IM526-B INVERTEC V300-PRO - Lincoln Electric

INVERTEC V300-PRO

OPERATOR’S MANUAL

For use with machines Code 10256 and 10257.

IM526-BDecember,1999

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand 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 •

This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.

– 2 –

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. 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 pur-chase 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 theLincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WELDING SPARKS cancause fire or explosion.4.a..Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

4.b. Where compressed gases are to be used at the job site, spe-cial precautions should be used to prevent hazardous situa-tions. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for the equip-ment being used.

4.c. When not welding, make certain no part of the electrode cir-cuit is touching the work or ground. Accidental contact cancause overheating and create a fire hazard.

4.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned.” For information purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

4.e. Vent hollow castings or containers before heating, cutting orwelding. 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 andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

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

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

ELECTRIC SHOCK cankill.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 bareskin or wet clothing. Wear dry, hole-freegloves to insulate hands.

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

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardous condi-tions (in damp locations or while wearing wet clothing;on metal structures such as floors, gratings or scaf-folds; when in cramped positions such as sitting, kneel-ing or lying, if there is a high risk of unavoidable or acci-dental contact with the workpiece or ground) use the fol-lowing 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 weld-ing gun are also electrically“hot”.

1.d. Always be sure the work cable makes a good electrical con-nection with the metal being welded. The connection shouldbe 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.

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

1.h. Never simultaneously touch electrically “hot” parts of elec-trode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

1.i. When working above floor level, use a safety belt to protectyourself 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 GASEScan be dangerous.3.a. Welding may produce fumes and gases haz-

ardous to health. Avoid breathing thesefumes and gases.When welding, keep yourhead out of the fume. Use enough ventila-tion and/or exhaust at the arc to keep fumes

and gases away from the breathing zone. When weldingwith electrodes which require special ventilation suchas stainless or hard facing (see instructions on contain-er or MSDS) or on lead or cadmium plated steel andother metals or coatings which produce highly toxicfumes, keep exposure as low as possible and belowThreshold Limit Values (TLV) using local exhaust ormechanical ventilation. In confined spaces or in somecircumstances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.

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

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

3.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow your employ-er’s safety practices. MSDS forms are available from yourwelding distributor or from the manufacturer.

3.e. Also see item 7b.

Apr. ‘93

– 3 –

FOR ENGINEpowered equipment.

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

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

7.b. Operate engines in open, well-ventilatedareas or vent the engine exhaust fumes out-doors.

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

FOR ELECTRICALLYpowered equipment.6.a. Turn off input power using the disconnect

switch at the fuse box before working onthe equipment.

6.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’s rec-ommendations.

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

CYLINDER may explodeif damaged.5.a. Use only compressed gas cylinders contain-

ing the correct shielding gas for the processused and properly operating regulatorsdesigned for the gas and pressure used. All

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

5.b. Always keep cylinders in an upright position securelychained 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 otherelectrically “hot” parts to touch a cylinder.

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

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

5.g. Read and follow the instructions on compressed gas cylin-ders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,”available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

7.c.Do not add the fuel near an open flame weld-ing arc or when the engine is running. Stopthe engine and allow it to cool before refuel-ing to prevent spilled fuel from vaporizing oncontact with hot engine parts and igniting.Do not spill fuel when filling tank. If fuel isspilled, wipe it up and do not start engineuntil fumes have been eliminated.

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

7.d. Keep all equipment safety guards, coversand devices in position and in good repair.Keep hands, hair, clothing and tools awayfrom V-belts, gears, fans and all other mov-ing parts when starting, operating or repair-ing equipment.

7.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

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

7.g. To prevent accidentally starting gasoline engines while turn-ing the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

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

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

Mar. ‘93

ELECTRIC AND MAGNETICFIELDSmay be dangerous8.a. Electric current flowing through any con-

ductor causes localized Electric andMagnetic Fields (EMF). Welding currentcreates EMF fields around welding cablesand welding machines.

8.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

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

8d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

8.d.1. Route the electrode and work cables together - Securethem 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 andwork 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 aspossible 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 oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in a weld-ing area.

4.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passing throughlifting chains, crane cables or other alternate circuits. This cancreate fire hazards or overheat lifting chains or cables untilthey fail.

4.h. Also see item 7c.

– 4 –

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nue oules vétements mouillés. Porter des gants secs et sans trouspour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un plancher met-allique 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 desoudage et la machine à souder en bon et sûr état defonc-tionnement.

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

e. Ne jamais toucher simultanément les parties sous tensiondes 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 decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

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

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 ainsiqu’un verre blanc afin de se protéger les yeux du rayon-nement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la peaude soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

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

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

zones où l’on pique le laitier.

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

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer un échauf-fement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible dela zone de travail qu’il est pratique de le faire. Si on place lamasse sur la charpente de la construction ou d’autres endroitséloignés de la zone de travail, on augmente le risque de voirpasser le courant de soudage par les chaines de levage,câbles de grue, ou autres circuits. Cela peut provoquer desrisques d’incendie ou d’echauffement des chaines et descâbles 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 tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voirle code “Code for safety in welding and cutting” CSA StandardW 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

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

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

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

Mar. ‘93

– 5 –

TABLE OF CONTENTSPage

Safety Precautions .............................................................................................................2-4Introductory Information .......................................................................................................6Product Description..............................................................................................................7Specifications.......................................................................................................................7Installation .........................................................................................................................7-10

Safety Precautions ........................................................................................................7Location .........................................................................................................................7Electrical Installation......................................................................................................7Input Voltage Setup .......................................................................................................8Power Cord Connection ................................................................................................8Connection of Wire Feeders to Invertec .....................................................................8-10Output Cables & Plugs .................................................................................................10

Operating Instructions ......................................................................................................11-13Safety Precautions .......................................................................................................11Controls Description and Function.............................................................................11-13

Maintenance.....................................................................................................................13-14Capacitor Discharge Procedure ...................................................................................13Routine Maintenance....................................................................................................13Periodic Maintenance ...................................................................................................14

Troubleshooting Guide .....................................................................................................14-20Matched Parts.....................................................................................................................20Switch P.C. Board Replacement Procedure .......................................................................20Replacement of Power Modules and Output Diodes .......................................................20-21Connection Diagrams.......................................................................................................22-31Wiring Diagrams...............................................................................................................32-33Parts Lists ......................................................................................................................appendix

– 6 –

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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 ithandy 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:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

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

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound 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 informationyou have recorded above.

PRODUCT DESCRIPTION

The Invertec V300-PRO is a 300 amp arc weldingpower source that utilizes single or three phase inputpower to produce either constant voltage or constantcurrent outputs. The V300-PRO is designed for 60 Hzsupply systems. The welding response of the Invertechas been optimized for GMAW, SMAW, TIG andFCAW processes. It is designed to be used with theLN-25 and LN-7 semiautomatic wire feeders.

