)

37 33 19

60 Hz

300A / 35/39/41V /60%

(2)

49 48 28

18.7*x10.8x

Invertec K1349-3 22.2”

V300- 208/230/460 250A / 30V / 60%

(1)

69 62 38 AMPS 64 lbs. (475x274x

PRO 1 Phase 160A / 28V / 100%

(1)

53 47 29 5-350 (29 kg) 564 mm)

60 Hz

250A / 37/41/43V / 60%

(2)

75 67 42

* Includes

575 300A / 32V / 60%

(1)

20 handle

K1349-4 3 Phase 250A / 30V / 100%

(1)

60 Hz 300A / 36V / 60%

(2)

(1 )

NEMA Class I Rated Output / Based on a 10 min. Period .

(2 )

Lincoln plus rating.

* Overall Height Including Handle, (16.4” (417mm without handle).

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INPUT VOLTAGE SETUP

POWER CORD CONNECTION

A 10 ft. (3.0m) power cord is provided and wired into the machine. Follow the power cord connection instructions. Incorrect connection may result in equipment damage.

Single Phase Input

1. Connect green lead to ground per U.S. National Electrical Code.

2. Connect black and white leads to power.

3. Wrap red lead with tape to provide 600V insulation.

Three Phase Input

1. Connect green lead to ground per U.S. National Electrical Code.

2. Connect black, red and white leads to power.

Install in accordance with all local and national electric codes.

CONNECTION OF WIRE FEEDERS TO THE INVERTEC

(Note: IEC units do not have 110 VAC auxiliary power).

LN-25 Connection Instructions

1. Turn the Invertec power switch “off”.

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

3. LN-25 with remote control options K431 and K432. Use K876 adapter with K432 cable or modify K432 cable with K867 universal adapter plug. See connection diagram S19899 and S19309 or S19405 at the back of this manual.

4. Place the local-remote switch in the “remote” position if output control is desired at the wire feeder rather than the Invertec. (LN-25 must have K431 and K432 options for remote output control operation).

LN-7 Connection Instructions

1. Turn the Invertec power switch “off”.

2. Connect the K480 control cable from the LN-7 to

the Invertec control cable connector. The control cable connector is located at the rear of the Invertec.

3. Connect the electrode cable to the output terminal

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

4. Place the local-remote switch in the “local” posi-

tion to allow output control at the Invertec. (K864

Recommended Fuse Sizes Based On The U.S.

National Electrical Code And Maximum

Machine Outputs

Fuse Size in Amps

Input Volts

(1)

(Time Delay Fuses)

3 phase 208 60

50/60 Hz 230 60

460 40

1 phase 208

(2)

50/60 Hz 230

(2)

460 50

3 phase 575 30

60 Hz

(1)

Input voltage must be within ±10% of rated value.

(2)

When operating on these inputs, at outputs exceeding 200A/60% or 165A/100%, the input line cord should be changed to an input conductor of 6 AWG or larger.

DO NOT ATTEMPT TO POWER THIS UNIT FROM THE AUXILIARY POWER SUPPLY OF AN ENGINE WELDER.

• Special protection circuits may operate, causing loss of output.

• The supply from engine welders often has excessive voltage peaks because the voltage waveform is usually triangular shaped instead of sinusoidal.

• If voltage peaks from the engine welder exceed 380V, the input circuits of this machine protecting the filter capacitors, FETS and other components from damage will not

be energized .

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CAUTION

RECONNECT PROCEDURE

1. BE SURE POWER SWITCH IS OFF.

2. CONNECT LEAD ’A’ TO DESIRED

INPUT VOLTAGE RANGE.

440-460V

380-415V

220-230V

200-208V

3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.

Disconnect input power before inspecting or servicing machine.

Do not operate with wraparound removed.

Do not touch electrically live parts.

Only qualified persons should install,

’A’

IF MACHINE CEASES TO OPERATE (NO METER, NO FAN) AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE; REPLACE WITH A 3 AMP SLOW BLOW ONLY.

use or service this equipment.

VOLTAGE=380-460V

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

9-11-92

VOLTAGE=200-230V

S20324

BLACK

GREEN

RED

WHITE

Page 9

– 9 –– 9 –

remote control adapter and K857 remote control are required for remote output control).

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

6. If K480 is not available, see connection diagram S19404 for modification of K291 or K404 LN-7 input cable with K867 universal adapter plug.

General Instructions for Connection of Wire Feeders to Invertec

Wire feeders other than LN-7 and LN-25 may be used provided that the auxiliary power supply capacity of the Invertec is not exceeded. K867 universal adapter plug is required. See connection diagram S19406 and S19386 at the back of this manual for more information.

Remote Control of Invertec

Remote control K857, hand amptrol K963 and foot amptrol K870 require K864 remote control adapter. See 19309 instruction at the back of this manual for connection information.

K954-1 MIG PULSER

The MIG Pulser is a hand-held “pendant” type GMAW Pulsing option for the V300 Power Source. Refer to the Mig Pulser’s IM manual (IM555) for connection information.

Parallel Operation

The Invertec’s are operable in parallel in both CC and CV modes. For best results, the currents of each machine should be reasonably well shared. As an example, with two machines set up in parallel for a 400 amp procedure, each machine should be set to deliver approximately 200 amps, not 300 amps from one and 100 amps from the other. This will minimize nuisance shutdown conditions. In general, more than two machines in parallel will not be effective due to the voltage requirements of procedures in that power range.

To set machine outputs, start with output control pots and arc force/pinch pots in identical positions. If running in a CC mode, adjust outputs and arc forces to maintain current sharing while establishing the proper output current. In CV modes, the pots in identical positions. Then switch the machine meters to amps and adjust one of the output control pots for current balance. Check the voltage and if readjustment is necessary, repeat the current balancing step. Pinch settings should also be kept identical on the machines.

K900-1 DC TIG Starter Connection

This versatile new kit was made to mate with the Invertec.

A control cable assembly is supplied with the kit to connect the kit to an Invertec. The cable can be connected, either end, at the DC TIG Starter kit and at the Invertec by attaching to the 14-pin Amphenols on the backs of each unit. Refer to diagram S20405 at the back of this manual.

A negative output cable assembly is also supplied with the DC TIG Starter kit to connect the kit with the Invertec’s negative output terminal.

All Magnum™ one and two piece water-cooled torches with 7/8 left-hand threads and gas-cooled torches with 7/8 and 5/16 right-hand threads can be connected to the starter kit.

To secure the DC TIG Starter kit to the bottom of the Invertec and for more detailed instructions, refer to the K900-1 manual.

