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IM526-B
â„?
INVERTEC V300-PRO December,1999
For use with machines Code 10256 and 10257.
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 thought-
ful 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:
OPERATOR’S MANUAL
� World's Leader in Welding and Cutting Products �
� 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
WARNING ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information it is strongly recommended that you 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 the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can FUMES AND GASES
kill. can be dangerous.
1.a. The electrode and work (or ground) circuits 3.a. Welding may produce fumes and gases haz-
are electrically “hot� when the welder is on. ardous to health. Avoid breathing these
Do not touch these “hot� parts with your bare fumes and gases.When welding, keep your
skin or wet clothing. Wear dry, hole-free head out of the fume. Use enough ventila-
gloves to insulate hands. tion 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 contain-
1.b. Insulate yourself from work and ground using dry insulation.
er or MSDS) or on lead or cadmium plated steel and
Make certain the insulation is large enough to cover your full
other metals or coatings which produce highly toxic
area of physical contact with work and ground.
fumes, keep exposure as low as possible and below
Threshold Limit Values (TLV) using local exhaust or
In addition to the normal safety precautions, if welding
mechanical ventilation. In confined spaces or in some
must be performed under electrically hazardous condi-
circumstances, outdoors, a respirator may be required.
tions (in damp locations or while wearing wet clothing;
Additional precautions are also required when welding
on metal structures such as floors, gratings or scaf-
on galvanized steel.
folds; when in cramped positions such as sitting, kneel-
ing or lying, if there is a high risk of unavoidable or acci- 3.b. Do not weld in locations near chlorinated hydrocarbon vapors
dental contact with the workpiece or ground) use the fol- coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
lowing equipment:
form phosgene, a highly toxic gas, and other irritating prod-
� Semiautomatic DC Constant Voltage (Wire)
ucts.
Welder.
� DC Manual (Stick) Welder. 3.c. Shielding gases used for arc welding can displace air and
� AC Welder with Reduced Voltage Control. cause injury or death. Always use enough ventilation, espe-
cially in confined areas, to insure breathing air is safe.
1.c. In semiautomatic or automatic wire welding, the electrode,
3.d. Read and understand the manufacturer’s instructions for this
electrode reel, welding head, nozzle or semiautomatic weld-
equipment and the consumables to be used, including the
ing gun are also electrically“hot�.
material safety data sheet (MSDS) and follow your employ-
er’s safety practices. MSDS forms are available from your
1.d. Always be sure the work cable makes a good electrical con-
welding distributor or from the manufacturer.
nection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Also see item 7b.
1.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
WELDING SPARKS can
1.f. Maintain the electrode holder, work clamp, welding cable and
cause fire or explosion.
welding machine in good, safe operating condition. Replace
damaged insulation.
4.a..Remove fire hazards from the welding area.
1.g. Never dip the electrode in water for cooling. If this is not possible, cover them to prevent
the welding sparks from starting a fire.
1.h. Never simultaneously touch electrically “hot� parts of elec- Remember that welding sparks and hot
trode holders connected to two welders because voltage materials from welding can easily go through small cracks
between the two can be the total of the open circuit voltage and openings to adjacent areas. Avoid welding near
of both welders. hydraulic lines. Have a fire extinguisher readily available.
1.i. When working above floor level, use a safety belt to protect
4.b. Where compressed gases are to be used at the job site, spe-
yourself from a fall should you get a shock.
cial precautions should be used to prevent hazardous situa-
tions. Refer to “Safety in Welding and Cutting� (ANSI
1.j. Also see Items 4.c. and 6.
Standard 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 can
ARC RAYS can burn. cause overheating and create a fire hazard.
2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and 4.d. Do not heat, cut or weld tanks, drums or containers until the
the rays of the arc when welding or observing proper steps have been taken to insure that such procedures
open arc welding. Headshield and filter lens will not cause flammable or toxic vapors from substances
should conform to ANSI Z87. I standards. inside. They can cause an explosion even though they have
been “cleaned.� For information purchase “Recommended
2.b. Use suitable clothing made from durable flame-resistant Safe Practices for the Preparation for Welding and Cutting of
material to protect your skin and that of your helpers from Containers and Piping That Have Held Hazardous
the arc rays. Substances�, AWS F4.1 from the American Welding Society
(see address above).
2.c. Protect other nearby personnel with suitable non-flammable
screening and/or warn them not to watch the arc nor expose 4.e. Vent hollow castings or containers before heating, cutting or
themselves to the arc rays or to hot spatter or metal. welding. They may explode.
�2�
Apr. �93
4.f. Sparks and spatter are thrown from the welding arc. Wear oil 7.c.Do not add the fuel near an open flame weld-
free protective garments such as leather gloves, heavy shirt, ing arc or when the engine is running. Stop
cuffless trousers, high shoes and a cap over your hair. Wear the engine and allow it to cool before refuel-
ear plugs when welding out of position or in confined places. ing to prevent spilled fuel from vaporizing on
Always wear safety glasses with side shields when in a weld- contact with hot engine parts and igniting.
ing area. Do not spill fuel when filling tank. If fuel is
spilled, wipe it up and do not start engine
4.g. Connect the work cable to the work as close to the welding until fumes have been eliminated.
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 7.d. Keep all equipment safety guards, covers
lifting chains, crane cables or other alternate circuits. This can and devices in position and in good repair.
create fire hazards or overheat lifting chains or cables until Keep hands, hair, clothing and tools away
they fail. from V-belts, gears, fans and all other mov-
ing parts when starting, operating or repair-
4.h. Also see item 7c. ing equipment.
CYLINDER may explode 7.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
if damaged. guards only when necessary and replace them when the
maintenance requiring their removal is complete.
5.a. Use only compressed gas cylinders contain-
Always use the greatest care when working near moving
ing the correct shielding gas for the process
parts.
used and properly operating regulators
designed for the gas and pressure used. All 7.f. Do not put your hands near the engine fan. Do not
hoses, fittings, etc. should be suitable for the application and attempt to override the governor or idler by pushing on
maintained in good condition. the throttle control rods while the engine is running.
5.b. Always keep cylinders in an upright position securely
7.g. To prevent accidentally starting gasoline engines while turn-
chained to an undercarriage or fixed support.
ing the engine or welding generator during maintenance
5.c. Cylinders should be located: work, disconnect the spark plug wires, distributor cap or
� Away from areas where they may be struck or subjected to magneto wire as appropriate.
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 7.h. To avoid scalding, do not remove the radia-
electrically “hot� parts to touch a cylinder. tor pressure cap when the engine is hot.
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.
ELECTRIC AND MAGNETIC
5.g. Read and follow the instructions on compressed gas cylin-
FIELDS
ders, associated equipment, and CGA publication P-l,
may be dangerous
“Precautions for Safe Handling of Compressed Gases in
Cylinders,â€available from the Compressed Gas Association
8.a. Electric current flowing through any con-
1235 Jefferson Davis Highway, Arlington, VA 22202.
ductor causes localized Electric and
Magnetic Fields (EMF). Welding current
creates EMF fields around welding cables
FOR ELECTRICALLY and welding machines.
powered equipment. 8.b. EMF fields may interfere with some pacemakers, and
6.a. Turn off input power using the disconnect welders having a pacemaker should consult their physician
switch at the fuse box before working on before welding.
the equipment.
8.c. Exposure to EMF fields in welding may have other health
6.b. Install equipment in accordance with the U.S. National effects which are now not known.
Electrical Code, all local codes and the manufacturer’s rec-
ommendations. 8d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations. 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.
FOR ENGINE
powered equipment. 8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right side,
7.a. Turn the engine off before troubleshooting and maintenance the work cable should also be on your right side.
work unless the maintenance work requires it to be running.
--------------------------------------------------------------------------------------- 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.
7.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes out-
doors.
---------------------------------------------------------------------------------------
�3� Mar. �93
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un échauf-
fement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
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
a. Les circuits à l’électrode et à la piéce sont sous tension
masse sur la charpente de la construction ou d’autres endroits
quand la machine à souder est en marche. Eviter toujours
éloignés de la zone de travail, on augmente le risque de voir
tout contact entre les parties sous tension et la peau nue ou
passer le courant de soudage par les chaines de levage,
les vétements mouillés. Porter des gants secs et sans trous
câbles de grue, ou autres circuits. Cela peut provoquer des
pour isoler les mains.
risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble de
produit des fumeés toxiques.