SPECIFICATIONS

– 7 –

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.---------------------------------------------------------------------

WARNING

LOCATION

The Invertec has been designed with many features toprotect it from harsh environments. Even so, it isimportant that simple preventative measures are fol-lowed in order to assure long life and reliable opera-tion.• The machine must be located where there is free

circulation of clean air such that air movement intothe sides and out the bottom and front will not berestricted. Dirt and dust that can be drawn into themachine should be kept to a minimum. Failure toobserve these precautions can result in excessiveoperating temperatures and nuisance shutdown ofthe Invertec.

• Keep machine dry. Shelter from rain and snow. Donot place on wet ground or in puddles.

ELECTRICAL INSTALLATION

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

2. Single voltage, 575 VAC machines, can only beconnected to 575 VAC. No internal reconnectionfor other input voltages is possible.

3. Initial 208 VAC and 230 VAC operation will requirea voltage panel setup, as will later reconnectionback 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 DimensionsName Information Voltage Amps/Volts/Duty Cycle

208 230 460 575Range 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) 16

60 Hz 300A / 36V / 60%(2) 22(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).

–– 8 –

INPUT VOLTAGE SETUP

POWER CORD CONNECTION

A 10 ft. (3.0m) power cord is provided and wired intothe machine. Follow the power cord connectioninstructions. Incorrect connection may result in equip-ment damage.

Single Phase Input

1. Connect green lead to ground per U.S. NationalElectrical Code.

2. Connect black and white leads to power.3. Wrap red lead with tape to provide 600V insula-

tion.

Three Phase Input

1. Connect green lead to ground per U.S. NationalElectrical Code.

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

Install in accordance with all local and national electriccodes.

CONNECTION OF WIRE FEEDERS TO THEINVERTEC(Note: IEC units do not have 110 VAC auxiliarypower).LN-25 Connection Instructions

1. Turn the Invertec power switch “off”.

2. Connect the electrode cable to the output terminalof polarity required by electrode. Connect the worklead to the other terminal.

3. LN-25 with remote control options K431 and K432.Use K876 adapter with K432 cable or modify K432cable with K867 universal adapter plug. See con-nection diagram S19899 and S19309 or S19405 atthe back of this manual.

4. Place the local-remote switch in the “remote” posi-tion if output control is desired at the wire feederrather than the Invertec. (LN-25 must have K431and K432 options for remote output control opera-tion).

LN-7 Connection Instructions


2. Connect the K480 control cable from the LN-7 tothe Invertec control cable connector. The controlcable connector is located at the rear of theInvertec.


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 AmpsInput Volts(1) (Time Delay Fuses)

3 phase 208 6050/60 Hz 230 60

460 40

1 phase 208(2) 8550/60 Hz 230(2) 80

460 50

3 phase 575 3060 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 inputconductor of 6 AWG or larger.

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

.

.

.

.

Do not touch electrically live parts.

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

RECONNECT PROCEDURE

REPLACE WITH A 3 AMP SLOW BLOW ONLY.

1. BE SURE POWER SWITCH IS OFF.

200-208V

220-230V

380-415V

440-460V

’A’

INPUT VOLTAGE RANGE. removed.Do not operate with wraparound

inspecting or servicing machine.

Disconnect input power before

IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)

2. CONNECT LEAD ’A’ TO DESIRED

3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.

S20324

AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;

VOLTAGE=380-460V VOLTAGE=200-230V

9-11-92

BLACKGREENREDWHITE

DO NOT ATTEMPT TO POWER THIS UNITFROM THE AUXILIARY POWER SUPPLYOF AN ENGINE WELDER.• Special protection circuits may operate, causing

loss of output.• The supply from engine welders often has exces-

sive voltage peaks because the voltage waveformis usually triangular shaped instead of sinusoidal.

• If voltage peaks from the engine welder exceed380V, the input circuits of this machine protectingthe filter capacitors, FETS and other componentsfrom damage will not be energized .

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

CAUTION

– 9 –– 9 –

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

5. Set the meter polarity switch on the rear of theInvertec to coincide with wire feeder polarity used.The wire feeder will now display the welding volt-age.

6. If K480 is not available, see connection diagramS19404 for modification of K291 or K404 LN-7input cable with K867 universal adapter plug.

General Instructions for Connection of WireFeeders to Invertec

Wire feeders other than LN-7 and LN-25 may be usedprovided that the auxiliary power supply capacity ofthe Invertec is not exceeded. K867 universal adapterplug is required. See connection diagram S19406 andS19386 at the back of this manual for more informa-tion.

Remote Control of Invertec

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

K954-1 MIG PULSER

The MIG Pulser is a hand-held “pendant” type GMAWPulsing option for the V300 Power Source. Refer tothe Mig Pulser’s IM manual (IM555) for connectioninformation.

Parallel Operation

The Invertec’s are operable in parallel in both CC andCV modes. For best results, the currents of eachmachine should be reasonably well shared. As anexample, with two machines set up in parallel for a400 amp procedure, each machine should be set todeliver approximately 200 amps, not 300 amps fromone and 100 amps from the other. This will minimizenuisance shutdown conditions. In general, more thantwo machines in parallel will not be effective due tothe voltage requirements of procedures in that powerrange.

To set machine outputs, start with output control potsand arc force/pinch pots in identical positions. If run-ning in a CC mode, adjust outputs and arc forces tomaintain current sharing while establishing the properoutput current. In CV modes, the pots in identicalpositions. Then switch the machine meters to ampsand adjust one of the output control pots for currentbalance. Check the voltage and if readjustment isnecessary, repeat the current balancing step. Pinchsettings should also be kept identical on themachines.

K900-1 DC TIG Starter Connection

This versatile new kit was made to mate with theInvertec.

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

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

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

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

MAR97

LN-9 GMA Connection Instructions


2. Connect the K596 control cable assembly from theLN-9 GMA to the Invertec control cable connector.The control cable connector is located at the rearof the Invertec.


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

5. Set the meter polarity switch on the rear of theInvertec to coincide with wire feeder polarity used.The wire feeder will now display the welding volt-age.

6. K608-1 adapter is required in LN-9 GMA for LN-9type control. K608-1 is installed in line with P10connection at the LN-9 GMA voltage board. Seediagram S20607 at the back of this manual.

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

8. If K596 is not available, see connection diagramS20608 at the back of this manual for modificationof K196 LN-9 GMA input cable with K867 universaladapter plug.

Output Cables

Select the output cable size based upon the followingchart.

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

Duty Length Up 61-76mCycle Current 61m (200 ft.) (200-250 ft.)