MAR97

Page 10

LN-9 GMA Connection Instructions

1. Turn the Invertec power switch “off”.

2. Connect the K596 control cable assembly from the LN-9 GMA to the Invertec control cable connector. The control cable connector is located at the rear of the Invertec.

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

4. Place the local-remote switch in the “remote” position to allow output control at the LN-9 GMA.

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

6. K608-1 adapter is required in LN-9 GMA for LN-9 type control. K608-1 is installed in line with P10 connection at the LN-9 GMA voltage board. See diagram S20607 at the back of this manual.

7. K442-1 Pulse Power Filter Board is also required for GMAW, but should be disconnected for FCAW.

8. If K596 is not available, see connection diagram S20608 at the back of this manual for modification of K196 LN-9 GMA input cable with K867 universal adapter plug.

Output Cables

Select the output cable size based upon the following chart.

Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75° rated:

Duty Length Up 61-76m

Cycle Current 61m (200 ft.) (200-250 ft.)

100% 250 1/0 1/0

60% 300 1/0 2/0

Quick Disconnect Plugs

A quick disconnect system is used for the welding cable connections. The welding plug included with the machine is designed to accept a welding cable size of 1/0 to 2/0.

1. Remote 25mm (1 in.) of welding cable insulation.

– 10 –

2. Slide rubber boot onto cable end. The boot end may be trimmed to match the cable diameter. Soap or other lubricant will help to slide the boot over the cable.

3. Slide the copper tube into the brass plug.

4. Insert cable into copper tube.

5. Tighten set screw to collapse copper tube. Screw must apply pressure against welding cable. The top of the set screw will be well below the surface of the brass plug after tightening.

6. Slide rubber boot over brass plug. The rubber boot must be positioned to completely cover all electrical surfaces after the plug is locked into the receptacle.

25 mm

1 in.

WELDING CABLE

BOOT

TRIM

SET SCREW

BRASS PLUG

COPPER TUBE

Page 11

– 11 –

OPERATING INSTRUCTIONS

DUTY CYCLE

The Invertec is rated at 300 amps, 60% duty cycle for 3 phase inputs (based on a 10 minute cycle). It is also rated at 250 amps, 100% duty cycle.

CONTROL FUNCTION / OPERATION Power Switch - Place the lever in the “ON” position to

energize the machine. When the power is on, the digital meter will activate and the fan will operate.

ELECTRIC SHOCK can kill.

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

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

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

FUMES AND GASES can be danger-

ous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

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

WELDING SPARKS can cause fire or

explosion.

• Keep flammable material away.

• Do not weld on closed containers.

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

ARC RAYS can burn eyes and skin.

• Wear eye, ear and body protection.

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

See additional warning information at

front of this operator’s manual.

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

WARNING

Output Control - This controls the output voltage in

the CV modes and output current in the CC modes. Control is provided over the entire output range of the

power source with 1 turn of the control knob. This control may be adjusted while under load to change power source output.

Local/Remote Switch - Place in the “LOCAL” position to allow output adjustment at the machine. Place in the “REMOTE” position to allow output adjustment at the wire feeder or with a remote control option package.

Digital Meter Switch - Select either “A” for amps or “V” for volts to display welding current or voltage on the meter.

When welding current is not present, the meter will display the set current for the CC modes or the set voltage for the CV modes. This set reading is an indication of machine control setting. For a more precise process reading, read meter during actual welding.

Mode Switch

GTAW Optimized for both scratch start and Hi-

Freq kit use.

CC SOFT Best for EXX18 thru EXX28 stick elec-

trodes.

CC Crisp Use this mode for stick welding with

EXX10 thru EXX14 electrodes. Nonwelding applications such as resistive heating or output tests with resistive loads should be done in this mode with Arc Force Control set to minimum.

OUTPUT

REMOTE

OFF

Page 12

–

CV FCAW This setting has been optimized for

Innershield®and Outershield®flux-cored electrodes.

CV GMAW Short circuit, glob and spray transfer

solid wire and gas welding are done in this mode. Low end procedures, less than 17V, may operate better in the FCAW mode. Voltage in the GMAW

mode can become erratic when welding is attempted using voltages equal to or less than 17V DC+.

Output Terminals Switch

For processes and equipment that require energized machine terminals (stick, TIG, air-carbon arc cutting or hot tip LN-25), set the Output Terminals Switch to “ON” position.

Set to the REMOTE (OFF) position when using LN-25 with K431 and K432 options or LN-7 which will allow the gun trigger to energize the welding terminals.

Arc Force / Inductance Control

This control functions in all modes except GTAW. For CC modes, this control acts as an Arc Force adjustment. The arc is soft at the minimum settings and more forceful or driving at the maximum settings. Higher spatter levels may be present at the maximum settings.

For CV modes, this control will set the degree of “pinch effect” which predominantly affects short circuit transfer. In FCAW, the maximum setting is generally preferred. With GMAW, the upper half of the range is preferred with CO2or high content CO2mixed. The

lower half is for inert gas mixes.

– 12 –

Recommended Arc Force / Inductance Settings

For Selected Applications

Full Range Is 1-10,

1 Is Very Soft, 10 Is Very Crisp

Nominal Recommended

Mode Process Setting Adjustment Range

CC SMAW 1 EXX18 thru 5 1 (gentle, may stick) to 9

EXX28 stick (forceful, more spatter)

CC SMAW 2 EXX10 thru 6 3 to 10

EXX14 stick

Air Carbon Arc 1 None

Cutting

CV FCAW Innershield or 10 None

Outershield

Air Carbon Arc 1 None

Cutting

CV GMAW* CO2or 25% CO27.5 5 to 10

or similar

gas mixes

98% Ar-2% O2Ar, 5 1 to 10

90% He-7.5% Ar

2.5% CO2and other

predominantly

inert gases

* 1 = Lowest pinch, highest inductance and least spatter.

10 = Highest pinch, lowest inductance and most spatter.

GMAW

FCAW

SMAW CRISP

SMAW SOFT

GTAW

OUTPUT

TERMINALS

REMOTE

Page 13

– 13 –

Meter Polarity Switch

The wire feeder polarity switch is located at the rear of the machine. The switch provides a work connection for wire feeder voltmeters. Place the switch in the position of the electrode polarity indicated by the decal. The switch does not change the welding polarity.

Auxiliary Power

A 24 VAC @ 1 amp supply is included for use with the LN-25 wire feeder (24 volts needed for K431 and K432 options). This supply is protected by a selfresetting current limiter.

A 42 VAC @ 5.5 amp supply is included for use with other wire feeders. This supply is protected by a 6 amp breaker located on the rear of the machine.