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
f. Si on utilise la machine à souder comme une source de
le code “Code for safety in welding and cutting� CSA Standard
courant pour soudage semi-automatique, ces precautions
W 117.2-1974.
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.
PRÉCAUTIONS DE SÛRETÉ POUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
LES MACHINES À SOUDER À
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
TRANSFORMATEUR ET À
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou
REDRESSEUR
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
1. Relier à la terre le chassis du poste conformement au code de
de soudeur et des aides contre le rayonnement de l‘arc.
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
c. Protéger l’autre personnel travaillant à proximité au
bonne mise à la terre.
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
4. Des gouttes de laitier en fusion sont émises de l’arc de
effectués par un électricien qualifié.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
3. Avant de faires des travaux à l’interieur de poste, la debrancher
talons sans revers, et chaussures montantes.
à l’interrupteur à la boite de fusibles.
5. Toujours porter des lunettes de sécurité dans la zone de
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
soudage. Utiliser des lunettes avec écrans lateraux dans les
�4� Mar. �93
TABLE OF CONTENTS
Page
Safety Precautions .............................................................................................................2-4
Introductory Information .......................................................................................................6
Product Description..............................................................................................................7
Specifications.......................................................................................................................7
Installation .........................................................................................................................7-10
Safety Precautions ........................................................................................................7
Location .........................................................................................................................7
Electrical Installation......................................................................................................7
Input Voltage Setup .......................................................................................................8
Power Cord Connection ................................................................................................8
Connection of Wire Feeders to Invertec .....................................................................8-10
Output Cables & Plugs .................................................................................................10
Operating Instructions ......................................................................................................11-13
Safety Precautions .......................................................................................................11
Controls Description and Function.............................................................................11-13
Maintenance.....................................................................................................................13-14
Capacitor Discharge Procedure ...................................................................................13
Routine Maintenance....................................................................................................13
Periodic Maintenance ...................................................................................................14
Troubleshooting Guide .....................................................................................................14-20
Matched Parts.....................................................................................................................20
Switch P.C. Board Replacement Procedure .......................................................................20
Replacement of Power Modules and Output Diodes .......................................................20-21
Connection Diagrams.......................................................................................................22-31
Wiring Diagrams...............................................................................................................32-33
Parts Lists ......................................................................................................................appendix
�5�
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
�6�
PRODUCT DESCRIPTION
The Invertec V300-PRO is a 300 amp arc welding
power source that utilizes single or three phase input
power to produce either constant voltage or constant
current outputs. The V300-PRO is designed for 60 Hz
supply systems. The welding response of the Invertec
has been optimized for GMAW, SMAW, TIG and
FCAW processes. It is designed to be used with the
LN-25 and LN-7 semiautomatic wire feeders.
SPECIFICATIONS
Product Ordering Input AC Rated DC Output Input Amps at Rated DC Output Output Weight Dimensions
Name Information Voltage Amps/Volts/Duty Cycle Range with Gun HxWxD
208 230 460 575 (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
NEMA Class I Rated Output / Based on a 10 min. Period .
(1 )
Lincoln plus rating.
(2 )
* Overall Height Including Handle, (16.4� (417mm without handle).
INSTALLATION
WARNING ELECTRICAL INSTALLATION
ELECTRIC SHOCK can kill.
� Have an electrician install and service 1. The Invertec should be connected only by a quali-
this equipment. fied electrician. Installation should be made in
� Turn the input power off at the fuse accordance with the U.S. National Electrical Code,
box before working on equipment. all local codes and the information detailed below.
� Do not touch electrically hot parts.
--------------------------------------------------------------------- 2. Single voltage, 575 VAC machines, can only be
connected to 575 VAC. No internal reconnection
LOCATION
for other input voltages is possible.
The Invertec has been designed with many features to
3. Initial 208 VAC and 230 VAC operation will require
protect it from harsh environments. Even so, it is
a voltage panel setup, as will later reconnection
important that simple preventative measures are fol-
back to 460 VAC:
lowed in order to assure long life and reliable opera-
tion.
a. Open the access panel on the right side of
� The machine must be located where there is free
the machine.
circulation of clean air such that air movement into
b. For 208 or 230: Position the large switch to
the sides and out the bottom and front will not be
200-230.
restricted. Dirt and dust that can be drawn into the
For 460: Position the large switch to 380-460.
machine should be kept to a minimum. Failure to
c. Move the “A� lead to the appropriate terminal.
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.
�7�
INPUT VOLTAGE SETUP Recommended Fuse Sizes Based On The U.S.
National Electrical Code And Maximum
Machine Outputs
CAUTION
DO NOT ATTEMPT TO POWER THIS UNIT
Fuse Size in Amps
FROM THE AUXILIARY POWER SUPPLY Input Volts(1) (Time Delay Fuses)
OF AN ENGINE WELDER. 3 phase 208 60
� Special protection circuits may operate, causing 50/60 Hz 230 60
460 40
loss of output.
� The supply from engine welders often has exces- 1 phase 208(2) 85
sive voltage peaks because the voltage waveform 50/60 Hz 230(2) 80
460 50
is usually triangular shaped instead of sinusoidal.
� If voltage peaks from the engine welder exceed 3 phase 575 30
380V, the input circuits of this machine protecting 60 Hz
the filter capacitors, FETS and other components
Input voltage must be within ±10% of rated value.
(1)
from damage will not be energized .
When operating on these inputs, at outputs exceeding 200A/60%
(2)
--------------------------------------------------------------------- or 165A/100%, the input line cord should be changed to an input
conductor of 6 AWG or larger.
RECONNECT PROCEDURE
. Disconnect input power before
1. BE SURE POWER SWITCH IS OFF. inspecting or servicing machine.
CONNECTION OF WIRE FEEDERS TO THE
. Do not operate with wraparound
2. CONNECT LEAD ’A� TO DESIRED
removed.
INPUT VOLTAGE RANGE.
INVERTEC
. Do not touch electrically live parts.
440-460V
(Note: IEC units do not have 110 VAC auxiliary
. Only qualified persons should install,
’A� use or service this equipment.
380-415V
power).
220-230V
IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)
LN-25 Connection Instructions
AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;
200-208V
REPLACE WITH A 3 AMP SLOW BLOW ONLY.
3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.
1. Turn the Invertec power switch “off�.
VOLTAGE=380-460V VOLTAGE=200-230V
2. Connect the electrode cable to the output terminal
of polarity required by electrode. Connect the work
lead to the other terminal.
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. 9-11-92 S20324
POWER CORD CONNECTION
3. LN-25 with remote control options K431 and K432.
Use K876 adapter with K432 cable or modify K432
A 10 ft. (3.0m) power cord is provided and wired into
cable with K867 universal adapter plug. See con-
the machine. Follow the power cord connection
nection diagram S19899 and S19309 or S19405 at
instructions. Incorrect connection may result in equip-
the back of this manual.
ment damage.
4. Place the local-remote switch in the “remote� posi-
BLACK
GREEN
tion if output control is desired at the wire feeder
RED
rather than the Invertec. (LN-25 must have K431
WHITE
and K432 options for remote output control opera-
tion).
LN-7 Connection Instructions
Single Phase Input
1. Connect green lead to ground per U.S. National
1. Turn the Invertec power switch “off�.
Electrical Code.
2. Connect black and white leads to power.
2. Connect the K480 control cable from the LN-7 to
3. Wrap red lead with tape to provide 600V insula-
the Invertec control cable connector. The control
tion.
cable connector is located at the rear of the
Invertec.
Three Phase Input
3. Connect the electrode cable to the output terminal
1. Connect green lead to ground per U.S. National
of polarity required by electrode. Connect the work
Electrical Code.
lead to the other terminal.
2. Connect black, red and white leads to power.
4. Place the local-remote switch in the “local� posi-
Install in accordance with all local and national electric
tion to allow output control at the Invertec. (K864
codes.
�8� �
remote control adapter and K857 remote control Parallel Operation
are required for remote output control).