100% 250 1/0 1/060% 300 1/0 2/0

Quick Disconnect Plugs

A quick disconnect system is used for the weldingcable connections. The welding plug included with themachine is designed to accept a welding cable size of1/0 to 2/0.

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

– 10 –

2. Slide rubber boot onto cable end. The boot endmay be trimmed to match the cable diameter.Soap or other lubricant will help to slide the bootover 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. Screwmust apply pressure against welding cable. Thetop of the set screw will be well below the surfaceof the brass plug after tightening.

6. Slide rubber boot over brass plug. The rubberboot must be positioned to completely cover allelectrical surfaces after the plug is locked into thereceptacle.

25 mm

1 in.

WELDING CABLE

BOOT

TRIM

SET SCREW

BRASS PLUGCOPPER TUBE

– 11 –

OPERATING INSTRUCTIONS

DUTY CYCLE

The Invertec is rated at 300 amps, 60% duty cycle for3 phase inputs (based on a 10 minute cycle). It is alsorated at 250 amps, 100% duty cycle.

CONTROL FUNCTION / OPERATION

Power Switch - Place the lever in the “ON” position toenergize the machine. When the power is on, the digi-tal 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 orexplosion.

• 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 atfront of this operator’s manual.

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

WARNING

Output Control - This controls the output voltage inthe CV modes and output current in the CC modes.

Control is provided over the entire output range of thepower source with 1 turn of the control knob. This con-trol may be adjusted while under load to changepower source output.

Local/Remote Switch - Place in the “LOCAL” posi-tion to allow output adjustment at the machine. Placein the “REMOTE” position to allow output adjustmentat the wire feeder or with a remote control optionpackage.

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

When welding current is not present, the meter willdisplay the set current for the CC modes or the setvoltage for the CV modes. This set reading is an indi-cation of machine control setting. For a more preciseprocess 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 withEXX10 thru EXX14 electrodes. Non-welding applications such as resistiveheating or output tests with resistiveloads should be done in this mode withArc Force Control set to minimum.

OFF

OUTPUT

REMOTE

–

CV FCAW This setting has been optimized forInnershield® and Outershield® flux-coredelectrodes.

CV GMAW Short circuit, glob and spray transfersolid wire and gas welding are done inthis mode. Low end procedures, lessthan 17V, may operate better in theFCAW mode. Voltage in the GMAWmode can become erratic whenwelding is attempted using voltagesequal to or less than 17V DC+.

Output Terminals Switch

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

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

Arc Force / Inductance Control

This control functions in all modes except GTAW. ForCC modes, this control acts as an Arc Force adjust-ment. The arc is soft at the minimum settings andmore forceful or driving at the maximum settings.Higher spatter levels may be present at the maximumsettings.

For CV modes, this control will set the degree of“pinch effect” which predominantly affects short circuittransfer. In FCAW, the maximum setting is generallypreferred. With GMAW, the upper half of the range ispreferred with CO2 or high content CO2 mixed. Thelower half is for inert gas mixes.

– 12 –

Recommended Arc Force / Inductance SettingsFor Selected Applications

Full Range Is 1-10,1 Is Very Soft, 10 Is Very Crisp

Nominal RecommendedMode Process Setting Adjustment Range

CC SMAW 1 EXX18 thru 5 1 (gentle, may stick) to 9EXX28 stick (forceful, more spatter)

CC SMAW 2 EXX10 thru 6 3 to 10EXX14 stick

Air Carbon Arc 1 NoneCutting

CV FCAW Innershield or 10 NoneOutershield

Air Carbon Arc 1 NoneCutting

CV GMAW* CO2 or 25% CO2 7.5 5 to 10or similargas mixes

98% Ar-2% O2Ar, 5 1 to 1090% He-7.5% Ar2.5% CO2 and

otherpredominantly

inert gases

* 1 = Lowest pinch, highest inductance and least spatter.10 = Highest pinch, lowest inductance and most spatter.

GMAW

FCAWSMAWCRISP

SMAWSOFT

GTAW

OUTPUTTERMINALS

ON

REMOTE

– 13 –

Meter Polarity Switch

The wire feeder polarity switch is located at the rear ofthe machine. The switch provides a work connectionfor wire feeder voltmeters. Place the switch in theposition of the electrode polarity indicated by thedecal. The switch does not change the weldingpolarity.

Auxiliary Power

A 24 VAC @ 1 amp supply is included for use with theLN-25 wire feeder (24 volts needed for K431 andK432 options). This supply is protected by a self-resetting current limiter.

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

A 110/115 VAC @ 2 amp supply is included for usewith the LN-7 or LN-9 GMA wire feeders. This supplyis protected by a 2.5 amp breaker located on the rearof 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 resis-tor terminals across the two hex head cap screwsin the position shown. Hold in each position for 1second. For 575 VAC only, repeat for secondcapacitor. Repeat for the capacitor(s) on the otherside of the machine

3. Use a DC voltmeter to check that voltage is notpresent across either capacitor.

Routine Maintenance

1. Every 6 months or so the machine should becleaned with a low pressure airstream. Keepingthe machine clean will result in cooler operationand higher reliability. Be sure to clean these areas:

• Power, switch, driver, protection and control printedcircuit 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 con-dition to insure that high voltage parts are protected andcorrect spacings are maintained. All external sheetmetal screws must be in place to insure case strengthand electrical ground continuity.

CAPACITORTERMINALS

RESISTOR

T13086-84




EXPLODING PARTS can causeinjury.• 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

– 14 –

PERIODIC MAINTENANCE

Overload Protection

The machine is electrically protected from producinghigh output currents. Should the output currentexceed 340-360A, an electronic protection circuit willreduce the current to approximately 150A. Themachine will continue to produce this low current untilthe protection circuit is reset. Reset occurs when theoutput load is removed.

Thermal Protection

Thermostats protect the machine from excessiveoperating temperatures. Excessive temperatures maybe caused by a lack of cooling air or operating themachine beyond the duty cycle and output rating. Ifexcessive operating temperature should occur, thethermostat will prevent output voltage or current. Themeter will remain energized during this time.

Thermostats are self-resetting once the machine coolssufficiently. If the thermostat shutdown was caused byexcessive output or duty cycle and the fan is operatingnormally, the Power Switch may be left on and thereset should occur within a 15 minute period. If the fanis not turning or the air intake louvers were obstructed,then the power must be switched off for 15 minutes inorder to reset. The fan problem or air obstruction mustalso be corrected.

Filter Capacitor Conditioning

A protection circuit is included to monitor the voltageacross filter capacitors C1 and C2 (also C14 and C15on 575 VAC units). In the event that the capacitor volt-age is too high, the protection circuit will prevent out-put. The protection circuit may prevent output provid-ing all these circumstances are met:

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

2. Machine did not have power applied for manymonths.

3. Machine did not produce output when power wasfirst switched on.

If these circumstances apply, the proper action is toswitch the machine on and let it idle for up to 30 min-utes. This is required to condition the filter capacitorsafter an extended storage time. The protection circuitwill automatically reset once the capacitor conditioningand resultant voltage levels are acceptable. It may benecessary to turn the power switch off and back onagain after this period.