A 110/115 VAC @ 2 amp supply is included for use with the LN-7 or LN-9 GMA wire feeders. This supply is protected by a 2.5 amp breaker located on the rear of the machine. It is NOT

available on IEC units.

All three supplies are not to be loaded simultaneously.

MAINTENANCE

Capacitor Discharge Procedure

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

2. Hold resistor body with electrically insulated glove. DO NOT TOUCH TERMINALS. Connect the resistor terminals across the two hex head cap screws in the position shown. Hold in each position for 1 second. For 575 VAC only, repeat for second capacitor. Repeat for the capacitor(s) on the other side of the machine

3. Use a DC voltmeter to check that voltage is not present across either capacitor.

Routine Maintenance

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

• Power, switch, driver, protection and control printed

circuit boards.

• Power switch

• Main transformer

• Input rectifier (located in front of fan blade)

• Heat sink fins

2. Examine the sheet metal case for dents or breakage.

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

CAPACITOR TERMINALS

RESISTOR

T13086-84

ELECTRIC SHOCK can kill.

• Have an electrician install and service this equipment.

• Turn the input power off at the fuse box before working on equipment.

• Do not touch electrically hot parts.

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

EXPLODING PARTS can cause injury.

•

Failed parts can explode or cause other

parts to explode when power is applied.

•

Always wear a face shield and long sleeves when servicing.

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

WARNING

Page 14

– 14 –

PERIODIC MAINTENANCE

Overload Protection

The machine is electrically protected from producing high output currents. Should the output current exceed 340-360A, an electronic protection circuit will reduce the current to approximately 150A. The machine will continue to produce this low current until the protection circuit is reset. Reset occurs when the output load is removed.

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. If the fan is not turning or the air intake louvers were obstructed, then the power must be switched off for 15 minutes in order to reset. The fan problem or air obstruction must also be corrected.

Filter Capacitor Conditioning

A protection circuit is included to monitor the voltage across filter capacitors C1 and C2 (also C14 and C15 on 575 VAC units). In the event that the capacitor voltage is too high, the protection circuit will prevent output. The protection circuit may prevent output providing all these circumstances are met:

1. Machine is internally connected for 380 VAC, or higher input voltage.

2. Machine did not have power applied for many months.

3. Machine did not produce output when power was first switched on.

If these circumstances apply, the proper action is to switch the machine on and let it idle for up to 30 minutes. This is required to condition the filter capacitors after an extended storage time. The protection circuit will automatically reset once the capacitor conditioning and resultant voltage levels are acceptable. It may be necessary to turn the power switch off and back on again after this period.

TROUBLESHOOTING

Visual Inspection

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

Open Circuit Voltage

The open circuit voltage of the Invertec V300-PRO is 60 to 75 VDC and cannot be adjusted by the output control.

Test Conditions

Perform all testing at the lowest input voltage available, except where a higher voltage is required by a test step. Make ohmmeter checks only after power has been disconnected from machine and after capacitors have been discharged.

Certain high voltage connections have been insulated with RTV sealant. It is necessary to break through the sealant with a sharp probe in order to make voltage or resistance checks.

Disconnect any control cables from remote control receptacle.

ELECTRIC SHOCK can kill.

• Have an electrician install and service this equipment.

• Turn the input power off at the fuse box before working on equipment.

• Do not touch electrically hot parts.

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

EXPLODING PARTS can cause injury.

•

Failed parts can explode or cause other

parts to explode when power is applied.

•

Always wear a face shield and long sleeves when servicing.

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

WARNING

Page 15

– 15 –

TROUBLESHOOTING GUIDE

Trouble What To Do

Not output but fan operates and meter is on.

Poor welding, weld settings drift, or output power is low.

Main fuses open or Switch PC boards overheated.

Output turns on momentarily then switches off and repeats. Machine is connected for 380 VAC or higher input voltage.

OCV is normal (approx. 65-75V) but output power is low (less than 20V and 100A). Machine makes squealing noise while under load. Machine is connected for 230 VAC, or lower, input voltage.

Open circuit voltage is 1-2 volts.

Output control not functioning on remote control. Local control OK.

Machine does not produce more than 250A output when connected to 3 phase supply.

Machine does not produce more than 200 A output while connected to 1 phase supply.

Machine operates OK at 230 VAC or lower. No output at 380 VAC or higher.

Poor EXX10 stick electrode (5P) performance. Arc “pops out”.

No output or reduced output the first time power is applied to the machine.

Perform test steps 1A and 1B.

1. Check front panel wiring and controls.

2. Replace Control PC Board.

Perform test steps 4 and 5 for both Switch PC Boards and 7.

Perform test steps 3B, 4 and 5.

Perform test steps 4 and 5 for both Switch PC Boards.

Perform test step 6.

1. Check remote control assembly.

2. Check S3, Local/Remote switch.

1. Replace main fuse if blown.

2. Replace Protection PC Board.

3. Replace Control PC Board.

4. Perform test step 7. Normal operation.

Perform test step 2.

Check D6 and D12, L1 and L2.

Check reconnect panel - connections and fuse.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

Page 16

–– 16 –

TEST PROCEDURES

Step

Next Test Step

and

Test

Output pilot circuit (set S4 on)

Protection PC board output (set S4 on)

Static capacitor balance (set S4 off)

380 VAC input and higher test

Dynamic capacitor balance (set S4 on)

380 VAC input and higher test

Repair Action

Replace Power and Control PC Boards

Replace Protection PC Board

Check

223A to 210

302 (pos) to 275D (neg)

313 (neg) to 311 (pos)

Compare voltage across terminals 9 & 12 of each Switch PC Board. 575 VAC -- 407 VDC 460 VAC -- 325 VDC 440 VAC -- 311 VDC 415 VAC -- 293 VDC 380 VAC -- 269 VDC 575 VAC only - compare voltage across 9A & 13 and 13 & 12A; then, 9B & 15 and 15 & 12B

Connect as in step 3A. Same voltages as above.

Test

Result

24 VAC

0 VAC

15 VDC

0 VDC

<1 VDC

>5 VDC

<25 VDC

difference

between readings

>25 VDC

difference

<25 VDC

>25 VDC

Conclusion

Fan thermostat, choke thermostat, T1 transformer and S4 all OK.

Check above components.

T1 and 15V power supply OK.

Check T1 and Power PC Board.

Protection PC Board OK

C1, C2, R1, R9 - OK (575 VAC machine C14, C15 - OK)

Check above components.

Power PC Board or Switch PC Boards are damaged.

CAUTION

Page 17

– 17 –

Step

Next Test Step

cont

Test

Switch PC Board resistance test.

No dynamic test is possible.

Remove leads 401/403, 1/8, 9, 12, 4/5 and 402/404.