The Invertec’s are operable in parallel in both CC and
5. Set the meter polarity switch on the rear of the CV modes. For best results, the currents of each
Invertec to coincide with wire feeder polarity used. machine should be reasonably well shared. As an
The wire feeder will now display the welding volt- example, with two machines set up in parallel for a
age. 400 amp procedure, each machine should be set to
deliver approximately 200 amps, not 300 amps from
6. If K480 is not available, see connection diagram one and 100 amps from the other. This will minimize
S19404 for modification of K291 or K404 LN-7 nuisance shutdown conditions. In general, more than
input cable with K867 universal adapter plug. two machines in parallel will not be effective due to
the voltage requirements of procedures in that power
General Instructions for Connection of Wire range.
Feeders to Invertec
To set machine outputs, start with output control pots
Wire feeders other than LN-7 and LN-25 may be used and arc force/pinch pots in identical positions. If run-
provided that the auxiliary power supply capacity of ning in a CC mode, adjust outputs and arc forces to
the Invertec is not exceeded. K867 universal adapter maintain current sharing while establishing the proper
plug is required. See connection diagram S19406 and output current. In CV modes, the pots in identical
S19386 at the back of this manual for more informa- positions. Then switch the machine meters to amps
tion. and adjust one of the output control pots for current
balance. Check the voltage and if readjustment is
Remote Control of Invertec necessary, repeat the current balancing step. Pinch
settings should also be kept identical on the
Remote control K857, hand amptrol K963 and foot machines.
amptrol K870 require K864 remote control adapter.
See 19309 instruction at the back of this manual for K900-1 DC TIG Starter Connection
connection information.
This versatile new kit was made to mate with the
K954-1 MIG PULSER Invertec.
The MIG Pulser is a hand-held “pendant� type GMAW A control cable assembly is supplied with the kit to
Pulsing option for the V300 Power Source. Refer to connect the kit to an Invertec. The cable can be con-
the Mig Pulser’s IM manual (IM555) for connection nected, either end, at the DC TIG Starter kit and at
information. 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 Magnumâ„? one and two piece water-cooled torch-
es with 7/8 left-hand threads and gas-cooled torches
with 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 the
Invertec and for more detailed instructions, refer to
the K900-1 manual.
�9� MAR97
LN-9 GMA Connection Instructions 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
1. Turn the Invertec power switch “off�. over the cable.
BOOT
2. Connect the K596 control cable assembly from the WELDING CABLE
LN-9 GMA to the Invertec control cable connector.
The control cable connector is located at the rear
of the Invertec.
25 mm
TRIM
1 in.
3. Connect the electrode cable to the output terminal
of polarity required by electrode. Connect the work 3. Slide the copper tube into the brass plug.
lead to the other terminal.
4. Insert cable into copper tube.
4. Place the local-remote switch in the “remote� posi- SET SCREW
tion 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 volt- BRASS PLUG
COPPER TUBE
age.
5. Tighten set screw to collapse copper tube. Screw
6. K608-1 adapter is required in LN-9 GMA for LN-9 must apply pressure against welding cable. The
type control. K608-1 is installed in line with P10 top of the set screw will be well below the surface
connection at the LN-9 GMA voltage board. See of the brass plug after tightening.
diagram S20607 at the back of this manual.
6. Slide rubber boot over brass plug. The rubber
7. K442-1 Pulse Power Filter Board is also required boot must be positioned to completely cover all
for GMAW, but should be disconnected for FCAW. electrical surfaces after the plug is locked into the
receptacle.
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 �
OPERATING INSTRUCTIONS Output Control - This controls the output voltage in
the CV modes and output current in the CC modes.
WARNING Control is provided over the entire output range of the
power source with 1 turn of the control knob. This con-
ELECTRIC SHOCK can kill.
trol may be adjusted while under load to change
� Do not touch electrically live parts or
power source output.
electrode with skin or wet clothing.
� Insulate yourself from work and OUTPUT
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
Local/Remote Switch - Place in the “LOCAL� posi-
fumes from breathing zone.
tion to allow output adjustment at the machine. Place
------------------------------------------------------------------------
in the “REMOTE� position to allow output adjustment
WELDING SPARKS can cause fire or
at the wire feeder or with a remote control option
explosion.
package.
� Keep flammable material away.
� Do not weld on closed containers.
REMOTE
------------------------------------------------------------------------
ARC RAYS can burn eyes and skin.
� Wear eye, ear and body
protection.
------------------------------------------------------------ Digital Meter Switch - Select either “A� for amps or
“V� for volts to display welding current or voltage on
See additional warning information at the meter.
front of this operator’s manual.
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 indi-
cation of machine control setting. For a more precise
DUTY CYCLE
process reading, read meter during actual welding.
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
Mode Switch
energize the machine. When the power is on, the digi-
tal meter will activate and the fan will operate.
GTAW Optimized for both scratch start and Hi-
Freq kit use.
OFF
CC SOFT Best for EXX18 thru EXX28 stick elec-
trodes.
CC Crisp Use this mode for stick welding with
EXX10 thru EXX14 electrodes. Non-
welding applications such as resistive
heating or output tests with resistive
loads should be done in this mode with
Arc Force Control set to minimum.
� 11 �
CV FCAW This setting has been optimized for Arc Force / Inductance Control
Innershield® and Outershield® flux-cored
electrodes. This control functions in all modes except GTAW. For
CC modes, this control acts as an Arc Force adjust-
CV GMAW Short circuit, glob and spray transfer ment. The arc is soft at the minimum settings and
solid wire and gas welding are done in more forceful or driving at the maximum settings.
this mode. Low end procedures, less Higher spatter levels may be present at the maximum
than 17V, may operate better in the settings.
FCAW mode. Voltage in the GMAW
mode can become erratic when For CV modes, this control will set the degree of
welding is attempted using voltages “pinch effect� which predominantly affects short circuit
equal to or less than 17V DC+. transfer. In FCAW, the maximum setting is generally
preferred. With GMAW, the upper half of the range is
preferred with CO2 or high content CO2 mixed. The
SMAW
lower half is for inert gas mixes.
CRISP FCAW
SMAW
SOFT GMAW
GTAW
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 Recommended Arc Force / Inductance Settings
“ON� position. For Selected Applications
Set to the REMOTE (OFF) position when using LN-25 Full Range Is 1-10,
with K431 and K432 options or LN-7 which will allow 1 Is Very Soft, 10 Is Very Crisp
the gun trigger to energize the welding terminals.
ON Nominal Recommended
Mode Process Setting Adjustment Range
OUTPUT
TERMINALS
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
REMOTE Air Carbon Arc 1 None
Cutting
CV FCAW Innershield or 10 None
Outershield
Air Carbon Arc 1 None
Cutting
CV GMAW* CO2 or 25% CO2 7.5 5 to 10
or similar
gas mixes
98% Ar-2% O2Ar, 5 1 to 10
90% He-7.5% Ar
2.5% CO2 and
other
predominantly
inert gases
* 1 = Lowest pinch, highest inductance and least spatter.
10 = Highest pinch, lowest inductance and most spatter.
� 12 � �
Meter Polarity Switch MAINTENANCE
WARNING
The wire feeder polarity switch is located at the rear of
the machine. The switch provides a work connection ELECTRIC SHOCK can kill.
for wire feeder voltmeters. Place the switch in the � Have an electrician install and service
position of the electrode polarity indicated by the this equipment.
decal. The switch does not change the welding � Turn the input power off at the fuse
polarity. 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.
T13086-84
----------------------------------------------------------------------------------
Capacitor Discharge Procedure
Auxiliary Power
1. Obtain a power resistor (25 ohms, 25 watts).
A 24 VAC @ 1 amp supply is included for use with the
LN-25 wire feeder (24 volts needed for K431 and 2. Hold resistor body with electrically insulated glove.
K432 options). This supply is protected by a self- DO NOT TOUCH TERMINALS. Connect the resis-
resetting current limiter. tor terminals across the two hex head cap screws
in the position shown. Hold in each position for 1
A 42 VAC @ 5.5 amp supply is included for use with second. For 575 VAC only, repeat for second
other wire feeders. This supply is protected by a 6 capacitor. Repeat for the capacitor(s) on the other
amp breaker located on the rear of the machine. side 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
RESISTOR
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.
CAPACITOR
TERMINALS
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 con-
dition 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.
� 13 �
PERIODIC MAINTENANCE TROUBLESHOOTING
WARNING
Overload Protection
ELECTRIC SHOCK can kill.