TROUBLESHOOTING

Visual Inspection

Clean interior of machine with a low pressureairstream. Make a thorough inspection of all compo-nents. Look for signs of overheating, broken leads orother obvious problems. Many problems can beuncovered with a good visual inspection.

Open Circuit Voltage

The open circuit voltage of the Invertec V300-PRO is60 to 75 VDC and cannot be adjusted by the outputcontrol.

Test Conditions

Perform all testing at the lowest input voltage avail-able, except where a higher voltage is required by atest step. Make ohmmeter checks only after powerhas been disconnected from machine and aftercapacitors have been discharged.

Certain high voltage connections have been insulatedwith RTV sealant. It is necessary to break through thesealant with a sharp probe in order to make voltage orresistance checks.

Disconnect any control cables from remote controlreceptacle.







WARNING

– 15 –

TROUBLESHOOTING GUIDE

Trouble What To Do

Not output but fan operates and meter is on.

Poor welding, weld settings drift, or output power islow.

Main fuses open or Switch PC boards overheated.

Output turns on momentarily then switches off andrepeats. Machine is connected for 380 VAC or higherinput voltage.

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

Open circuit voltage is 1-2 volts.

Output control not functioning on remote control. Localcontrol OK.

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

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

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

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

No output or reduced output the first time power isapplied 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 Boardsand 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, con-tact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

–– 16 –

TEST PROCEDURES

Step

1A

1B

2

3A

3B

NextTestStep

1B

2

3A

3B

4and5

Test

Output pilot circuit(set S4 on)

Protection PCboard output (setS4 on)

Static capacitorbalance (set S4off)

380 VAC inputand higher test

Dynamic capaci-tor balance (setS4 on)

380 VAC inputand higher test

Repair Action

Replace Powerand Control PCBoards

ReplaceProtection PCBoard

Check

223A to 210

302 (pos) to 275D (neg)

313 (neg) to 311 (pos)

Compare voltage acrossterminals 9 & 12 of eachSwitch PC Board.575 VAC -- 407 VDC460 VAC -- 325 VDC440 VAC -- 311 VDC415 VAC -- 293 VDC380 VAC -- 269 VDC575 VAC only - comparevoltage across 9A & 13and 13 & 12A; then, 9B &15 and 15 & 12B

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

TestResult

24 VAC

0 VAC

15 VDC

0 VDC

<1 VDC

>5 VDC

<25 VDCdifferencebetweenreadings

>25 VDCdifference

<25 VDC

>25 VDC

Conclusion

Fan thermostat, chokethermostat, T1 trans-former and S4 all OK.

Check above compo-nents.

T1 and 15V power sup-ply OK.

Check T1 and Power PCBoard.

Protection PC Board OK

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

Check above compo-nents.

OK

Power PC Board orSwitch PC Boards aredamaged.


CAUTION

– 17 –

Step

4

NextTestStep

cont

5

cont

5

cont

5

cont

5

cont

5

cont

5

cont

5

cont

5

cont

5

cont

5

cont

5

cont

5

Test

Switch PC Boardresistance test.

No dynamic testis possible.

Remove leads401/403, 1/8, 9,12, 4/5 and402/404.

Repair Action

Replace Switch PC Board












Check

Terminals on SwitchPC Board:1/8 (pos) to12 (neg)

1/8 (neg) to12 (pos)

9 (pos) to4/5 (neg)

9 (neg) to4/5 (pos)

1/8 (pos) to9 (neg)

1/8 (neg) to 9 (pos)

12 (pos) to4/5 (neg)

12 (neg) to4/5 (pos)

12 (pos) to401/403 (neg)

12 (neg) to401/403 (pos)

9 (pos) to402/404 (neg)

9 (neg) to402/404 (pos)

TestResult

>1K ohms

<100 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

OK

Short

OK

Open

OK

Short

OK

Open

OK

Open

OK

Short

OK

Open

OK

Short

OK

Short

OK

Open

OK

Open

OK

Short


CAUTION

– 18 –

Step

5

6

NextTestStep

cont

cont

cont

cont

Test

SnubberResistors

Disconnect leads401, 402, 403 and404 from SwitchPC Board

Output diodes

Remove outputload

Repair Action

Replace R4

Replace R5

Replace R6

Replace R7

Test individually

Check

Lead 401 to terminal12




+ output plug (pos) to

- output plug (neg)

TestResult

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 openR4 shorted

OK

R5 openR5 shorted

OK

R6 openR6 shorted

OK

R7 openR7 shorted

Shorted outputdiode D1 thru D12

Output diodes OK


CAUTION

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

Shorted

OK

Shorted

OK

Shorted

OK

Shorted

OK

Shorted

OK

Open

OK

Open

OK

Open

OK

Open

OK

Open

OK

Open

– 19 –

Step

7

NextTestStep

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 InputRectifier

TestResult

>1K ohms

<100 ohms

>1K ohms

<100 ohms

>1K ohms

<100 ohms

>1K ohms

<100 ohms

>1K ohms

<100 ohms

>1K ohms

<100 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

–

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 D5Output diodes: D7, D8, D9, D10 and D11Capacitor bleeder resistors: R1 and D9Capacitors: C1 and C2Capacitors: 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 identicalpart numbers. A defective module is likely to damageother devices in the power circuitry. The defect maybe subtle and not detectable by an ohmmeter mea-surement. Unknown defective parts may cause newlyreplaced parts to fail.

In addition to replacing the Switch PC Boards, replaceC1 and C2 (also C14 and C15 of the 575 VAC V300-PRO) if the following conditions are met:

1. Machine was operating from 380 VAC or highersupply when failure occurred.

2. Switch PC Boards have burned areas.

Switch PC Board Replacement Procedure

1. Carefully disconnect the leads at the top of theSwitch PC Board.

2. Remove the four socket head cap screws with a3/16” hex key wrench.

3. While holding the Switch PC Board, remove thehex head cap screws from the center area of theboard.

4. Remove the board.

– 20 –

5. Thoroughly clean the heat sink surface.

6. Apply a thin layer (ideally .005-.010”) of Dow 340Heat Sink Compound to the module mounting sur-faces of the new Switch PC Board and a thinnerlayer (.002”) to the capacitor terminals. Keep theheat sink compound away from the screw threadssince this compound will affect the torque specifi-cations.

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

8. Caution: The heat sink and the capacitor terminalsare relatively soft material and it is very easy tocross-thread the mounting screws. Holding theSwitch PC Board, install the 4 socket head capscrews, finger tight only. Then install the hex headcap screws into the capacitor, finger tight only.

