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IM526-B
™
December,1999
INVERTEC V300-PRO
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
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ARC WELDING can be hazardous. WARNING 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 c
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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- c
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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 échau
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TABLE OF CONTENTS Page Safety Precautions .............................................................................................................2-4 Introductory Information .......................................................................................................6 Product Description..............................................................................................................7 Specifications......................................................................
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for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• 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
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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 Out
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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 (1) FROM THE AUXILIARY POWER SUPPLY Input Volts (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- (2) 1 phase 208 85 (2) sive voltage peaks because the voltage waveform 50/60 Hz 230
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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 mach
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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 WELDING CABLE 2. Connect the K596 control cable assembly from the LN-9 GMA to the Invertec control cable connector. The control cable connector is located at the rear of the Invertec. 25 mm TRIM 1 in. 3. Connect the electrode cable to the output terminal of p
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Output Control - This controls the output voltage in OPERATING INSTRUCTIONS the CV modes and output current in the CC modes. Control is provided over the entire output range of the WARNING 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. OUTPUT • Insulate yourself from work and ground. • Always wear dry insulating glov
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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
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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 pa
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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 electri
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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 voltag
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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
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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
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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 Sh
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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 (ne
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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 resis