Repair Action

Replace Switch PC Board

Check

Terminals on Switch PC Board: 1/8 (pos) to 12 (neg)

1/8 (neg) to 12 (pos)

9 (pos) to 4/5 (neg)

9 (neg) to 4/5 (pos)

1/8 (pos) to 9 (neg)

1/8 (neg) to 9 (pos)

12 (pos) to 4/5 (neg)

12 (neg) to 4/5 (pos)

12 (pos) to 401/403 (neg)

12 (neg) to 401/403 (pos)

9 (pos) to 402/404 (neg)

9 (neg) to 402/404 (pos)

Test

Result

>1K ohms

<100 ohms

>1K ohms

>1K ohms <100 ohms <100 ohms

>1K ohms <100 ohms

>1K ohms

>1K ohms <100 ohms <100 ohms

>1K ohms

>1K ohms <100 ohms

>1K ohms <100 ohms <100 ohms

>1K ohms <100 ohms

>1K ohms

>1K ohms <100 ohms

Conclusion

Short

OK Open OK Short OK Open OK Open OK Short OK Open OK Short OK Short OK Open OK Open OK Short

CAUTION

Page 18

– 18 –

Step

Next Test Step

cont

Test

Snubber Resistors

Disconnect leads 401, 402, 403 and 404 from Switch PC Board

Output diodes

Remove output load

Repair Action

Replace R4

Replace R5

Replace R6

Replace R7

Test individually

Check

Lead 401 to terminal 12

Lead 402 to terminal 9

Lead 403 to terminal 12

Lead 404 to terminal 9

+ output plug (pos)

- output plug (neg)

Test

Result

25 ohms

>30 ohms <20 ohms

25 ohms

>30 ohms <20 ohms

25 ohms

>30 ohms <20 ohms

25 ohms

>30 ohms <20 ohms

<100 ohms

>200 ohms

Conclusion

OK R4 open

R4 shorted OK R5 open

R5 shorted OK R6 open

R6 shorted OK R7 open

R7 shorted

Shorted output diode D1 thru D12

Output diodes OK

CAUTION

Page 19

Repair Action

Replace D13, inspect S1, test C1 and C2

Check

9 (pos) to H1 (neg)

9 (pos) to A (neg)

9 (pos) to H5 (neg)

12 (neg) to H1 (pos)

12 (neg) to A (pos)

12 (neg) to H5 (pos)

9 (neg) to H1 (pos)

9 (neg) to A (pos)

9 (neg) to H5 (pos)

12 (pos) to H1 (neg)

12 (pos) to A (neg)

12 ( pos) to H5 (neg)

Conclusion

OK Shorted

OK Open

– 19 –

Step

Next Test Step

cont

4-5

cont

4-5

cont

4-5

cont

4-5

cont

4-5

cont

4-5

cont

4-5

cont

4-5

cont

4-5

cont

4-5

cont

4-5

cont

4-5

Test

D13 Input Rectifier

Test

Result

>1K ohms

<100 ohms

>1K ohms

<100 ohms

>1K ohms

<100 ohms

>1K ohms

<100 ohms

>1K ohms

<100 ohms

>1K ohms

<100 ohms

>1K ohms

<100 ohms

>1K ohms

<100 ohms

>1K ohms

<100 ohms

>1K ohms

<100 ohms

>1K ohms

<100 ohms

>1K ohms

Page 20

–

Matched Parts

Certain parts must be replaced in matched sets. Matched sets are required in the following areas:

Output diodes: D1, D2, D3, D4 and D5 Output diodes: D7, D8, D9, D10 and D11 Capacitor bleeder resistors: R1 and D9 Capacitors: C1 and C2 Capacitors: C1, C2, C14 and C15 (575 VAC only)

Switch PC Board Repairs If a test indicates that a Switch PC Board is defective,

both Switch PC Boards must be replaced. Replacement boards must

have completely identical part numbers. A defective module is likely to damage other devices in the power circuitry. The defect may be subtle and not detectable by an ohmmeter measurement. Unknown defective parts may cause newly replaced parts to fail.

In addition to replacing the Switch PC Boards, replace C1 and C2 (also C14 and C15 of the 575 VAC V300PRO) if the following conditions are met:

1. Machine was operating from 380 VAC or higher

supply when failure occurred.

2. Switch PC Boards have burned areas.

Switch PC Board Replacement Procedure

1. Carefully disconnect the leads at the top of the

Switch PC Board.

2. Remove the four socket head cap screws with a

3/16” hex key wrench.

3. While holding the Switch PC Board, remove the

hex head cap screws from the center area of the board.

4. Remove the board.

– 20 –

5. Thoroughly clean the heat sink surface.

6. Apply a thin layer (ideally .005-.010”) of Dow 340 Heat Sink Compound to the module mounting surfaces of the new Switch PC Board and a thinner layer (.002”) to the capacitor terminals. Keep the heat sink compound away from the screw threads since this compound will affect the torque specifications.

7. Carefully place the Switch PC Board onto the heat sink. Be sure the mounting holes are lined up before making full contact with the heat sink.

8. Caution: The heat sink and the capacitor terminals are relatively soft material and it is very easy to cross-thread the mounting screws. Holding the Switch PC Board, install the 4 socket head cap screws, finger tight only. Then install the hex head cap screws into the capacitor, finger tight only.

9. Torque the 4 socket head cap screws to 44 inchlbs force (5 N - m). Then torque the capacitor hex head cap screws to 55 inch-lbs force (6 N - m).

10. Reconnect all the leads to the board.

Before applying input power to the machine, check all electrical connections. An incorrect connection will result in machine damage when the power is switched on.

Test After Repair

1. Short terminals 14 and 53 of the Protection PC Board. Connect an ohmmeter, set for X1000 range, to terminals 9 (+) and 12 (-) of the Switch PC Board. The meter will show the capacitors charging up. The meter may take a minute or so to stabilize. The value must not exceed 8600 ohms. Test both boards. For 575V only units - measure across each power capacitor, 2 per switch board; All four readings should be approximately 5,000 ohms.

2. If OK, remove the short and proceed with the power test.

3. Fuse input supply with 5 amp fuses.

4. Check output open circuit voltages. Do not apply output load.

5. Connect machine for 460 (V300-PRO), or 575 (V300-PRO, 575V), or 380, 415 or 440 (V300-I) VAC input.

6. Check output open circuit voltages. Do not apply output load.

7. Fuse for 20 amps and test under load.

ELECTRIC SHOCK can kill.

• Have an electrician install and service this equipment.

• Turn the input power off at the fuse box before working on equipment.

• Do not touch electrically hot parts.

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

EXPLODING PARTS can cause injury.