9. Torque the 4 socket head cap screws to 44 inch-lbs force (5 N - m). Then torque the capacitor hexhead 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 allelectrical connections. An incorrect connection will resultin machine damage when the power is switched on.

Test After Repair

1. Short terminals 14 and 53 of the Protection PCBoard. Connect an ohmmeter, set for X1000range, to terminals 9 (+) and 12 (-) of the SwitchPC Board. The meter will show the capacitorscharging up. The meter may take a minute or so tostabilize. The value must not exceed 8600 ohms.Test both boards. For 575V only units - measureacross each power capacitor, 2 per switch board;All four readings should be approximately 5,000ohms.

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

3. Fuse input supply with 5 amp fuses.

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

7. Fuse for 20 amps and test under load.







WARNING

– 21 –

Replacement of Power Modules and OutputDiodes

Input rectifier, D13, is a power module. When mount-ing power modules, the heat sink and module mount-ing surface should be clean and free of burrs and for-eign material. Apply heatsink compound (Dow 340) asa uniform layer ideally .010” thick, to eliminate all airpockets. This may be verified by mounting and thenremoving the module. When removed, the compoundon both surfaces will appear textured as if a vacuumhad created veinlike ridges when the parts were sepa-rated. If the compound does not have this appear-ance, apply more heatsink compound and recheck.

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

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

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

Component to Heat Sink TerminalComponent 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 RTVsealant to prevent malfunction in severe environ-ments. Sealant must be applied to connections whichhave been opened or otherwise lost their protection. Anoncorrosive electronic grade sealant such as DowCorning 3140, 3145, 738, Columbus Adhesives 0172or GE RTV-162 is recommended. Sealant may alsobe purchased from Lincoln Electric (order E2519Silicone Rubber RTV Coating). Apply sealant aftermachine 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 dispersestatic charges.

3. Inspect PC Board for burned conductors or com-ponents. If damage is visible, inspect the machinewiring for grounds or shorts to avoid damaging anew PC Board.

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

– 22 –

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.

STRAIGHT PLUG (14 PIN)

TO POWER SOURCE

CABLE RECEPTACLE (6 SOCKET)


TO: 1) LN-7 WIRE FEEDERS

TO: 1) K857 REMOTE CONTROL

2) K963 HAND AMPTROL

3) K870 FOOT AMPTROL

K864 STRAIGHT PLUG (14 PIN)

TO POWER SOURCE

K876


TO: 1) LN-25 WIRE FEEDERS

S19309

4-19-96D

REMOTE CONTROL ADAPTERS

– 23 –

INSTALLATION INSTRUCTIONS

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

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

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

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

THE STANDARD CONNECTOR PIN DESIGNATIONS AND FUNCTIONS ARE SHOWN BELOW.

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

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

14-PIN BOX RECEPTACLE, FRONT VIEW

AND 14-PIN CABLE PLUG, REAR VIEW

14-PIN BOX RECEPTACLE, REAR VIEW

AND 14-PIN CABLE PLUG, FRONT VIEW

K=42

A=32 B=GND

C=2

L=82

D=4

E=77

M=81

F=76

G=75

N=SPARE

H=21I=41J=31

K=42

J=31 I

=41

H=21

N=SPARE

G=75

F=76

M=81

E=77

D=4

C=2

L=82

B=GND

A=32

PIN

SPARE

WELDING MODE CONTROL

A B C D E F G H I J K L M N

81

82

42

31

41

21

75

76

7742

GND

32

LEAD

WELDING MODE CONTROL

STANDARD FUNCTION

24V AC

42V AC

115V AC

42V AC

WORK

OUTPUT CONTROL

OUTPUT CONTROL

OUTPUT CONTROL

TRIGGER CIRCUIT

TRIGGER CIRCUIT

CHASSIS CONNECTION

115V AC

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

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

THIS ADAPTER TO WIRE FEEDER CABLE.

(SEE APPROPRIATE WIRING DIAGRAM)

THESE FUNCTIONS ARE LISTED FOR

REFERENCE ONLY AND EACH MAY OR

MAY NOT BE PRESENT IN YOUR EQUIPMENT.

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

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

S19386

3-16-90

K867 UNIVERSAL ADAPTER FOR 14-PIN WIRE FEEDER RECEPTACLE

– 24 –

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.

ELECTRODE CABLE

TO LN-7

TO

WORK

-+

14 PIN

AMPHENOL

SPARE

82

81

42

41

31

322421

GND

75

76

77

31

322421

GND

N.C.

K291 OR K404

INPUT CABLE

K775 OPTIONAL

REMOTE CONTROL

K867 UNIVERSAL

ADAPTER PLUG

LN-7

CONTROL

BOX

75

76

77 GREEN

N.D.

N.D. SPLICE LEADS AND INSULATE.

POWER SOURCE

AUXILIARY POWER

Only qualified persons should install, use or

service this machine.

using the disconnect switch at the fuse box

WARNINGTurn off input power to the Welding Power Source

Before connecting the wire feeder.

ELECTRIC

SHOCK

CAN KILL

INVERTEC

WITH 115VAC

S19404

K867 PLUG TO LN-7 - CONNECTION DIAGRAM





ELECTRODE CABLE

TO LN-7

TO

WORK

-+

14 PIN

AMPHENOL

SPARE

82

81

42

41

31

322421

GND

75

76

77

31

322421

GND

N.C.

K291 OR K404

INPUT CABLE

K775 OPTIONAL

REMOTE CONTROL

K867 UNIVERSAL

ADAPTER PLUG

LN-7

CONTROL

BOX

75

76

77 GREEN

N.D.


POWER SOURCE

AUXILIARY POWER




WARNINGTurn off input power to the Welding Power Source


ELECTRIC

SHOCK

CAN KILL

INVERTEC

WITH 115VAC

S19404

12-10-93A






ELECTRODE CABLE

TO LN-7

TO

WORK

- +

14 PIN

AMPHENOL

SPARE

82

81

42

41

31

32 2 4 21

GND

75

76

77

31

32 2 4 21

GND

N.C.

K291 OR K404

INPUT CABLE

K775 OPTIONAL

REMOTE CONTROL

K867 UNIVERSAL

ADAPTER PLUG

LN-7

CONTROL

BOX

75

76

77GREEN

N.D.


POWER SOURCE

AUXILIARY POWER




WARN

ING

Turn off input power to the Welding Power Source


ELEC

TRIC

SHOC

K

CAN

KILL

INVERTEC

WITH 115VAC

S19404






ELECTRODE CABLE

TO LN-7

TO

WORK

- +

14 PIN

AMPHENOL

SPARE

82

81

42

41

31

32 2 4 21

GND

75

76

77

31

32 2 4 21

GND

N.C.