The machine is electrically protected from producing � Have an electrician install and service
high output currents. Should the output current this equipment.
exceed 340-360A, an electronic protection circuit will � Turn the input power off at the fuse
reduce the current to approximately 150A. The box before working on equipment.
machine will continue to produce this low current until � Do not touch electrically hot parts.
the protection circuit is reset. Reset occurs when the ---------------------------------------------------------------------
output load is removed. EXPLODING PARTS can cause
injury.
Thermal Protection
� Failed parts can explode or cause other
parts to explode when power is applied.
Thermostats protect the machine from excessive
operating temperatures. Excessive temperatures may � Always wear a face shield and long sleeves when servicing.
be caused by a lack of cooling air or operating the ----------------------------------------------------------------------------------
machine beyond the duty cycle and output rating. If Visual Inspection
excessive operating temperature should occur, the
thermostat will prevent output voltage or current. The Clean interior of machine with a low pressure
meter will remain energized during this time. airstream. Make a thorough inspection of all compo-
nents. Look for signs of overheating, broken leads or
Thermostats are self-resetting once the machine cools other obvious problems. Many problems can be
sufficiently. If the thermostat shutdown was caused by uncovered with a good visual inspection.
excessive output or duty cycle and the fan is operating
normally, the Power Switch may be left on and the Open Circuit Voltage
reset should occur within a 15 minute period. If the fan
is not turning or the air intake louvers were obstructed, The open circuit voltage of the Invertec V300-PRO is
then the power must be switched off for 15 minutes in 60 to 75 VDC and cannot be adjusted by the output
order to reset. The fan problem or air obstruction must control.
also be corrected.
Test Conditions
Filter Capacitor Conditioning
Perform all testing at the lowest input voltage avail-
A protection circuit is included to monitor the voltage able, except where a higher voltage is required by a
across filter capacitors C1 and C2 (also C14 and C15 test step. Make ohmmeter checks only after power
on 575 VAC units). In the event that the capacitor volt- has been disconnected from machine and after
age is too high, the protection circuit will prevent out- capacitors have been discharged.
put. The protection circuit may prevent output provid-
ing all these circumstances are met: Certain high voltage connections have been insulated
with RTV sealant. It is necessary to break through the
1. Machine is internally connected for 380 VAC, or sealant with a sharp probe in order to make voltage or
higher input voltage. resistance checks.
2. Machine did not have power applied for many
months. Disconnect any control cables from remote control
3. Machine did not produce output when power was receptacle.
first switched on.
If these circumstances apply, the proper action is to
switch the machine on and let it idle for up to 30 min-
utes. 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.
� 14 �
TROUBLESHOOTING GUIDE
Trouble What To Do
Not output but fan operates and meter is on. Perform test steps 1A and 1B.
Poor welding, weld settings drift, or output power is 1. Check front panel wiring and controls.
low. 2. Replace Control PC Board.
Main fuses open or Switch PC boards overheated. Perform test steps 4 and 5 for both Switch PC Boards
and 7.
Output turns on momentarily then switches off and Perform test steps 3B, 4 and 5.
repeats. Machine is connected for 380 VAC or higher
input voltage.
OCV is normal (approx. 65-75V) but output power is Perform test steps 4 and 5 for both Switch PC Boards.
low (less than 20V and 100A). Machine makes
squealing noise while under load. Machine is connect-
ed for 230 VAC, or lower, input voltage.
Open circuit voltage is 1-2 volts. Perform test step 6.
Output control not functioning on remote control. Local 1. Check remote control assembly.
control OK. 2. Check S3, Local/Remote switch.
Machine does not produce more than 250A output 1. Replace main fuse if blown.
when connected to 3 phase supply. 2. Replace Protection PC Board.
3. Replace Control PC Board.
4. Perform test step 7.
Machine does not produce more than 200 A output Normal operation.
while connected to 1 phase supply.
Machine operates OK at 230 VAC or lower. No output Perform test step 2.
at 380 VAC or higher.
Poor EXX10 stick electrode (5P) performance. Arc Check D6 and D12, L1 and L2.
“pops out�.
No output or reduced output the first time power is Check reconnect panel - connections and fuse.
applied to the machine.
CAUTION
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.
� 15 �
TEST PROCEDURES
Next
Test Test
Step Test Check Result Conclusion Step Repair Action
1A Output pilot circuit 223A to 210 24 VAC Fan thermostat, choke 1B
(set S4 on) thermostat, T1 trans-
former and S4 all OK.
0 VAC Check above compo-
nents.
1B 302 (pos) to 275D (neg) 15 VDC T1 and 15V power sup- 2
ply OK.
0 VDC Check T1 and Power PC
Board.
2 Protection PC 313 (neg) to 311 (pos) <1 VDC Protection PC Board OK Replace Power
board output (set and Control PC
S4 on) Boards
>5 VDC 3A
3A Static capacitor Compare voltage across <25 VDC C1, C2, R1, R9 - OK
balance (set S4 terminals 9 & 12 of each difference (575 VAC machine C14,
off) Switch PC Board. between C15 - OK)
575 VAC -- 407 VDC readings
380 VAC input 460 VAC -- 325 VDC Replace
and higher test 440 VAC -- 311 VDC Protection PC
415 VAC -- 293 VDC 3B Board
380 VAC -- 269 VDC
575 VAC only - compare >25 VDC Check above compo-
voltage across 9A & 13 difference nents.
and 13 & 12A; then, 9B &
15 and 15 & 12B
3B Dynamic capaci- Connect as in step 3A. <25 VDC OK
tor balance (set Same voltages as above.
S4 on)
380 VAC input >25 VDC Power PC Board or 4
and higher test Switch PC Boards are and
damaged. 5
CAUTION
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.
� 16 � �
Next
Test
Test
Step Test Conclusion Step Repair Action
Check Result
4 Switch PC Board OK cont
Terminals on Switch >1K ohms
resistance test. PC Board:
1/8 (pos) to
Short 5 Replace Switch PC Board
12 (neg) <100 ohms
No dynamic test OK cont
1/8 (neg) to <100 ohms
is possible. 12 (pos)
Open 5 Replace Switch PC Board
>1K ohms
Remove leads OK cont
9 (pos) to >1K ohms
401/403, 1/8, 9, 4/5 (neg)
12, 4/5 and Short 5 Replace Switch PC Board
<100 ohms
402/404.
OK cont
9 (neg) to <100 ohms
4/5 (pos)
Open 5 Replace Switch PC Board
>1K ohms
OK cont
1/8 (pos) to <100 ohms
9 (neg)
Open 5 Replace Switch PC Board
>1K ohms
OK cont
1/8 (neg) to >1K ohms
9 (pos)
Short 5 Replace Switch PC Board
<100 ohms
OK cont
12 (pos) to <100 ohms
4/5 (neg)
Open 5 Replace Switch PC Board
>1K ohms
OK cont
12 (neg) to >1K ohms
4/5 (pos)
Short 5 Replace Switch PC Board
<100 ohms
OK cont
12 (pos) to >1K ohms
401/403 (neg)
Short 5 Replace Switch PC Board
<100 ohms
OK cont
12 (neg) to <100 ohms
401/403 (pos)
Open 5 Replace Switch PC Board
>1K ohms
OK cont
9 (pos) to <100 ohms
402/404 (neg)
Open 5 Replace Switch PC Board
>1K ohms
OK cont
9 (neg) to >1K ohms
402/404 (pos)
Short 5 Replace Switch PC Board
<100 ohms
CAUTION
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.
� 17 �
Next
Test
Test
Step Test Conclusion Step Repair Action
Check Result
5 Snubber OK cont
Lead 401 to terminal 25 ohms
Resistors 12
R4 open Replace R4
>30 ohms
R4 shorted
<20 ohms
Disconnect leads OK cont
25 ohms
401, 402, 403 and Lead 402 to terminal
404 from Switch R5 open Replace R5
9 >30 ohms
PC Board R5 shorted
<20 ohms
OK cont
25 ohms
R6 open
Lead 403 to terminal >30 ohms
R6 shorted Replace R6
12 <20 ohms
OK cont
25 ohms
R7 open Replace R7
>30 ohms
R7 shorted
Lead 404 to terminal <20 ohms
9
Shorted output Test individually
<100 ohms
6 Output diodes diode D1 thru
D12
+ output plug (pos)
to
Output diodes OK
- output plug (neg) >200 ohms
Remove output
load
CAUTION
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.
� 18 �
Next
Test
Test
Step Test Conclusion Step Repair Action
Check Result
7 D13 Input OK cont
9 (pos) to H1 (neg) >1K ohms
Rectifier
Shorted 4-5 Replace D13, inspect S1,
<100 ohms
test C1 and C2
OK cont
9 (pos) to A (neg) >1K ohms
Shorted 4-5 Replace D13, inspect S1,
<100 ohms
test C1 and C2
OK cont
9 (pos) to H5 (neg) >1K ohms
Shorted 4-5 Replace D13, inspect S1,
<100 ohms
test C1 and C2
OK cont
12 (neg) to H1 (pos) >1K ohms
Shorted 4-5 Replace D13, inspect S1,
<100 ohms
test C1 and C2
OK cont
12 (neg) to A (pos) >1K ohms
Shorted 4-5 Replace D13, inspect S1,
<100 ohms
test C1 and C2
OK cont
12 (neg) to H5 (pos) >1K ohms
Shorted 4-5 Replace D13, inspect S1,
<100 ohms
test C1 and C2
OK cont
9 (neg) to H1 (pos) <100 ohms
Open 4-5 Replace D13, inspect S1,
>1K ohms
test C1 and C2
OK cont
9 (neg) to A (pos) <100 ohms
Open 4-5 Replace D13, inspect S1,
>1K ohms
test C1 and C2
OK cont
9 (neg) to H5 (pos) <100 ohms
Open 4-5 Replace D13, inspect S1,
>1K ohms
test C1 and C2
OK cont
12 (pos) to H1 (neg) <100 ohms
Open 4-5 Replace D13, inspect S1,
>1K ohms
test C1 and C2
OK cont
12 (pos) to A (neg) <100 ohms
Open 4-5 Replace D13, inspect S1,
>1K ohms
test C1 and C2
OK cont
12 ( pos) to H5 (neg) <100 ohms
Open 4-5 Replace D13, inspect S1,
>1K ohms
test C1 and C2
� 19 �
Matched Parts 5. Thoroughly clean the heat sink surface.
Certain parts must be replaced in matched sets. 6. Apply a thin layer (ideally .005-.010�) of Dow 340
Matched sets are required in the following areas: Heat Sink Compound to the module mounting sur-
faces of the new Switch PC Board and a thinner
Output diodes: D1, D2, D3, D4 and D5 layer (.002�) to the capacitor terminals. Keep the
Output diodes: D7, D8, D9, D10 and D11 heat sink compound away from the screw threads
Capacitor bleeder resistors: R1 and D9 since this compound will affect the torque specifi-
Capacitors: C1 and C2 cations.
Capacitors: C1, C2, C14 and C15 (575 VAC only)
7. Carefully place the Switch PC Board onto the heat
Switch PC Board Repairs sink. Be sure the mounting holes are lined up
before making full contact with the heat sink.
If a test indicates that a Switch PC Board is defective,
both Switch PC Boards must be replaced. 8. Caution: The heat sink and the capacitor terminals
Replacement boards must have completely identical are relatively soft material and it is very easy to
part numbers. A defective module is likely to damage cross-thread the mounting screws. Holding the
other devices in the power circuitry. The defect may Switch PC Board, install the 4 socket head cap
be subtle and not detectable by an ohmmeter mea- screws, finger tight only. Then install the hex head
surement. Unknown defective parts may cause newly cap screws into the capacitor, finger tight only.
replaced parts to fail.
9. Torque the 4 socket head cap screws to 44 inch-
In addition to replacing the Switch PC Boards, replace lbs force (5 N - m). Then torque the capacitor hex
C1 and C2 (also C14 and C15 of the 575 VAC V300- head cap screws to 55 inch-lbs force (6 N - m).
PRO) if the following conditions are met:
10. Reconnect all the leads to the board.
1. Machine was operating from 380 VAC or higher
supply when failure occurred. Before applying input power to the machine, check all
2. Switch PC Boards have burned areas. electrical connections. An incorrect connection will result
in machine damage when the power is switched on.
Switch PC Board Replacement Procedure
Test After Repair
WARNING
1. Short terminals 14 and 53 of the Protection PC
ELECTRIC SHOCK can kill.
Board. Connect an ohmmeter, set for X1000
� Have an electrician install and service
range, to terminals 9 (+) and 12 (-) of the Switch
this equipment.
PC Board. The meter will show the capacitors
� Turn the input power off at the fuse
charging up. The meter may take a minute or so to
box before working on equipment.
stabilize. The value must not exceed 8600 ohms.
� Do not touch electrically hot parts.
Test both boards. For 575V only units - measure
---------------------------------------------------------------------
across each power capacitor, 2 per switch board;
EXPLODING PARTS can cause All four readings should be approximately 5,000
injury. ohms.
� Failed parts can explode or cause other
parts to explode when power is applied. 2. If OK, remove the short and proceed with the
power test.
� Always wear a face shield and long sleeves when servicing.
----------------------------------------------------------------------------------
3. Fuse input supply with 5 amp fuses.
1. Carefully disconnect the leads at the top of the
Switch PC Board. 4. Check output open circuit voltages. Do not apply
output load.
2. Remove the four socket head cap screws with a
3/16� hex key wrench. 5. Connect machine for 460 (V300-PRO), or 575
(V300-PRO, 575V), or 380, 415 or 440 (V300-I)
3. While holding the Switch PC Board, remove the VAC input.
hex head cap screws from the center area of the
board. 6. Check output open circuit voltages. Do not apply
output load.
4. Remove the board.
7. Fuse for 20 amps and test under load.
� 20 � �
Replacement of Power Modules and Output The compound should be applied to the heat sink in a
Diodes very thin layer, less than 0.001 in. DO NOT apply on
diode stud and mounting nut threads.
Input rectifier, D13, is a power module. When mount-
ing power modules, the heat sink and module mount- Components must have proper torque applied to
ing surface should be clean and free of burrs and for- mounting screws and to electrical terminals. Torque
eign material. Apply heatsink compound (Dow 340) as the modules according to the following:
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 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 steel
wool. Compound should be used on surface between
diode and heat sink when mounting individual diodes.
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)
Retorque after 3 hours to allow for spread of compound.
(1)
Tighten in staggered fashion one quarter turn at a time.
(2)
Environment Protection Printed Circuit Board Replacement
High voltage connections are covered with an RTV 1. Handle PC Boards by edges only.
sealant to prevent malfunction in severe environ-
ments. Sealant must be applied to connections which 2. Store PC Boards only in the bags that disperse
have been opened or otherwise lost their protection. A static charges.
noncorrosive electronic grade sealant such as Dow
Corning 3140, 3145, 738, Columbus Adhesives 0172 3. Inspect PC Board for burned conductors or com-
or GE RTV-162 is recommended. Sealant may also ponents. If damage is visible, inspect the machine
be purchased from Lincoln Electric (order E2519 wiring for grounds or shorts to avoid damaging a
Silicone Rubber RTV Coating). Apply sealant after new PC Board.
machine is repaired and tested.
4. If there is no visible damage to the PC Board,
High voltage areas which require sealant are as listed: install a new PC Board and see if the problem is
- Input rectifier D13, all 5 terminals. fixed. 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 the
wiring harness and plugs for loose connections.
� 21 �
REMOTE CONTROL ADAPTERS
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)
CABLE RECEPTACLE (6 SOCKET)
TO POWER SOURCE
TO: 1) K857 REMOTE CONTROL
2) K963 HAND AMPTROL
3) K870 FOOT AMPTROL
K864
� 22 �
CABLE RECEPTACLE (14 SOCKET)
TO: 1) LN-7 WIRE FEEDERS
STRAIGHT PLUG (14 PIN)
TO POWER SOURCE
CABLE RECEPTACLE (6 SOCKET)
K876
TO: 1) LN-25 WIRE FEEDERS
4-19-96D
S19309
K867 UNIVERSAL ADAPTER FOR 14-PIN WIRE FEEDER RECEPTACLE
INSTALLATION INSTRUCTIONS
THIS CONNECTOR IS MEANT TO BE USED WITH LINCOLN POWER SOURCES WHICH HAVE A 14-PIN
WIRE FEEDER RECEPTACLE. IT IS DESIGNED TO ALLOW THE USER TO MAKE CONNECTIONS
TO ANY OF THE 14 CIRCUITS PRESENT IN THE WIRE FEEDER RECEPTACLE.