•

Failed parts can explode or cause other

parts to explode when power is applied.

•

Always wear a face shield and long sleeves when servicing.

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

WARNING

Page 21

– 21 –

Replacement of Power Modules and Output Diodes

Input rectifier, D13, is a power module. When mounting power modules, the heat sink and module mounting surface should be clean and free of burrs and foreign material. Apply heatsink compound (Dow 340) as a uniform layer ideally .010” thick, to eliminate all air pockets. This may be verified by mounting and then removing the module. When removed, the compound on both surfaces will appear textured as if a vacuum had created veinlike ridges when the parts were separated. If the compound does not have this appearance, apply more heatsink compound and recheck.

Replacement of output diodes D1 thru D12 is similar. Clean and brighten mounting surface with fine steel wool. Compound should be used on surface between diode and heat sink when mounting individual diodes.

The compound should be applied to the heat sink in a very thin layer, less than 0.001 in. DO NOT apply on diode stud and mounting nut threads.

Components must have proper torque applied to mounting screws and to electrical terminals. Torque the modules according to the following:

Component to Heat Sink Terminal

Component Torque ±10% Torque ±10%

Switch Board

Module 44 Inch - Lbs.

(1)

N.A.

(5N - m)

Capacitor N.A. 55 Inch - Lbs.

(6.3 N - m)

Input Rectifier 6 Inch - Lbs.

(2)

26 Inch - Lbs.

(M15454-1) (0.7 N - m) 3 (N - m)

Output Diode 25 Inch - Lbs. N.A.

(M15482-2) (3 N - m)

(1)

Retorque after 3 hours to allow for spread of compound.

(2)

Tighten in staggered fashion one quarter turn at a time.

Environment Protection

High voltage connections are covered with an RTV sealant to prevent malfunction in severe environments. Sealant must be applied to connections which have been opened or otherwise lost their protection. A noncorrosive electronic grade sealant such as Dow Corning 3140, 3145, 738, Columbus Adhesives 0172 or GE RTV-162 is recommended. Sealant may also be purchased from Lincoln Electric (order E2519 Silicone Rubber RTV Coating). Apply sealant after machine is repaired and tested.

High voltage areas which require sealant are as listed:

- Input rectifier D13, all 5 terminals.

Printed Circuit Board Replacement

1. Handle PC Boards by edges only.

2. Store PC Boards only in the bags that disperse static charges.

3. Inspect PC Board for burned conductors or components. If damage is visible, inspect the machine wiring for grounds or shorts to avoid damaging a new PC Board.

4. If there is no visible damage to the PC Board, install a new PC Board and see if the problem is fixed. If the problem is fixed by the new board, reinstall the old board and see if the problem reoccurs. If the problem does not reoccur, check the wiring harness and plugs for loose connections.

Page 22

– 22 –

2) K963 HAND AMPTROL

3) K870 FOOT AMPTROL TO: 1) LN-7 WIRE FEEDERS

TO: 1) K857 REMOTE CONTROL

CABLE RECEPTACLE (6 SOCKET)

CABLE RECEPTACLE (14 SOCKET)

S19309

4-19-96D

TO: 1) LN-25 WIRE FEEDERS

CABLE RECEPTACLE (6 SOCKET)

TURN THE POWER SWITCH OF THE WELDING POWER

SOURCE "OFF" BEFORE INSTALLING PLUGS ON CABLES

OR WHEN CONNECTING OR DISCONNECTING PLUGS TO

WELDING POWER SOURCE.

REMOTE CONTROL ADAPTERS

STRAIGHT PLUG (14 PIN)

TO POWER SOURCE

K864

STRAIGHT PLUG (14 PIN)

TO POWER SOURCE

K876

Page 23

– 23 –

A=32

B=GND

C=2

L=82

D=4

E=77

S19386

3-16-90

INSTALLATION INSTRUCTIONS

K=42

J=31

A=32

I=41

B=GND

N=SPARE

H=21

L=82

H=21

N=SPARE

C=2

G=75

D=4

F=76

E=77

M=81

14-PIN BOX RECEPTACLE, REAR VIEW

AND 14-PIN CABLE PLUG, FRONT VIEW

M=81

AND 14-PIN CABLE PLUG, REAR VIEW

14-PIN BOX RECEPTACLE, FRONT VIEW

MAY OR MAY NOT BE ISOLATED, INDEPENDENT CIRCUITS INSIDE THE WELDER.

TO ANY OF THE 14 CIRCUITS PRESENT IN THE WIRE FEEDER RECEPTACLE.

WIRE FEEDER RECEPTACLE. IT IS DESIGNED TO ALLOW THE USER TO MAKE CONNECTIONS

THIS CONNECTOR IS MEANT TO BE USED WITH LINCOLN POWER SOURCES WHICH HAVE A 14-PIN

THIS ADAPTER TO WIRE FEEDER CABLE.

K867 UNIVERSAL ADAPTER FOR 14-PIN WIRE FEEDER RECEPTACLE

CONSULT THE WIRING DIAGRAM OF THE POWER SOURCE AND WIRE FEEDER THIS ADAPTER WILL BE USED WITH.

1. TURN THE POWER SWITCH OF THE WELDING POWER SOURCE OFF BEFORE INSTALLING

NOT ALL CIRCUITS ARE PRESENT IN EVERY POWER SOURCE, NOR ARE THEY REQUIRED FOR PROPER WIRE FEEDER OPERATION.

NOTE: 115V AC (31, 32), 42V AC (41, 42), 24V AC (SPARE) AND TRIGGER CIRCUIT (2, 4)

THE STANDARD CONNECTOR PIN DESIGNATIONS AND FUNCTIONS ARE SHOWN BELOW.

2. CONSULT THE APPROPRIATE EQUIPMENT WIRING DIAGRAMS FOR THE CONNECTIONS TO UNIVERSAL ADAPTER.

IN THE UNIVERSAL ADAPTER. THE INSULATING METHOD MUST BE RATED FOR 120V AC OR GREATER.

3. USE LUG, CRIMP SPLICE OR SOLDER CONNECTIONS AS REQUIRED AND INSULATE EACH USED AND UNUSED LEAD STANDARD FUNCTION

115V AC

CHASSIS CONNECTION

TRIGGER CIRCUIT

GND

LEAD

REFERENCE ONLY AND EACH MAY OR

(SEE APPROPRIATE WIRING DIAGRAM)

MAY NOT BE PRESENT IN YOUR EQUIPMENT.