K291 OR K404

INPUT CABLE

K775 OPTIONAL

REMOTE CONTROL

K867 UNIVERSAL

ADAPTER PLUG

LN-7

CONTROL

BOX

75

76

77GREEN

N.D.


POWER SOURCE

AUXILIARY POWER




WARN

ING



ELEC

TRIC

SHOC

K

CAN

KILL

INVERTEC

WITH 115VAC

S19404

12-10-93A


– 25 –





TO

WORK

- +

14 PIN

AMPHENOL

N.C.

ELECTRODE CABLE

TO LN-25

K867 ADAPTER

LN-25 WITH

K431 OPTION

K432 REMOTE

CONTROL CABLE

E F D A B C77

76

75

SPARE

4221

82

81

42

41

GND

31

32

N.D.

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.

N.E. SPLICE LEADS AND INSULATE.




WARN

ING



ELEC

TRIC

SHOC

K

CAN

KILL

INVERTEC

POWER SOURCE

S19405

1-25-91


– 26 –





TO

WORK

- +

14 PIN

AMPHENOL

N.C.

76

82

K867 UNIVERSAL

ADAPTER PLUG

81

SPARE

2 4 41

42

31

32

GND

21

77

75

REMOTE OUTPUT CONTROL

NOT USED ON INVERTEC

24 VAC / 1 AMP

CONNECT TOGETHER FOR

WELDING OUTPUT

42 VAC / 5.5 AMP

115 VAC / 2 AMP

INVERTEC FRAME CONNECTION

N.D.

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

RELAY TO CLOSE LEADS 2 & 4.

2 4

TO

K867

ELECTRODE CABLE

WIRE FEEDER VOLTMETER CONNECTION

CONNECTS TO (WORK TERMINAL) OF INVERTEC

TO

WIRE FEEDER

10K

MIN.




WARN

ING



ELEC

TRIC

SHOC

K

CAN

KILL

INVERTEC

POWER SOURCE

WITH 115VAC

AUXILIARY POWER

S19406

12-10-93A

K867 UNIVERSAL ADAPTER / INVERTEC - CONNECTION DIAGRAM

– 27 –




WARN

ING



ELEC

TRIC

SHOC

K

CAN

KILL




TO

WORK

- +

14 PIN

AMPHENOL

ELECTRODE CABLE

TO LN-25

LN-25 WITH

K431 OPTION

K432 REMOTE

CONTROL CABLE

6 PIN

AMPHENOL

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

K876 ADAPTER

INVERTEC

POWER SOURCE

S19899

1-25-91

K876 ADAPTER TO LN-25 - CONNECTION DIAGRAM

– 28 –




WARN

ING



ELEC

TRIC

SHOC

K

CAN

KILL




ELECTRODE CABLE

TO LN-7

TO

WORK

- +

14 PIN

AMPHENOL

LN-7

CONTROL

BOX

POWER SOURCE

INVERTEC

K864

K480-7 INPUT CABLE

14 PIN

AMPHENOL

K857

REMOTE CONTROL

K963

HAND AMPTROL

K870

FOOT AMPTROL

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

6 PIN

AMPHENOL

ADAPTER

OR

OR

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

WITH 115VAC

AUXILIARY POWER

S19901

4-19-96D

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

– 29 –

TO

WORK

+

POWER SOURCE

INVERTEC

DC TIG STARTER

-

WARN

ING

ELEC

TRIC

SHOC

KCA

N KI

LL

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

Turn off input power to the Welding Power Source using the

disconnect switch at the fuse box before connecting the DC Tig

IN

OUT

K900-1

TO TIG

TORCH

K963

HAND AMPTROL

K870

FOOT AMPTROL

OR

K814

OR

ARC START SWITCH


AUXILIARY POWER

WITH 5.5 AMP 42 VOLT

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

to the DC Tig Starter.

TOP 14 PIN

AMPHENOL

WIRE FEEDER

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

N.C.

N.B.

BOTTOM 14 PIN

AMPHENOL

CONSULT INVERTEC INSTRUCTION MANUAL FOR

APPROPRIATE WIRE FEEDERS AMD CONNECTORS.

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

SWITCH TO POSITIVE.

4-19-96D

S20405

K900-1 DC TIG STARTER - CONNECTION DIAGRAM

– 30 –




WARN

ING



ELEC

TRIC

SHOC

K

CAN

KILL


TO

WORK

- +

14 PIN

AMPHENOL

ELECTRODE CABLE

TO LN-9 GMA

K596 REMOTE

CONTROL CABLE

ASSEMBLY

INVERTEC

POWER SOURCE

WITH 110/115V AUX.

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

K608-1 AND

K442-1 KITS.

S20607

P10’,J10

2 3 4 5 6 7 10

11

12

P10,J10’

2 3 4 5 6 11

12

7

3.9K

K608-1

CONNECTION

DETAIL

530A

521

500

500

524 C B

533

9-29-95C

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

– 31 –


TO

WORK

- +

14 PIN

AMPHENOL

SPARE

82

81

42

41

31

32 2 4 21

GND

75

76

77

31

32 2 4 21

GND

N.C.

K867 UNIVERSAL

ADAPTER PLUG

N.D.





WARN

ING



ELEC

TRIC

SHOC

K

CAN

KILL


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

A

K196

INPUT CABLE

ELECTRODE CABLE

TO LN-9 GMA

INVERTEC

POWER SOURCE

WITH 110/115V AUX.

LN-9 GMA WITH

K608-1 AND

K442-1 KITS.

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’.

S20608

P10’,J10

2 3 4 5 6 7 10

11

12

P10,J10’

2 3 4 5 6 11

12

7

3.9K

K608-1

CONNECTION

DETAIL

530A

521

500

500

524 C B

533

CB

9-11-92

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

– 32 –

CONTROL

CONTROL PANEL

ARC FORCE/INDUCTANCE

2

2W

R11

227

/INDUCTANCE

CONTROL

TERMINAL

CHOKE

10K

215

227

4

303

301

CW (MAX)

METER

TOP

S2

C5

L3

R8

D2

SHUNT

1

211A

3 8 1

BOARD

9

CONNECTOR CAVITY NUMBERING SEQUENCE

OUTPUT TERMINAL

S4

R = RED

243J2

J1

1

301

4

TP4

45

W

L4

9D

12B 12D

9C

1

5

R5

R12

275C

204B

65

206

3

215

AV

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

N

AUXILIARY

SPARE

-

T1

GND

CW (MAX)

275F

275D

303

302

304

J7

504

2

212A

J3

229

317

13

87

1

N.G.

N.F.