CONSULT THE WIRING DIAGRAM OF THE POWER SOURCE AND WIRE FEEDER THIS ADAPTER WILL BE USED WITH.
NOT ALL CIRCUITS ARE PRESENT IN EVERY POWER SOURCE, NOR ARE THEY REQUIRED FOR PROPER WIRE FEEDER OPERATION.
1. TURN THE POWER SWITCH OF THE WELDING POWER SOURCE OFF BEFORE INSTALLING
THIS ADAPTER TO WIRE FEEDER CABLE.
2. CONSULT THE APPROPRIATE EQUIPMENT WIRING DIAGRAMS FOR THE CONNECTIONS TO UNIVERSAL ADAPTER.
THE STANDARD CONNECTOR PIN DESIGNATIONS AND FUNCTIONS ARE SHOWN BELOW.
NOTE: 115V AC (31, 32), 42V AC (41, 42), 24V AC (SPARE) AND TRIGGER CIRCUIT (2, 4)
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
IN THE UNIVERSAL ADAPTER. THE INSULATING METHOD MUST BE RATED FOR 120V AC OR GREATER.
(SEE APPROPRIATE WIRING DIAGRAM)
THESE FUNCTIONS ARE LISTED FOR
� 23 �
K=42 K=42
REFERENCE ONLY AND EACH MAY OR
MAY NOT BE PRESENT IN YOUR EQUIPMENT. J=31
A=32 J=31 A=32
STANDARD FUNCTION
PIN LEAD
I=41
B=GND
I=41 B=GND
32 115V AC
A
L=82 N=SPARE
GND CHASSIS CONNECTION
B
C=2
H=21
2 TRIGGER CIRCUIT
C
4
D TRIGGER CIRCUIT H=21
C=2 L=82
N=SPARE
E 77 OUTPUT CONTROL
76
F D=4
OUTPUT CONTROL G=75
D=4 G=75
75
G OUTPUT CONTROL
E=77
F=76 F=76
E=77
21
H WORK
M=81
M=81
41 42V AC
I
J 115V AC
31 14-PIN BOX RECEPTACLE, REAR VIEW
14-PIN BOX RECEPTACLE, FRONT VIEW
42 42V AC
K
AND 14-PIN CABLE PLUG, FRONT VIEW
AND 14-PIN CABLE PLUG, REAR VIEW
WELDING MODE CONTROL
82
L
M 81 WELDING MODE CONTROL
N SPARE 24V AC 3-16-90
S19386
S19404
K867 PLUG TO LN-7 - CONNECTION DIAGRAM
K867 PLUG TO LN-7 - CONNECTION DIAGRAM
12-10-93A
WARNING
Turn off input power to the Welding Power Source
SPLICE LEADS AND INSULATE. N.D.
using the disconnect switch at the fuse box
INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.C.
Before connecting the wire feeder.
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
Only qualified persons should install, use or
ELECTRIC
SHOCK
SHOCK TO CHANGE POLARITY, TURN POWER "OFF",
DIAGRAM SHOWS ELECTRODE POSITIVE. N.B.
service this machine.
CAN KILL
CAN KILL
WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.A.
SPARE
N.D.
REMOTE CONTROL
82 LN-7
ELECTRODE CABLE
ELECTRODE CABLE
K775 OPTIONAL AUXILIARY POWER
81 N.C. CONTROL
TO LN-7
BOX
BOX
42
42
77 14 PIN 77 WITH 115VAC
TO
41
41
AMPHENOL
AMPHENOL
76 76
WORK POWER SOURCE
75
75
INVERTEC
31 31
-
- GREEN
32 32
ADAPTER PLUG
INPUT CABLE GND GND
2 2
K867 UNIVERSAL +
K291 OR K404 21 21 4 4
� 24 �
+
+ 21
21 21
21
4 4
K291 OR K404
K867 UNIVERSAL
GND
GND GND
GND INPUT CABLE
2 2
ADAPTER PLUG
GREEN
32 32 -
INVERTEC
75
75
31 31
POWER SOURCE
POWER SOURCE 76 76
WITH 115VAC 77 77 WORK
AMPHENOL
41
AUXILIARY POWER K775 OPTIONAL
TO
14 PIN
42
BOX
REMOTE CONTROL
N.D.
TO LN-7
CONTROL N.C. 81
N.A.
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. ELECTRODE CABLE
LN-7 82
N.B.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE.
DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
TO CHANGE POLARITY, TURN POWER "OFF",
SPARE
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. CAN KILL
N.D. SPLICE LEADS AND INSULATE. service this machine. SHOCK
ELECTRIC
Only qualified persons should install, use or
12-10-93A
Before connecting the wire feeder.
S19404
using the disconnect switch at the fuse box
Turn off input power to the Welding Power Source
WARNING
K867 PLUG TO LN-7 - CONNECTION DIAGRAM
K867 PLUG TO LN-25 - 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.
Only qualified persons should install, use or
ELECTRIC
SHOCK service this machine.
CAN KILL
21
82
81
42
ELECTRODE CABLE N.C.
LN-25 WITH
41
TO LN-25
K431 OPTION
GND
14 PIN
TO
31
AMPHENOL
WORK
32
2 E
� 25 �
- 4 F
D
SPARE
A
75
B
76 K432 REMOTE
+ K867 ADAPTER
77 C CONTROL CABLE
INVERTEC
N.E.
POWER SOURCE N.D.
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.
1-25-91
S19405
K867 UNIVERSAL ADAPTER / INVERTEC - 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.
Only qualified persons should install, use or
ELECTRIC
SHOCK service this machine.
N.C.
CAN KILL
81
NOT USED ON INVERTEC
82
N.D.
ELECTRODE CABLE SPARE
24 VAC / 1 AMP
2
CONNECT TOGETHER FOR
4
TO WELDING OUTPUT
41
14 PIN
WORK 42 VAC / 5.5 AMP
42
AMPHENOL
31
115 VAC / 2 AMP
- 32
INVERTEC FRAME CONNECTION
GND
� 26 �
21 WIRE FEEDER VOLTMETER CONNECTION
CONNECTS TO (WORK TERMINAL) OF INVERTEC
+
77 10K
K867 UNIVERSAL
76
INVERTEC REMOTE OUTPUT CONTROL
ADAPTER PLUG
75
POWER SOURCE MIN.
WITH 115VAC
AUXILIARY POWER
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. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION
2
RELAY TO CLOSE LEADS 2 & 4.
TO TO
K867 WIRE FEEDER
4
12-10-93A
S19406
K876 ADAPTER TO LN-25 - 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.
Only qualified persons should install, use or
ELECTRIC
SHOCK service this machine.
CAN KILL
ELECTRODE CABLE
LN-25 WITH
TO LN-25
K431 OPTION
6 PIN
14 PIN
TO
AMPHENOL
AMPHENOL
WORK
-
� 27 �
K432 REMOTE
+ K876 ADAPTER
CONTROL CABLE
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.
1-25-91
S19899
K864 ADAPTER TO LN-7 & REMOTE CONTROL - 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.
Only qualified persons should install, use or
ELECTRIC
SHOCK service this machine.
LN-7
CAN KILL
CONTROL
BOX
14 PIN
ELECTRODE CABLE AMPHENOL
TO LN-7
14 PIN
TO
AMPHENOL
WORK
K480-7 INPUT CABLE
-
6 PIN
AMPHENOL
� 28 �
+ K864 K857
ADAPTER REMOTE CONTROL
INVERTEC OR
POWER SOURCE K963
WITH 115VAC HAND AMPTROL
AUXILIARY POWER OR
K870
FOOT AMPTROL
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. K480-7 INPUT CABLE CAN BE CONNECTED DIRECTLY IF REMOTE CONTROL IS NOT REQUIRED.
N.D. K864 ADAPTER CANNOT BE USED WITH AN LN-25.
4-19-96D
S19901
K900-1 DC TIG STARTER - CONNECTION DIAGRAM
WARNING
Turn off input power to the Welding Power Source using the
disconnect switch at the fuse box before connecting the DC Tig
Starter to the power source, or the Amptrol or Wire Feeder
to the DC Tig Starter.
ELECTRIC
Only qualified persons should install, use or service this machine.
SHOCK
CAN KILL
CONSULT INVERTEC INSTRUCTION MANUAL FOR
WIRE FEEDER
APPROPRIATE WIRE FEEDERS AMD CONNECTORS.
N.B.
BOTTOM 14 PIN K963
AMPHENOL HAND AMPTROL
K900-1
OR
DC TIG STARTER
K870
TO TIG
TOP 14 PIN OUT FOOT AMPTROL
TORCH
AMPHENOL
� 29 �
OR
IN
K814
ARC START SWITCH
INVERTEC - N.C.
POWER SOURCE
WITH 5.5 AMP 42 VOLT
AUXILIARY POWER TO
+ WORK
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. A WIRE FEEDER CAN BE PLUGGED INTO THE DC TIG STARTER TO REDUCE PROCESS CONVERSION TIME.
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
LN-9 GMA WITH K596 CABLE TO INVERTEC - 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.
Only qualified persons should install, use or
ELECTRIC
SHOCK service this machine.
CAN KILL
K608-1
CONNECTION
DETAIL
LN-9 GMA WITH
ELECTRODE CABLE
K608-1 AND P10,J10� P10�,J10
TO LN-9 GMA
K442-1 KITS.
2 2
530A
14 PIN
TO
AMPHENOL 3 3
521
WORK
4 4
500
5 5
500
-
6 6
524
� 30 �
7 11
C
10
K596 REMOTE
+ 3.9K
CONTROL CABLE
11 7
ASSEMBLY B
INVERTEC
12 12
533
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.C. INSTALL K608-1 ADAPTER IN LINE WITH P10 TO LN-9 GMA VOLTAGE BOARD
PER INSTRUCTIONS IN V300 MANUAL.
N.D. FOR GMAW WELDING, INSTALL PULSE POWER FILTER KIT K442-1 IN LN-9 GMA.
9-29-95C
S20607
LN-9 GMA WITH K196 CABLE AND K867 PLUG TO INVERTEC - CONNECTION DIAGRAM
K608-1
CONNECTION
WARNING
Turn off input power to the Welding Power Source DETAIL
using the disconnect switch at the fuse box
P10,J10� P10�,J10
Before connecting the wire feeder. 2 2
530A
3 3
521
Only qualified persons should install, use or
ELECTRIC
4 4
500
SHOCK service this machine.
CAN KILL
5 5
500
6 6
524
SPARE
7 11
C
82
ELECTRODE CABLE
81 N.C.
TO LN-9 GMA 10
42
14 PIN K196
3.9K
TO
41
AMPHENOL INPUT CABLE
WORK
11 7
B
31 31 12 12
533
- 32 32
2 2
4 4
21 21
� 31 �
+ K867 UNIVERSAL
GND GND
ADAPTER PLUG
INVERTEC
LN-9 GMA WITH
A
75
POWER SOURCE
K608-1 AND
76 B
WITH 110/115V AUX.
K442-1 KITS.
77 C
N.D.
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.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.D. SPLICE LEADS AND INSULATE.
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�.
N.F. FOR GMAW WELDING, INSTALL PULSE POWER FILTER KIT K442-1 IN LN-9 GMA.
9-11-92
S20608
WIRING DIAGRAM V300-PRO Code 10256, V300-I Code 10258
311 313
306
275F
N.G.
9
9A
52 52 + ARC
9A
N.F. L2 229 229
14 4 T2
4,5
14
1 3
2 4 RIGHT
R7 402, 404 229
53 TP5
53 D1A 400A
MAIN
52 25 250 C5
+
51
51 SHUNT
TRANSFORMER
J8 S F
R8
25W C2 25W
SWITCH
+
7500
H5 H5
R1
PROTECTION 25W TP6
1 314 BOARD F
25 4 L3
2200 F
F 286
BOTTOM
2 25W (LEFT)
BOARD 14 450V - TOP
AUX
3 316 401, 403
R6
J15 D2
OUTSIDE S - ARC
CHOKE
4 315 285
S
1,8 1 S5
53 12A R W
R
W
5
METER
12
12A S F RW PANEL
6 317 L5 BOTTOM
BOTTOM FUNCTION METER
INSIDE SWITCH
C9 C6 204C
F S V
3 10
3 09 309 3 10 1 1
1
9C 9D
9D 220
INPUT
TP4 2 2
307 308 A
S1 RECTIFIER
CR 2
CR1 3 3
D13
9A
POWER 214 4 4
6 4
3251 34
12
ON
OFF 5 5
D+
A
J11
W J10
12B 6 6
DRIVER
U H1 9D
TP1
H1 BOARD 226
CHOKE
THERMOSTAT
12D J16 J9 L4
B
R 227
INPUT
V S7
H5
PER 275C
TP3 503A
1 224
8
2 12 13 14
3 7 3 1
6254
RECONNECT
N.A.
9B
TP2
B 9B
9C 203
C F-
W 31 4 317
52 9D
A
12A 316
3 15 12D
12B T3 CC GTAW
12C
G 215
12A CURRENT CC SOFT
1
S2
206
TRANSFORMER
12A
9B 2
I
12D CC CRISP MODE
204A
12C 12D
3 SWITCH
9B 9 204B CV FCAW
4
5
N.G. 5 S
4,5
213
F 2
1
9B W
220
N.H. W W
R R CV GMAW
5
J3
I BOTTOM
Y Y 1 218
204A
R5 R
10
402, 404
A N.F. TOP
OUTSIDE
25 76 5
D3
+ S F
3 AMP SWITCH
25W C1 3 77B
7500 + 203
CW (MAX)
SLOW
R9
S
BOARD
25W 1
4 77A
206
25 R11
2200 F S
BLOW TOP 10K
502
2
12
51 (RIGHT) 276
25W 211A
TOP OUTPUT
R11
450V - INSIDE 2W
J4
A 8
AUX 229
223A 11 275C
R4 CONTROL
401, 403
F F 228
13
2
12B 1,8 8 8 275B
227
D1B 207
12
12 9 275A
F 213
12B S
208
7
214 6
H1 H3 J13 J12 3 276
L1 8
275B LOCAL
REMOTE MIN J5
H1 S3
LEFT 6 218
504
1
1
H1 228
226 7
OUTPUT 200-
G 75
75 LOCAL/REMOTE
REMOTE
14 75 204B
CONTROL 208V SWITCH
H2
FAN 18V 77A
4
H2 4 204C
MOTOR
76 F 76
11 215
H3 H3
4 501
2
E 77B H3
77
110V 10
CB2 207 CW (MAX)
2
275F
220- R12
6
31 32A 2
J 212 305
7
307
110/115 2AMP 306
5
POWER
230V 3 ARC FORCE
8 10K
308 301
VAC 7
BOARD 9 208
1
275D /INDUCTANCE
R12
2W
32 H4
A 32 309 302
6
2
3
H4 CONTROL
301 5
42V
42 32A
I 212 N.D. 310 303
41 4 3
380- J1
5 42A 302 Y
6 1
VAC J7
42 CB1
K 42 501 304
415V 5 8
4 212A
305 Y
J6 3
6AMP 24V
2 6
C 212 504 275D
1 J2
3 503
� 32 �
212B
7
303 210 S4
4
A 6
H6
42A
212C 211A
1 4 ON
H5 OUTPUT
0V
TRIGGER 304 8 275A
440- 2
2
223B
4 D 212D 211B
3 5
FAN TERMINAL
460V 223B
REMOTE
212B
9
THERMOSTAT SWITCH
CONTROL 223A
311 1
M 212D
81 10 BOARD
T1
313 2
82 L J14
224 502
+ AUXILIARY
S6 3
21 H 21 THERMAL
TRANSFORMER 4
WIRE FEEDER
N.C. B GND
GND - OVERLOAD
Y
WELDING 212C
285
N
SPARE 211B INDICATOR
POLARITY
(V300-I ONLY)
212A 210
150 5W 503
229 SWITCH
503A
REMOTE
WIRE
CONTROL
FEEDER
RECEPTACLE
NOTES:
N.A.
S4
1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO)
OUTPUT TERMINAL
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. S2
J9, J10, J12
J2, J8 SWITCH
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT. MODE SWITCH
J13, J15 J1, J7
J3 J11, J14
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
COLOR CODE:
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. S3
B= BLACK
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. LOCAL/REMOTE S5
G= GREEN
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I) SWITCH METER FUNCTION
R= RED
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. SWITCH
W= WHITE J4
J6
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT. J5, J16
Y= YELLOW
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. R11
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT. OUTPUT CONTROL
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
CONNECTOR CAVITY NUMBERING SEQUENCE
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. R12
THERMAL
(VIEWED FROM COMPONENT SIDE OF BOARD) ARC FORCE/INDUCTANCE
N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "I". OVERLOAD
CONTROL
INDICATOR
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
ELECTRICAL SYMBOLS PER E1537 (V300-I ONLY)
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.
CONNECTION SHOWN IS FOR 380-460V OPERATION. CONTROL PANEL
LAYOUT
B
L10189
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
WIRING DIAGRAM V300-PRO CODE 10257 (575V)
311 313
306
275F
N.F.
9
9A
52 52 9A
4
14
14 4, 5
1 3
2 4 R7 402, 404
53 53
52 25
51
51 + ARC
L2 229
+
J8 229
25W T2
C2 +
H5 H5 RIGHT
229
TP5
D1A
PROTECTION 10K
1 400A
MAIN
314
C5
250
SWITCH
2 25W SHUNT
TRANSFORMER S F
R8
BOARD
R1
13,15
13 25W
3 BOARD
316 TP6
C14
J15 +
4 F
315 4
(LEFT)
14 L3
F 286
BOTTOM
25
5
TOP
AUX
6 25W
317 D2
- OUTSIDE S - ARC
CHOKE 285
401, 403
R6 S5
S
1 METER
1, 8
12A
53 R W
R
W S F RW PANEL
FUNCTION
BOTTOM
BOTTOM
12
912 METER
L5 INSIDE SWITCH
C9 C6 204C
F S V
1 1
1
220
TP4 2 2
A
INPUT
307 308 3 3
S1 9D
RECTIFIER 9D 214 4 4
310
309
D13
POWER
5 5
6 4
3251 34
12
ON
OFF
6 6
D+
A CR1
W J11
J10
DRIVER
U H1 9A
TP1 226
BOARD
H1
L4
J9 227
J16
B
R 275C
INPUT CHOKE
1
V 9D 8
2 12 13 14
3 7 3 1
6254
H5 THERMOSTAT
PER TP3
N.A.
TP2 203
314 317
9D 503A
B 224
C F- 316
315 52
W T3 CC GTAW
H6
215
CURRENT CC SOFT
1
G S2
206
TRANSFORMER 2
I CC CRISP MODE
12B 204A
3 SWITCH
912 9 204B CV FCAW
4
5
N.F. 5 S
4,5
213
F 2
1
9B W
220
W W
R R CV GMAW
5
J3
I BOTTOM
Y Y 1 218
204A
R5 R
10
402, 404
TOP
OUTSIDE
25 76 5
+ D3
S F
SWITCH
25W +
C1 3 77B
203
CW (MAX)
S
BOARD 1
4 77A
206 R11
10K S
TOP 10K
13,15 502
2
12
15 (RIGHT) 276
211A
TOP OUTPUT
R9
R11
25W INSIDE 2W
J4
C15 8
AUX
+ 229
223A 11 275C CONTROL
F F 228
13
2
1, 8 8 8 275B
227
25 D1B 207
12
9 275A
F 213
S
51 25W -
208
7
214 6
R4 401, 403
3 276
L1 8
275B LOCAL
12B
J5 S3
REMOTE LEFT 6 218 228
226 7
12
12B LOCAL/REMOTE
OUTPUT REMOTE
14 75 204B
� 33 �
SWITCH
CONTROL
77A
4
H1 204C
H3 J13 J12
MIN 11
H1 215
504
1
1
H1
G 75
75 10 207 CW (MAX)
2
275F R12
2 305
7
307
FAN 306
5
POWER
18V 3 ARC FORCE
8 10K
308 301
7
MOTOR
76 F 76 BOARD 9 208
1
275D /INDUCTANCE
R12
H3 2W
309 302
6
2
4 501
2
E 77B H3
77 CONTROL
301 5
110V
CB2 310 303
4 3
220- 6 J1
31 32A
J 212
110/115 2AMP 302
J7 Y
6 1
230V 501 304
5 8
VAC 4 212A
305
J6 Y
3
6
504 275D
1 J2
32 A 32 212B
7
303 210 S4
4
211A
42V 1 4
42 32A ON
41 I 212 OUTPUT
304 8 275A
2
5 42A
VAC 211B
5
3
42 CB1
K 42 TERMINAL
223B
REMOTE
575V 212B
9
6AMP 24V
2 C 212 SWITCH
CONTROL 223A
3 503 311 1 212D
6 10
H6
42A BOARD
212C H5 313 2
0V
TRIGGER J14
2 502
223B
4 212D
D FAN 3
THERMAL
THERMOSTAT 4
OVERLOAD
Y
M
81 T1
INDICATOR
82 L 224
+ AUXILIARY
S6 (V300-I ONLY)
21 H 503
21 TRANSFORMER
WIRE FEEDER
N.C. B GND
GND 503A
-
WELDING 212C
285
N
SPARE 211B
POLARITY
212A 210
150 5W
229 SWITCH
REMOTE
WIRE
CONTROL
FEEDER
RECEPTACLE
J9, J10, J12
J2, J8 S4 S2
J13, J15 J1, J7
J3 OUTPUT TERMINAL
J11, J14 MODE SWITCH
SWITCH
NOTES:
N.A. S5
S3
1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO) METER FUNCTION
COLOR CODE: LOCAL/REMOTE
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. J4
J6 SWITCH
J5, J16
B= BLACK SWITCH
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.
G= GREEN
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. R= RED
R11
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. W= WHITE
OUTPUT CONTROL
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. Y= YELLOW
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I)
CONNECTOR CAVITY NUMBERING SEQUENCE
R12
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
(VIEWED FROM COMPONENT SIDE OF BOARD) THERMAL ARC FORCE/INDUCTANCE
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.
OVERLOAD
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. CONTROL
INDICATOR
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT. ELECTRICAL SYMBOLS PER E1537
(V300-I ONLY)
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".
CONTROL PANEL
N.F. C1, C2, C14, C15 CAPACITORS ARE A MATCHED SET.
B
LAYOUT
MAR97
L10191
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..
NOTES
INVERTEC V300-PRO & V300-I
NOTES
INVERTEC V300-PRO & V300-I
NOTES
INVERTEC V300-PRO & V300-I
Now Available...12th Edition New Lessons in Arc Welding
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With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects,
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q Do not touch electrically live parts or q Keep flammable materials away. q Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
q Insulate yourself from work and
ground.
Spanish
q No toque las partes o los electrodos q Mantenga el material combustible q Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION q Aislese del trabajo y de la tierra.
French q Ne laissez ni la peau ni des vête- q Gardez à l’écart de tout matériel q Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
q Isolez-vous du travail et de la terre.
German q Berühren Sie keine stromführenden q Entfernen Sie brennbarres Material! q Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
q Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
q Não toque partes elétricas e elec- q Mantenha inflamáveis bem guarda- q Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
q Isole-se da peça e terra.
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 HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
� 38 �
q Keep your head out of fumes. q Turn power off before servicing. q Do not operate with panel open or
WARNING
q Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
Spanish
q Los humos fuera de la zona de res- q Desconectar el cable de ali- q No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
q Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
q Débranchez le courant avant l’entre- q N’opérez pas avec les panneaux
q Gardez la tête à l’écart des fumées.
tien. ouverts ou avec les dispositifs de
q Utilisez un ventilateur ou un aspira-
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
q Strom vor Wartungsarbeiten q Anlage nie ohne Schutzgehäuse
q Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
nen; Maschine anhalten!) Betrieb setzen!
q Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Portuguese
q Não opere com as tampas removidas. q Mantenha-se afastado das partes
q Mantenha seu rosto da fumaça.
q Desligue a corrente antes de fazer moventes.
q Use ventilação e exhaustão para
ATENÇÃO
serviço. q Não opere com os paineis abertos
remover fumo da zona respiratória.
q Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� 39 �
� World's Leader in Welding and Cutting Products �
� 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
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