THESE FUNCTIONS ARE LISTED FOR

WORK

42V AC

OUTPUT CONTROL

TRIGGER CIRCUIT

OUTPUT CONTROL

42V AC

115V AC

24V AC

WELDING MODE CONTROL

SPARE

Page 24

– 24 –

LN-7

CONTROL

BOX

LN-7

CONTROL

BOX

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.D. SPLICE LEADS AND INSULATE.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.

INVERTEC

WITH 115VAC

INVERTEC

WITH 115VAC

POWER SOURCE

AUXILIARY POWER

828142

SPARE

AUXILIARY POWER

N.C.

ADAPTER PLUG

K291 OR K404

INPUT CABLE

K291 OR K404

K867 UNIVERSAL

INPUT CABLE

GND

GREEN

WORK

757677

14 PIN

AMPHENOL

14 PIN

AMPHENOL

757677

TO LN-7

K775 OPTIONAL

REMOTE CONTROL

K775 OPTIONAL

REMOTE CONTROL

ELECTRODE CABLE

CAN KILL

ELECTRIC

SHOCK

N.D.

Only qualified persons should install, use or

service this machine.

S19404

12-10-93A

K867 PLUG TO LN-7 - CONNECTION DIAGRAM

WARNING

Turn off input power to the Welding Power Source

using the disconnect switch at the fuse box

Before connecting the wire feeder.

GND

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

N.D.

SHOCK

ELECTRIC

CAN KILL

WARNING

K867 PLUG TO LN-7 - CONNECTION DIAGRAM

12-10-93A

S19404

CAN KILL

REMOTE CONTROL

ELECTRODE CABLE

TO LN-7

ELECTRODE CABLE

TO LN-7

14 PIN

AMPHENOL

14 PIN

AMPHENOL

K775 OPTIONAL

WORK

GND

GREEN

K291 OR K404

INPUT CABLE

K291 OR K404

INPUT CABLE

K867 UNIVERSAL

ADAPTER PLUG

INVERTEC

N.C.

CONTROL

BOX

CONTROL

BOX

AUXILIARY POWER

POWER SOURCE

AUXILIARY POWER

WITH 115VAC

SPARE

LN-7

N.D. SPLICE LEADS AND INSULATE.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.

N.D. SPLICE LEADS AND INSULATE.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

Page 25

– 25 –

LN-25 WITH

N.C.

2182814241

K431 OPTION

GND

K432 REMOTE

SPARE

CONTROL CABLE

C77

N.D.

N.E.

S19405

1-25-91

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

ELECTRIC

WARNING

CAN KILL

14 PIN

AMPHENOL

K867 PLUG TO LN-25 - CONNECTION DIAGRAM

WORK

ELECTRODE CABLE

TO LN-25

K867 ADAPTER

INVERTEC

POWER SOURCE

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.D. REMOVE 6 PIN PLUG FROM K432 CABLE IN ORDER TO CONNECT K867 PLUG.

LABEL EACH LEAD (A THRU F) AS THEY ARE REMOVED FROM 6 PIN PLUG.

N.E. SPLICE LEADS AND INSULATE.

Page 26

– 26 –

N.D.

N.C.

CONNECT TOGETHER FOR

NOT USED ON INVERTEC

WELDING OUTPUT

24 VAC / 1 AMP

115 VAC / 2 AMP

42 VAC / 5.5 AMP

WIRE FEEDER VOLTMETER CONNECTION

CONNECTS TO (WORK TERMINAL) OF INVERTEC

INVERTEC FRAME CONNECTION

REMOTE OUTPUT CONTROL

MIN.

10K

WIRE FEEDER

12-10-93A

S19406

GND

SPARE

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

ELECTRIC

WARNING

K867 UNIVERSAL ADAPTER / INVERTEC - CONNECTION DIAGRAM

CAN KILL

14 PIN

AMPHENOL

ELECTRODE CABLE

WORK

K867 UNIVERSAL

ADAPTER PLUG

INVERTEC

POWER SOURCE

WITH 115VAC

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

AUXILIARY POWER

REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.

K867

N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION

RELAY TO CLOSE LEADS 2 & 4.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

Page 27

– 27 –

LN-25 WITH

K431 OPTION

6 PIN

AMPHENOL

K432 REMOTE

CONTROL CABLE

S19899

1-25-91

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

ELECTRIC

WARNING

CAN KILL

14 PIN

AMPHENOL

K876 ADAPTER

K876 ADAPTER TO LN-25 - CONNECTION DIAGRAM

WORK

ELECTRODE CABLE

TO LN-25

INVERTEC

POWER SOURCE

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.

N.C. FOR INVERTECS WITH 6 PIN AMPHENOL, K432 CABLE CAN BE CONNECTED DIRECTLY.

Page 28

– 28 –

LN-7

CONTROL

BOX

14 PIN

AMPHENOL

K857

REMOTE CONTROL

K963

K480-7 INPUT CABLE

6 PIN

AMPHENOL

HAND AMPTROL

K870

FOOT AMPTROL

S19901

4-19-96D

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

ADAPTER

SHOCK

ELECTRIC

WARNING

CAN KILL

14 PIN

AMPHENOL

ELECTRODE CABLE

WORK

TO LN-7

K864 ADAPTER TO LN-7 & REMOTE CONTROL - CONNECTION DIAGRAM

K864

INVERTEC

AUXILIARY POWER

WITH 115VAC

POWER SOURCE

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.C. K480-7 INPUT CABLE CAN BE CONNECTED DIRECTLY IF REMOTE CONTROL IS NOT REQUIRED.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.

N.D. K864 ADAPTER CANNOT BE USED WITH AN LN-25.

Page 29

– 29 –

K963

K870

HAND AMPTROL

FOOT AMPTROL

K814

ARC START SWITCH

4-19-96D

S20405

CONSULT INVERTEC INSTRUCTION MANUAL FOR

APPROPRIATE WIRE FEEDERS AMD CONNECTORS.

Starter to the power source, or the Amptrol or Wire Feeder

Turn off input power to the Welding Power Source using the

to the DC Tig Starter.

disconnect switch at the fuse box before connecting the DC Tig

Only qualified persons should install, use or service this machine.

TO TIG

TORCH

OUT

N.C.

WORK

WARNING

SHOCK

ELECTRIC

CAN KILL

WIRE FEEDER

K900-1

DC TIG STARTER

N.B.

BOTTOM 14 PIN

AMPHENOL

TOP 14 PIN

AMPHENOL

AUXILIARY POWER

WITH 5.5 AMP 42 VOLT

POWER SOURCE

INVERTEC

N.C. SET UP SHOWN IS FOR DC NEGATIVE TIG WELDING. DC POSITIVE WELDING IS OBTAINED BY REVERSING

THE OUTPUT CONNECTIONS ON THE INVERTEC AND SETTING THE INVERTEC’S ELECTRODE POLARITY

N.B. A WIRE FEEDER CAN BE PLUGGED INTO THE DC TIG STARTER TO REDUCE PROCESS CONVERSION TIME.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

K900-1 DC TIG STARTER - CONNECTION DIAGRAM

SWITCH TO POSITIVE.