14

14

R7

52

BOARD

2200 F

214

3J15

U

H1 82

SWITCH

METER FUNCTION

S5

S2

OUTPUT CONTROL

R11

INDICATOR

OVERLOAD

THERMAL

SWITCH

OUTPUT

REMOTE

223B

IG

MIN

9A9A

BOARD

52

1

311

V W

6

H5 A

B

TP3

76

F -

FEEDER

12D

12D

12C

9B

51

N.H.

0V

2

503

4

150 5W

H1

N.C.

WIRE

COLOR CODE:

MODE SWITCH

MODE SWITCH

OUTPUT

CONTROL

503A

Y

306

75

532

212B

42A

42

J13

W

212D

F1

INSIDE

S

BOTTOM

THERMAL

F229

11

12B

213

208

77A

S

R4

J3

C1+

25

208V

85

203

D3

76

SWITCH

MODE

211A

S

220

J4

Y

AUX

77A

226

Y

R

CONTROL

BOARD

12C

12B

523

G

41

J5, J16

D

2

W

ON

4

A

316

4,5

D +

25W

-

12A

RIGHT

9D

212D

54 632

4

PANEL

226

CV GMAW

2

3

TP6

5

25W

1

400A

BOTTOM

401, 403

TOP

450V

25W

(RIGHT)

2200 F

25

BOARD

H125W

1200-

5

H2

302

4,5

6

2

N.G.

9B

275D

42

24V

2

211B

H4

64501

H3

L

AUX

TOP

11,8

212A

W

14 4

RW

R315

53

12

12A

5

317

23

TRIGGER

F8

7

305

304

SWITCH

212B

10

H1

CC CRISP

CC SOFT

LOCAL

275B

OVERLOAD

502

TP5

250

BOTTOM

401, 403

6H6

440-

A42A

+

R

214

12D

R

SWITCH

H2

H3

220-

H3

309

212

J31

3

S

N.D.

FAN

311

229

THERMOSTAT

H5

6

ARC FORCE

6

11

S4

5

4

ON

223A

MOTOR

Y

206

110V

275A

E

2

S

3

C6

R12

INDICATOR

(V300-I ONLY)

(V300-I ONLY)

LOCAL/REMOTE

REMOTE

SWITCH

FUNCTION

METER

S5

R

72

212C

3

224

J6

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.

2W

208

1

116

7

54287

81,8

-

FR9

504

7500

F

402, 404

I

CU

RREN

T

CHOKE

+

207

204C

204B

228

3

275A

228

502

276

77B

21

4

218

SWITCH

S3

LOCAL/REMOTE

308

INPUT

S1

RECTIFIER

9D

9C

D13

9A

R6

450V

8

2

4

POWER

CB2

32A

212

CB1

6AMP

REMOTE

460V

S6

BLOW

SLOW

T3

229

D1A

(LEFT)

L10189

6OFF

307

CC GTAW

TP1

C

CV FCAW

R12

6

BOTTOM

OUTSIDE

3 AMP

A

L5

R11

12

TOP

207

INSIDE

9

204A

J5

F

I

S

9

4

310

5

501

J16

13

276

RECONNECT

9D

9B

TRAN

SFOR

MER

12A

VAC

32

310

309

310

203

275C

75

OUTPUT

76

F

77

3

313

316

H1

314315

9B

W

12A

9

W

12A

TP2

SWITCH

9B

12

A

42V

230V

FAN

H4

75

380-

415V

77B

TRANSFORMER

32

A

42

110/115

212

212

212C

H B

21

L2

4

MAIN

34

53

53

S3

1

J10

12 7

210

J6

308

J12

210

14

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.

14

52

63

J11

43

21

309

B

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

THERMOSTAT

503A

224

S2

R

1

BOARD

INPUT

S7

12

PER

CR2

CR1

POWER

J9

1S

286

SWITCH

C2

N.A.

B

211B

- ARC

OUTSIDE

+ ARC

314

25W

H5

PROTECTION

H5

J8

51

9

1

285

204C

C9

SS

51

204A

25

213

229

T2

FS F

TRANSFORMER

4F

313306

402, 404

275F

F

52

+25

+

R1

7500

25W

ELECTRICAL SYMBOLS PER E1537

J2, J8

J11, J14

J13, J15

J9, J10, J12

J4

3503

5

305

2307

32A

LEFT

2AMP

M81

21

GND

Y

1

L1

10K

18V

H3

12B

10

25W

J14

KVAC

N.F.

C

D1B

214

8

218

275B

10

223B

223A

CONTROL

220

NO

TE:

This

dia

gram

is fo

r ref

eren

ce o

nly.

It

may

not

be

accu

rate

for a

ll m

achi

nes

cove

red

by th

is m

anua

l. T

he s

peci

fic d

iagr

am fo

r a p

artic

ular

cod

e is

pas

ted

insi

deth

e m

achi

ne o

n on

e of

the

encl

osur

e pa

nels

. If

the

diag

ram

is il

legi

ble,

writ

e to

the

Serv

ice

Dep

artm

ent f

or a

repl

acem

ent.

Giv

e th

e eq

uipm

ent c

ode

num

ber..

MAR97

– 33 –

21

2

RECTIFIER

9D

C2

R7

9A9A

N.F.

CONTROL PANEL

J11, J14

SF

9

H5

402, 404

ON

OFF

H1

RV

CH6

12B

BOTTOM

51

WIRING DIAGRAM V300-PRO CODE 10257 (575V)

SHUNT

R8

250

L3

L1

C1

TP2

9D

S1

1, 8

POWER

J12

401, 403

12B

12B

25

J13

G

25W

R = RED

R4

W = WHITE

1

32

1

J11

J9

45

26

3

F

D13

317

6

9A

J16

514

315

316

51

LAYOUT

504

4H3

6

J5, J16

32

32

227

213

214

INSIDE

STOP

+

S

TOP

5

2

W

303

3 8J6

1

18V

285

AUX

TOP

OUTSIDE

SBOTTOM

F

226

S

F4

FS

TRANSFORMER

MAIN

L2

CHOKE

FS

53

41

52

36

52

53

53

14

REMOTE

214

SWITCH

POLARITY

WELDING

WIRE FEEDER

S6

42A

+

5

W

501

R

7

317316

9D

6

314

RW

POWER

R

BOARD

8

5

8

402, 404

307

+T2

+

CU

RREN

T

J2

M

J2, J8

S4

OUTPUT TERMINAL

SWITCH

25W

CV FCAW

+25

+Y

10K

YR5

9B

N.F.

912

2W

10K

R12REMOTE

275A

LOCAL

2W

275B

207

77A

275C

276

150 5W

204B

228

212C

208

20376

77B

204C

204A

220

229

R11

285

MODE SWITCH

S2

/INDUCTANCE

LOCAL/REMOTE

NSPARE

GND

218

BGND

275C

227

226

275B

CONTROL

4

77A

75218

276

208

207

228

229

275D

301

305

4

D3

S

1

12

(V300-I ONLY)

210

211B

1

J1, J7

J9, J10, J12

J13, J15

6

J3

302

J7

4

309

224

TOP

AUX

H1

42

WB

N.A.

H5

H1

2H3

75

MIN

G75

76

24V

F76

E77

31

212C

CR1

+ ARC

400A

C6

RIGHT

C9

BOARD

S

W R

215

4

5

203

310

S5

503A 1

229

1

4

J14

32

CW (MAX)

215

CW (MAX)

306

212A

212B

J5

223B

712

210

13

J1

275A

2

309

J4

J6

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.

25

25W

42A

2AMP

H1

6AMP

212

212

212

I C D H

42 81

42

VAC

S2

MODE

SWITCH

R11

OUTPUT

CONTROL

S3

R12

S4

SWITCH

SWITCH

CONTROL

TERMINAL

THERMAL

OVERLOAD

INDICATOR

SWITCH

FUNCTION

METER

REMOTE

3503

313

6H6

H5

0V

FAN

212D

2

THERMOSTAT

AV

310

D1B

5 6

8F

4

301

8

2

4

223A

303

304

304

213

G = GREEN

2

FEEDER

NOTES:

N.A.

3

2

LOCAL/REMOTE

R11

F

501

2

2 3 4

PROTECTION

R1

B

+

912

25W

R9

D2

D1A

C15

L10191

CONTROL

ARC FORCE/INDUCTANCE

R12SWITCH

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

8

302

275D

CV GMAW

5 3

502

4 12

11

211A

2

3

9

6

6

Y

14

8

4

7

11

Y

10 5

Y

503

9

503A

2

1

TP6

3

3

C5

4

204C

L4

42V

32A

110V

25W

313

311

306

275F

44, 5

25W

BOARD

13,15

13

C14

(LEFT)

401, 403

DRIVER

BOARD

19D

L5

N.C.

L82

230V

4

220-

TRIGGER

54,5

I

10K

ON

223A

502

FAN

S3

MOTOR

SWITCH

CB2

J

575V

32A

A

CB1

212A

52 14

J15

51

J8

H5 1

1

INPUT

314

23

12A

7

R

812

13

14

229

SWITCH

BOARD

A

F -

H3

OUTPUT

OUTPUT

ARC FORCE

3

21

220

204B

204A

F1

INSIDE

1, 8

286

CHOKE

1

BOARD

305

5

308

-

1

CC SOFT

BOTTOM

S

206

-

J10

ELECTRICAL SYMBOLS PER E1537

(VIEWED FROM COMPONENT SIDE OF BOARD)

CONNECTOR CAVITY NUMBERING SEQUENCE

311

RECEPTACLE

TRANSFORMER

CONTROL

AUXILIARY

T1

REMOTE

WIRE

-21

43

52

25

10K

TP1 TP3

212

VAC

21

223B

PANEL

3

METER

4 5 6

5

- ARC

6

TP4

THERMOSTAT

W

J4

27

275F

7

504

1

CONTROL

1 3

9 10

224

PER

CC GTAW

CC CRISP

52

315

INPUT

TRAN

SFOR

MER

I

F

BOTTOM

9

206

U

OUTSIDE

WD +

308

307

229

S5

TP5

K

41

H1

77B

(RIGHT)

T3

110/115

13,15

15

1W

R

12

SWITCH

R6

25W

1J3

10

B

NO

TE:

This

dia

gram

is fo

r ref

eren

ce o

nly.

It

may

not

be

accu

rate

for a

ll m

achi

nes

cove

red

by th

is m

anua

l. T

he s

peci

fic d

iagr

am fo

r a p

artic

ular

cod

e is

pas

ted

insi

deth

e m

achi

ne o

n on

e of

the

encl

osur

e pa

nels

. If

the

diag

ram

is il

legi

ble,

writ

e to

the

Serv

ice

Dep

artm

ent f

or a

repl

acem

ent.

Giv

e th

e eq

uipm

ent c

ode

num

ber..

MAR97

INVERTEC V300-PRO & V300-I

NOTES

Now Available...12th EditionThe Procedure Handbook of Arc Welding

With over 500,000 copies of previous editions publishedsince 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry.

This printing wil l go fast so don’t delay. Place your order now using the coupon below.

The hardbound book contains over 750 pages of weldinginformation, techniques and procedures. Much of this material has never been included in any other book.

A must for all welders, supervisors, engineers anddesigners. Many welding instructors will want to use the bookas a reference for all students by taking advantage of the lowquantity discount prices which include shipping by4th class parcel post.

$15.00 postage paid U.S.A. Mainland

How To Read Shop Drawings

The book contains the latest information and applicationdata on the American Welding Society Standard WeldingSymbols. Detailed discussion tells how engineers anddraftsmen use the “short-cut” language of symbols to passon assembly and welding information to shop personnel.

Practical exercises and examples develop the reader’s abilityto visualize mechanically drawn objects as they will appearin their assembled form.

187 pages with more than 100 illustrations. Size 8-1/2” x 11”Durable, cloth-covered board binding.


New Lessons in Arc WeldingLessons, simply written, cover manipulatory techniques;

machine and electrode characteristics; related subjects,such as distortion; and supplemental information on arcwelding applications, speeds and costs. Practice materials,exercises, questions and answers are suggested for each lesson.

528 pages, well illustrated, 6” x 9” size, bound in simulated,gold embossed leather.


Need Welding Training?The Lincoln Electric Company operates the oldest and

most respected Arc Welding School in the United States at itscorporate headquarters in Cleveland, Ohio. Over 100,000 stu-dents have graduated. Tuit ion is low and the training is “hands on”

For details write: Lincoln Welding School22801 St. Clair Ave. Cleveland, Ohio 44117-1199.

and ask for bulletin ED-80 or call 216-383-2259 and ask for theWelding School Registrar.

Lincoln Welding SchoolBASIC COURSE $700.00

5 weeks of fundamentalsThere is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.Prices include shipment by 4 thClass Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:

$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 44117-1199BOOKS 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 ACFoundation Book Information Welding Preheat Calculator $3.00 WC-8

(JFLF-515) Pipe Welding Charts $4.50 ED-89SUB TOTAL

Additional Shipping Costs if anyTOTAL COST

– 38 –

WARNING

AVISO DEPRECAUCION

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 BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

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

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

– 39 –

WARNING

AVISO DEPRECAUCION

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 ASPRÁTICAS 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 loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung 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 máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; 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 orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

–• 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 •

IM526-B INVERTEC V300-PRO - Lincoln Electric

Documents

Transcript of IM526-B INVERTEC V300-PRO - Lincoln Electric