Page 30

– 30 –

P10’,J10

K608-1

CONNECTION

DETAIL

LN-9 GMA WITH

530A

P10,J10’

K608-1 AND

K442-1 KITS.

521

500

524

3.9K

K596 REMOTE

CONTROL CABLE

ASSEMBLY

533

S20607

9-29-95C

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

ELECTRIC

WARNING

CAN KILL

14 PIN

AMPHENOL

ELECTRODE CABLE

TO LN-9 GMA

WORK

INVERTEC

POWER SOURCE

WITH 110/115V AUX.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF", REVERSE

ELECTRODE AND WORK CABLE AT POWER SOURCE. SET METER POLARITY SWITCH ON REAR

OF INVERTEC TO COINCIDE WITH POLARITY USED. SET LN-9 GMA POLARITY SWITCH ALSO.

N.D. FOR GMAW WELDING, INSTALL PULSE POWER FILTER KIT K442-1 IN LN-9 GMA.

N.C. INSTALL K608-1 ADAPTER IN LINE WITH P10 TO LN-9 GMA VOLTAGE BOARD

PER INSTRUCTIONS IN V300 MANUAL.

LN-9 GMA WITH K596 CABLE TO INVERTEC - CONNECTION DIAGRAM

Page 31

– 31 –

K608-1

CONNECTION

DETAIL

P10’,J10

530A

P10,J10’

521

500

524

3.9K

K196

INPUT CABLE

N.C.

S20608

9-11-92

533

LN-9 GMA WITH

K608-1 AND

K442-1 KITS.

GND

N.D.

814241

SPARE

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

ELECTRIC

WARNING

CAN KILL

14 PIN

AMPHENOL

WORK

TO LN-9 GMA

ELECTRODE CABLE

GND

K867 UNIVERSAL

ADAPTER PLUG

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

INVERTEC

POWER SOURCE

WITH 110/115V AUX.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF", REVERSE

ELECTRODE AND WORK CABLE AT POWER SOURCE. SET METER POLARITY SWITCH ON REAR

N.D. SPLICE LEADS AND INSULATE.

OF INVERTEC TO COINCIDE WITH POLARITY USED. SET LN-9 GMA POLARITY SWITCH ALSO.

N.F. FOR GMAW WELDING, INSTALL PULSE POWER FILTER KIT K442-1 IN LN-9 GMA.

N.E. INSTALL K608-1 ADAPTER IN LINE WITH P10 TO LN-9 GMA VOLTAGE BOARD AND SECURE TO

ADJACENT HARNESS WITH WIRE TIE PROVIDED. TURN "START" TRIMMER ON VOLTAGE BOARD FULLY ’CCW’.

LN-9 GMA WITH K196 CABLE AND K867 PLUG TO INVERTEC - CONNECTION DIAGRAM

Page 32

– 32 –

CONTROL

CONTROL PANEL

ARC FORCE/INDUCTANCE

R11

227

/INDUCTANCE

CONTROL

TERMINAL

CHOKE

10K

215

227

303

301

CW (MAX)

METER

TOP

SHUNT

211A

BOARD

CONNECTOR CAVITY NUMBERING SEQUENCE

OUTPUT TERMINAL

R = RED

301

TP4

12B

12D

R12

275C

204B

206

215

LAYOUT

N.A.

NOTES:

B = BLACK

G = GREEN

W = WHITE

Y = YELLOW

FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.

FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.

CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.

N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "I".

N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.

CONNECTION SHOWN IS FOR 440-460V OPERATION.

N.F. R1, R9 BLEEDER RESISTORS ARE A MATCHED SET.

N.G. C1, C2 CAPACITORS ARE A MATCHED SET.

N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.

RECEPTACLE

CONTROL

SWITCH

REMOTE

POLARITY

285

WELDING

WIRE FEEDER

AUXILIARY

SPARE

GND

CW (MAX)

275F

275D

303

302

304

504

212A

229

317

N.G.

N.F.

BOARD

2200 F

J15

SWITCH

METER FUNCTION

OUTPUT CONTROL

R11

INDICATOR

OVERLOAD

THERMAL

SWITCH

OUTPUT

REMOTE

223B

MIN

BOARD

311

TP3

F -

FEEDER

12D

12C

N.H.

503

150 5W

N.C.

WIRE

COLOR CODE:

MODE SWITCH MODE SWITCH

OUTPUT

CONTROL

503A

306

212B

42A

J13

212D

INSIDESBOTTOM

THERMAL

229

12B

213

208

77A

208V

203

SWITCH

MODE

211A

220

AUX

77A

226

CONTROL

BOARD

12C

12B

J5, J16

316

4,5

D +

25W

12A

RIGHT

212D

PANEL

226

CV GMAW

TP6

25W

400A

BOTTOM

401, 403

TOP

450V

25W

(RIGHT)

2200 F

BOARD

25W

200-

302

4,5

N.G.

275D

24V

211B

501

AUX

TOP

1,8

212A

315

12A

317

2 3

TRIGGER

305

304

SWITCH

212B

CC CRISP

CC SOFT

LOCAL

275B

OVERLOAD

502

TP5

250

BOTTOM

401, 403

440-

42A

214

12D

SWITCH

220-

309

212J

N.D.

FAN

311

229

THERMOSTAT

ARC FORCE

223A

MOTOR

206

110V

275A

R12

INDICATOR

(V300-I ONLY)

LOCAL/REMOTE

REMOTE

SWITCH

FUNCTION

METER

212C

224

J1, J7

2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I)

CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.

CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.

(VIEWED FROM COMPONENT SIDE OF BOARD)

WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.

208

1,8

504

7500

402, 404

CURRENT

CHOKE

207

204C

204B

228

275A

228

502

276

77B

218

SWITCH

LOCAL/REMOTE

308

INPUTS1RECTIFIER

D13

450V

POWER

CB2

32A

212

CB1

6AMP

REMOTE

460V

BLOW

SLOW

229

D1A

(LEFT)

L10189

OFF

307

CC GTAW

TP1

CV FCAW

R12

BOTTOM

OUTSIDE

3 AMP

R11

TOP

207

INSIDE

204A

310

501

J16

276

RECONNECT

TRANSFORMER

12A

VAC

310

309

310

203

275C

OUTPUT

76F

313

316

314

315

12A

TP2

SWITCH

42V

230V

FAN

380-

415V

77B

TRANSFORMER

110/115

212212

212C

MAIN

J10

210

308

J12

210

DRIVER

1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO)

FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.

FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECTION SHOWN IS FOR 380-460V OPERATION.

4 5 2 6

J11

4 3 2 1

309

WIRING DIAGRAM V300-PRO Code 10256, V300-I Code 10258

THERMOSTAT

503A

224

BOARD

INPUT

PER

CR2

CR1

POWER

286

SWITCH

N.A.

211B

- ARC

OUTSIDE

+ ARC

314

25W

PROTECTION

285

204C

204A

213

229

TRANSFORMER

313

306

402, 404

275F

7500

25W

ELECTRICAL SYMBOLS PER E1537

J2, J8

J11, J14

J13, J15

J9, J10, J12

503

305

307

32A

LEFT

2AMP

GND

10K

18V

12B

25W

J14

VAC

N.F.

D1B

214

218

275B

223B

223A

CONTROL

220

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

MAR97

Page 33

– 33 –

RECTIFIER

N.F.

CONTROL PANEL

J11, J14

402, 404

OFF

12B

BOTTOM

WIRING DIAGRAM V300-PRO CODE 10257 (575V)

SHUNT

250

TP2

1, 8

POWER

J12

401, 403

12B

J13

25W

R = REDR4W = WHITE

3 2 1

J11

5 2 6

D13

317

J16

315

316

LAYOUT

504

J5, J16

227

213

214

INSIDESTOP

TOP

303

18V

285

AUX

TOP

OUTSIDE

BOTTOM

226

TRANSFORMER

MAIN

CHOKE

REMOTE

214

SWITCH

POLARITY

WELDING

WIRE FEEDER

42A

501

317

316

314

POWER

BOARD

402, 404

307

CURRENT

J2, J8

OUTPUT TERMINAL

SWITCH

25W

CV FCAW

10K

N.F.

912

10K

R12

REMOTE

275A

LOCAL

275B

207

77A

275C

276

150 5W

204B

228

212C

208

203

77B

204C

204A

220

229

R11

285

MODE SWITCH

/INDUCTANCE

LOCAL/REMOTE

SPARE

GND

218

GND

275C

227

226

275B

CONTROL

77A

218

276

208

207

228

229

275D

301

305

(V300-I ONLY)

210

211B

J1, J7

J9, J10, J12

J13, J15

302

309

224

TOP

AUX

N.A.

MIN

24V

F76E

212C

CR1

+ ARC

400A

RIGHT

BOARD

215

203

310

503A

229

J14

CW (MAX)

215

CW (MAX)

306

212A

212B

223B

210

275A

309

COLOR CODE:

B = BLACK

1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO)

Y = YELLOW

FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.

WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.

FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.

2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I)

FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.

LEFT

CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.

FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.

25W

42A

2AMP

6AMP

212

212212

VAC

MODE

SWITCH

R11

OUTPUT

CONTROL

R12

SWITCH

CONTROL

TERMINAL

THERMAL

OVERLOAD

INDICATOR

SWITCH

FUNCTION

METER

REMOTE

503

313

FAN

212D

THERMOSTAT

310

D1B

301

223A

303

304

213

G = GREEN

FEEDER

NOTES:

N.A.

LOCAL/REMOTE

R11

501

PROTECTION

912

25W

D1A

C15

L10191

CONTROL

ARC FORCE/INDUCTANCE

R12

SWITCH

METER FUNCTION

(V300-I ONLY)

INDICATOR

OVERLOAD

THERMAL

OUTPUT CONTROL

N.F. C1, C2, C14, C15 CAPACITORS ARE A MATCHED SET.

N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "I".

COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT

N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.

212D

212B

211B

211A

302

275D

CV GMAW

502

211A

503

503A

TP6

204C

42V

32A

110V

25W

313

311

306

275F

4, 5

25W

BOARD

13,15

C14

(LEFT)

401, 403

DRIVER

BOARD

N.C.

230V

220-

TRIGGER

4,5

10K

223A

502

FAN

MOTOR

SWITCH

CB2

575V

32A

CB1

212A

J15

INPUT

314

12A

229

SWITCH

BOARD

F -

OUTPUT

ARC FORCE

220

204B

204A

INSIDE

1, 8

286

CHOKE

BOARD

305

308

CC SOFT

BOTTOM

206

J10

ELECTRICAL SYMBOLS PER E1537

(VIEWED FROM COMPONENT SIDE OF BOARD)

CONNECTOR CAVITY NUMBERING SEQUENCE

311

RECEPTACLE

TRANSFORMER

CONTROL

AUXILIARY

REMOTE

WIRE

10K

TP1

TP3

212

VAC

223B

PANEL3METER

- ARC

TP4

THERMOSTAT

275F

504

CONTROL

224

PER

CC GTAW

CC CRISP

52315

INPUT

TRANSFORMER

BOTTOM

206

OUTSIDE

D +

308

307

229

TP5

77B

(RIGHT)

110/115

13,15

SWITCH

25W

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

MAR97

Page 34

INVERTEC V300-PRO & V300-I

NOTES

Page 35

INVERTEC V300-PRO & V300-I

NOTES

Page 36

INVERTEC V300-PRO & V300-I

NOTES

Page 37

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$5.00 For order value up to $49.99 $10.00 For order value between $50.00 & $99.99 $15.00 For order value between $100.00 & $149.00

For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost. Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment. METHOD OF PAYMENT: (Sorry, No C.O.D. Orders)

CHECK ONE:

Name: _______________________________________________

Please Invoice (only if order is over $50.00)

Address: _______________________________________________

Check or Money Order Enclosed, U.S. Funds only

_______________________________________________

Credit Card - Telephone:_______________________________________________

Signature as it appears on Charge Card:

Account No.

|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| Exp Date |_|_| |_|_|

______________________

Month Year

USE THIS FORM TO ORDER:

Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199

BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.

Lincoln Welding School Titles: Price Code Quantity Cost

(ED-80)

New Lessons in Arc Welding $5.00 L

Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH

(ED-45)

How to Read Shop Drawings $4.50 H

Educational Video Information Incentive Management $5.00 IM

(ED-93)

A New Approach to Industrial Economics $5.00 NA James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC Foundation Book Information Welding Preheat Calculator $3.00 WC-8

(JFLF-515)

Pipe Welding Charts $4.50 ED-89

SUB TOTAL

Additional Shipping Costs if any

TOTAL COST

Page 38

– 38 –

WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

Page 39

– 39 –

WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● Do not operate with panel open or

guards off.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Page 40

–

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Lincoln Electric V300-PRO User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual