Lincoln Electric INVERTEC IM526-B User's Manual
Contents
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3. 00 0 For use with machines Code 10256 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 RETURN TO MAIN MENU IM526 B December 1999 SSN LINCOLN amp ELECTRIC Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com WARNING ARC WELDING 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 amp Cutting ANSI Standard 249 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 Safe
4. spy 2 5 OINLOWTIH 10 esn eisur pinous suoszed 4100 e 39pooj ayy oi0jod 9Snj ou Je 3oeuuoosrp bursn ismod 43 qndut jjo UINL e WVHOVIG NOILOHNNOO SC N T OL oflId 498 25 909615 WE6 OT 2T T HWIM 1983 OL OL 2 Z v SAVAT 5010 OL AVIAU NOILVIOSI 8S0 LNdLno IVNDIS V LVHL HUIM AOA ATIVONGIAIGCNI GVH I GHSONN ALVINSNI 5 NHMOd LV ATED 5 uddOu NANL ALIWNVIOd OL HAILISOd SMOHS NOILVOI IddV dO ALNA LNAAAND AOA 715 HH LSOW 1 0 ONIG IHM AAVITIXNY OVASTT HLIM HOANOS AAMOd LNdLNAO ALOWAA L983 AOT O DHLAHANI IVNINWWHIL OL SLOANNOD NOILDANNOD AALAWNLIOA HAIM TC NOTLOHNNOD OHLAHANT AND ce OWA SII s en 1 Tr _ NId YI S S OWA ed LAdLNO 9NIG IUM AHHLHOOL LOZSNNOO NO AHS
5. TOALNOO ALOWAA IVNOILdO SLLA AAVITIXNV OVASTT HLIM 24005 AAMOd H IHVO L dNI IVSHHAINQ 983 TEZA NHOM OL TONHHANY xoa YI TOULNOD L N I OL L N I HGOOWILOS H NWO eurgoeu sty Xoo0Hs OINLOWTd asn easur prnous suosied e 19po9j 3 30euuoosTp y ONINSVM iemod uini e WVHOVIG NOILOHNNOD OL ON Id 4983 24 909615 HLWINSNI SAWAT 5 NId 9 NONA GHAONWNHW HAV SV 4 NAHL V GAVAT HOWE L98M LOSNNOO OL ZEPA NId 9 HAONWSS A I IVOITIAIGNI GVH I d4S 0NQ ALVINSNI HOUNOS LV HNHGOWLOWISH 5 uddOu WuMOd NANL ALIHVIOd HONVHO OL HAILISOd SMOHS NVHOVIG a NOILVOI IddV 40 H IDAO ALNA LNAAAND AOA 715 Aad LSOW ATAVO DNIG IHM NE sepes 5 AAMOd JHLAHANT IOWLNOO ALONHA ZEPA HWHLdVGIV 498A NHOM OL Nid 7 NOILdO TEPA Sc N I OL HLIM SC N T ar NWO
6. NO AYAT Nu SNIA ISO OVAPZ TAIM 3909 NOWWOD V ONIAVH ANLIDOWIO NO MOHS LON WVEDVIG SIHL dO ALITISVSONVHONZINI LDOHLIM AYN QNVOS LIDONIO V 40 AHLIDONIO YO SINSNOdHOO SONIS 1102812 ATAANS OL A STVNINNSL LOSNNOO S4009 TVOINLOSTZ ONY TVNOILVN INANI 434M1 1102812 ATAANS OL M STVNIWESL LOSNNOO S802 TVOIWIOSTZ IWOOT TVNOILVN Wd INANI SSVHd SIONIS I 00tA LNANI HLIM LON LIDONIO ATadNS OL SAYIT LOSNNOO 3009 2112314 TYNOILYN OL AYAT LOENNOD INANI SSVHd SSEHI NOILVTDSNI A009 SGIAONd OL SdVL 11023IO ATAANS OL ALIHM YOWTE LOSNNOO 4009 OINIOSTZ TVNOIIVN OL aval LOSNNOO lIndNI SSVHd SIONIS HO INANI HLIM 205 wezz 101802 aronga o RIDE aziz EL 27 RIOHSH si en vue SL URL RE
7. 9 sos 4 2 pi I z s 5 jet gt gx cee x pu Hac enl 20 9 l 60 Porc k b 6t A ai wouon 9L 9L V soe de s f Loz m rae ste H k HOLIMS t TOULNOD St je vt 1 anazno atz ie 9 i es g aiowzu WOOT 2 4 D t D 1 an zos r 1 S as d T i i HOLIMS owa STT OTT ete LL sarsino s e a Tr HOLIMS aaow asmo 7 zs T 1408 22 avi sarsur 2497 HIHUOJSNVML H Hors d aavog 8 i ASLS LSTOT 0 WVNOVIG MAR97 NOTES INVERTEC V300 PRO amp 300 1 LINCOLN NOTES INVERTEC V300 PRO amp 300 1 LINCOLN
8. Prot ger personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan Avant de faires des travaux l interieur de poste la debrancher talons sans revers et chaussures montantes p l interrupteur boite de fusibles Toujours porter des lunettes de s curit dans la zone de 2 Garder tous les couvercles dispositifs de sdret a leur place soudage Utiliser des lunettes avec crans lateraux dans les TABLE OF CONTENTS Page Safety Precautions ies cete e pee 2 4 Introductory Information ss 6 Product Description sister Reo te dec des Menton 7 Specificatii et e teet i a e d utendi as 7 Install tioti TR NR Up repe Be 7 10 Safety Pr cautions sde eee e 7 Dc 7 Electrical Installatiori i 7 Input Voltage Setup pee AER dd e ntl ca 8 Power Cord Connection suisses 8 Connection of Wire Feeders to Invertec 8 10 Output Gables amp PlUGS deo eite te eet ter eu 10 Operating 5 2 ii c 11 13 Safet
9. NOTES INVERTEC V300 PRO amp 300 1 LINCOLN P Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland There is 10 discount on all or
10. 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 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 Name Ordering Information Input AC Voltage Rated DC Output Amps Volts Duty Cycle 208 230 460 3 Phase 60 Hz 300A 32V 60 250A 30V 100 300A 35 39 41V 60 Invertec K1349 3 V300 PRO 208 230 460 1 Phase 60 Hz 250A 30V 60969 160
11. Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res Mantenga cabeza fuera de los humos Utilice ventilaci n aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria OHRARV EE SBELTFEL CHARME c EUR Ea fE e SH7IAE AASI 5 EE os an di j ade TJAN bacs jua qii 0 iai oe ial uc Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico toque as partes el tricas nuas e 4vTTULAOR CAURUD PSB ET BRAT FE e HHS AHS pha e Do not operate with panel open or guard
12. from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site spe cial precautions should be used to prevent hazardous situa tions Refer to Safety in Welding and Cutting ANSI Standard 249 1 and the operating information for the equip ment being used When not welding make certain no part of the electrode cir cuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 41 Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shi
13. of the fume Use enough ventila 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 er or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation espe cially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employ er s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 7b gt WELDING SPARKS can 2 7 cause fire or explosion 4 a Remove fire hazards
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15. 00 0 3402 OINIOSTS TVNOILVN OL QAYIT indNI sen vu NOIIVIDSNI A009 SGIAONd OL QAYIT AYAM 1 1 5 T man LIQO ID ATAANS OL SLIHM LOBNNOD HOLINS D NOV 802 OINLOZTS TVNOIIVN GNnOND OL N33HD IOZNNOJ LniNI SSVHd SIONTS iu NOILONNA se 2 ONd 00tA 3T8V2 LndNI HLIM QSITddnS 0000 L0 HOLIMS BOLING TVNIWNSI Ln4lnO ere vid rte ser ee Ave bene HOLIMS Ms ost A prado L Noon I 12 XINO 1 00 A H i nn TVWHSHL 1VLSONSRHL E wer oete cones mun LE de loses prim D ous p DNE wer cr eae 87
16. 4 ONIDLOANNOOSIG ONILOANNOO NAHM SH IHVO NO SONTd ONITIVLSNI 440 SONOS ONIGISM AHL 40 HOLIMS AHL NANL TID NVO 9141931 SUuHLdVGav IOWLNOO HLONHA HOUNOS OL 5 Id LHOIVULS 5 AAMOd OL vI LHOIVHLS ONINUVA Y 22 986615 MAIA guwas TOULNOD RME anv ANY 8 MHIA LNON4 NId PI ee 1 TOULNOD 29 TOULNOD eg SE E TOALNOD ond 8 WHO5INIL RES NOILOSNNOO SISSWHO ane 8 NOILON S GHNVGNVILS ava NId LNEWdINOA ANOA NI LNHSHHNd HH LON HOVH ANW A INO GHLSI TI AAY SNOTLONNA 5 NVHOVIG WNLVI HNdO WddV FAS AALVAHUD HO OV AOZT AOA LSOW GOHLHSN ONILWIOSNI NHLdVGV IVSHHSAIN AHL NI CASANN AHSA HOVH ALV INSNI SV SNOILOSNNOO HO HOI IdS dWINO onl ASA HHGO IHM AHL SGISNI 51100410 LON 7 AHDOIAL ANW HAVAS OW AP
17. 809 TIVLISNI ALWIOSNI SAVAT 5 GVS I AHSANN ALV INSNI OSTW HOLIMS VND 6 NT LAS AHSA ALIHV IOd HLIM OL AO HWVHH NO HOLIMS ALINV IOd AALAN LHS HOANOS LV S IHVO sudAHH uddOu HHMOd NUNL ALIAVTIOd HONVHO OL HAILISOd SMOHS NOILVOI IddV 40 ATOAD ALNA LNAAAND AOA CAZIS HH LSAN ONIGTAM SLIM ASTT OTT HLIM I 809 DANOS AAMOd HLIM 6 N I OF LAAANT TVSAHAINN L984 OL 96TA YI VND 6 N I OL AT VO HAOHLOAHTA o TOS n NWO sy 2014108 YOOHS DTALOATE esn eiasur suoszed 4100 e m 210704 esnj y YOITMS 32euuoosTp usn eoanog ey qndut uini e NOILOSNNOO ONINNVM 1 809 NOILOHNNOD OHLAMANT OL ONTId 498M WH IHVO 96TH HLIM VND 6 N I 31 Jequunu SAID 104 5 0 Sjoued
18. A 28V 100969 250A 37 41 43V 60 575 300A 32V 60969 3 Phase 250A 30V 100 60 Hz 300A 36V 6096 NEMA Class Rated Output Based on a 10 min Period Lincoln plus rating Overall Height Including Handle 16 4 417mm without handle INSTALLATION WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts K1349 4 K LOCATION The Invertec has been designed with many features to protect it from harsh environments Even so it is important that simple preventative measures are fol lowed in order to assure long life and reliable opera tion The machine must be located where there is free circulation of clean air such that air movement into the sides and out the bottom and front will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown of the Invertec Keep machine dry Shelter from rain and snow Do not place on wet ground or in puddles Input Amps at Rated DC Output 48 37 49 69 53 75 Dimensions HxWxD Output Range continuous 43 33 48 18 7 x10 8x 22 2 62 475 274 7 564 67 Includes handle QE 24 19 28 38 29 42 20 16 22 ELECTRICAL INSTALLATIO
19. A LON TIIA NWO 5143 esn easur perjrienb 4100 e 3 YOITMS 32euuoosrp eua bursn eua jjo uini e ONINSVM NVADVIA NOILOSNNOO 5 98 26 668615 AILOSNHIG NWO ZEPA NId 9 HLIM SOSHLMWHANI 24005 AAMOd LV H IHVO HGOWLOH IH ASAYAAAA uddOu NHMOd NANL ALINVIOd OL HAILISOd SMOHS NOILVOI IddV JO ATOAD LNAAAND AOA 4215 HH LSOW NIATAM 5 AAMOd TOALNOO 9 83 OL TONXHANY TONXHANY NId 9 Nid 7 NOILdO HLIM SZ NT ST N T OL NWO spy 2074108 X20HS OINLOS T4 10 esn eisur pinous suosied ATuO 19p99j ayy eua y lt onu WY ismod qndut jjo e WYYOVId NOILOHNNOO ScC N I O
20. C1 and C2 Replace D13 inspect S1 test C1 and C2 D13 inspect 1 test C1 and C2 Replace 013 inspect 1 test C1 and C2 D13 inspect 1 test C1 and C2 Replace D13 inspect S1 test C1 and C2 Replace D13 inspect S1 test C1 and C2 Replace D13 inspect 1 test C1 and C2 Replace D13 inspect 1 test C1 and C2 Replace D13 inspect S1 test C1 and C2 D13 inspect 1 test C1 and C2 Replace D13 inspect S1 test C1 and C2 Matched Parts Certain parts must be replaced in matched sets Matched sets are required in the following areas Output diodes D1 D2 D3 D4 and D5 Output diodes D7 08 D9 D10 and 011 Capacitor bleeder resistors R1 and D9 Capacitors C1 and C2 Capacitors C1 C2 C14 and C15 575 VAC only Switch PC Board Repairs If a test indicates that a Switch PC Board is defective both Switch PC Boards must be replaced Replacement boards must have completely identical part numbers A defective module is likely to damage other devices in the power circuitry The defect may be subtle and not detectable by an ohmmeter mea surement Unknown defective parts may cause newly replaced parts to fail In addition to replacing the Switch PC Boards replace C1 and C2 also C14 and C15 of the 575 VAC V300 PRO if the following conditions are met 1 Machine was operating from 380 VAC or higher supply when failure occurred 2 Switch PC Boards have burned
21. L 948m 27 106615 96 61 SC N I NV HLIM 5 LONNVO 9 0 LON SI AI GHLOSNNOO 44 NVO INANI L 0873 lOWLdNWV QlOWLdNWV 963 IOWLNOO ALOWNAA 1483 NId 9 14 087 xog TOALNOD L N I HOUNOS AAMOd LV H IdVO 5 uddOu JAMOA NANL ALIWNVIOd OL WHAILISOd SMOHS NOILVOI IddV 40 H IOAO ALNA LNAMAND AOA 715 HH LSOW ONIG IHM WHMOd ANVI IIX V OVASTT HLIM 432031008 DHLAHANT 798 OL TONXHANY Nid 7 L N I OL TONXH4NY NId NWO euTyoem sy 2 5 1 414 esn suosied ATUO e 19pooj 910704 esnz 43 YOITMS eua ONINSVM ismod du jjo uini e WYYOVId IOWLNOO OL 793m 28 909025 96 61 HAILISOd OL HOLIMS ALIYVTOd S OALYAANT AHL ONILLAS SNOILOSNNOO L
22. N 1 The Invertec should be connected only by a quali fied electrician Installation should be made in accordance with the U S National Electrical Code all local codes and the information detailed below Single voltage 575 VAC machines can only be connected to 575 VAC No internal reconnection for other input voltages is possible Initial 208 VAC and 230 VAC operation will require a voltage panel setup as will later reconnection back to 460 VAC a Open the access panel on the right side of the machine b For 208 or 230 Position the large switch to 200 230 For 460 Position the large switch to 380 460 c Move the lead to the appropriate terminal INPUT VOLTAGE SETUP A CAUTION DO NOT ATTEMPT TO POWER THIS UNIT FROM THE AUXILIARY POWER SUPPLY OF AN ENGINE WELDER Special protection circuits may operate causing loss of output The supply from engine welders often has exces sive voltage peaks because the voltage waveform is usually triangular shaped instead of sinusoidal If voltage peaks from the engine welder exceed 380V the input circuits of this machine protecting the filter capacitors FETS and other components from damage will not be energized WARNING before RECONNECT PROCEDURE Disconnect input power BE SURE POWER SWITCH IS OFF inspecting or ser vicing machine CONNECT LEAD TO DESIRED INPUT VOLTAGE RANGE not operate with wraparound rem
23. NI HOVL TIOA 6 N I OL HLIM SNIT NI I 8093 T IVLSNI OSTW HOLIMS ALIWNV IOd VND 6 N I LAS AHSA ALIAV IOd HLIM S4GaroNIOO OL OHLHWHANI AO NO HOLIMS ALINV IOd AALAN LAS HOUNOS AAMOd LV SSHHASNH uddO WuMOd NANL ALINVIOd HONVHO OL HAILISOd SMOHS NVHOVIG NOILVOI IddV AO ATIOAD ALNA AOA AAZIS HH LSAW S IHVO ONIGTAM ASTT OTT HLIM 524005 AAMOd A IdNHSSV JX IHVO TOALNOO ALONSA 96 NHOM OL Nid vI SLIM I cCYTYVM 1T 809 HLIM 6 N I 6 N I OL 4 IdVO TIIA NWO spy 8 OINLONTS esn pinous suosied pergr enb 4100 e 3epeej 810794 esng eua YOITMS 32euuoosTp equa bursn eua uini e ONINSVM WVSOVIG NOILOHNNOO OHLYHANI OL 1490 9683 HLIM 6 30 809025 6 NT NI LIN AALTIIA WuMOd TIVLSNI MVNO M2O AOVLIOA NO nu LAVLSu AIL HLIM SSHNHVH LNHOV PGV OL GHWVOH SOVL IOA 6 NT OL HLIM ANIT NI 1
24. NdLNO AHL ONISAHAHA AH GSNIVILGSO SI HAILISOd ONIGTAM OIL HSAILVOSN AOA SI NMOHS LAS HNIL NOISAHANOD SS32O0Nd AONGAA OL AHLAVLS OIL AHL OLNI Hd NWO HAIM V NOILVOI IddV dO ATOAD 404 GHZIS LSOW OL HuMOd AAVITIXAV LIOA v dWW HLIM 5 OHLHHANI HOLIMS LAVLS JAW O HO4OL 110 DIL OL E HHINVILS DIL T 00695 IOWLdWV SHOLOSNNOO ALVIAdOAddY NOILONALSNI L INSNOO NWO STU esn reasur pInous suoszed pergjrienb e 312088 OINLONIH 5 BTL eua O43duy eua y 35 BIL esnj 1170 UINL e 9 WYYOVId NOILOJNNOO 5 SIL od 006 lONSHdNWV 401 lONSHdNWV WOLLOG HN 29 109028 096 62 6 NOILOS3NNOO l H093 NNO 6 NT NI I ZvN LIN TIIVLSNI ONIGTIEM MVNO 00 SNOILONALS
25. OFT Best for EXX18 thru EXX28 stick elec trodes CC Crisp Use this mode for stick welding with EXX10 thru EXX14 electrodes 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 FCAW This setting has been optimized for Innershield and Outershield flux cored electrodes Short circuit glob and spray transfer solid wire and gas welding are done in this mode Low end procedures less than 17V may operate better in the FCAW mode Voltage in the GMAW mode can become erratic when welding is attempted using voltages equal to or less than 17V DC Arc Force Inductance Control This control functions in all modes except GTAW For CC modes this control acts as an Arc Force adjust ment The arc is soft at the minimum settings and more forceful or driving at the maximum settings Higher spatter levels may be present at the maximum settings For CV modes this control will set the degree of pinch effect which predominantly affects short circuit transfer In FCAW the maximum setting is generally preferred With GMAW the upper half of the range is preferred with CO or high content mixed The lower half is for inert gas mixes 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 O
26. T Tr Iv OW CEE TE 0X ASTI LON MOTH NMOHS HAW SNOTLONOA SNOILVNOISSG NId HOLOHSNNOO QAAWVANWLS AHL WHLdVGV IVSHHAINN OL SNOILOSNNOO SWVHOVIG HLVINdOHddV L INSNOO H IHVO HAIM OL SIHL AAO AOUNOS AAMOd NIATAM AHL AO HOLIMS 4 AHL NANL NOILVHHdO HAIM AOA QHAINOHU ADANOS HHMOd ANHAH NI LNASAAd AAY SLINDAID TIY LON CASA TTIM SIHL JAIM AAMOd AO AHL LTASNOD AHL NI INASAAd SLINOAIO AHL AO ANW OL SNOILOWNNOO AMVW OL ASSN AHL MOTTE OL GSNOISSG SI LI V HAVH 5404005 AAMOd NIOONIT HLIM ASSN HH OL LNVAW SI HOLOSNNOO SIHL SNOILONALSNI NOILV IIVILSNI HTOVLddodd AAIM AOF IVSAHAINN 983 293 707615 HLVINSNI SAWAT 4 GasnNn ALV INSNI HOUNOS AAMOd LV ATAVO 5 uddOu NYNL ALIUWIOd OL HAILISOd SMOHS NVNOVIG NOILVOI IddV 40 ALNA LNAAANDOD AOA 4215 A4 LSAN
27. als away Mantenga el material combustible fuera del area de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos CORRE e i 9 E BET AIX uie a Jo ALD a Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo e BH HRUBS ISUCRSREUCT RRR ez 12 0A amp s ESSA due gulag cl ysl gua e READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES 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 UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes
28. areas Switch PC Board Replacement Procedure A WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch 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 1 Carefully disconnect the leads at the top of the Switch PC Board 2 Remove the four socket head cap screws with a 3 16 hex key wrench 3 While holding the Switch PC Board remove the hex head cap screws from the center area of the board 4 Remove the board 5 Thoroughly clean the heat sink surface 6 Apply a thin layer ideally 005 010 of Dow 340 Heat Sink Compound to the module mounting sur faces of the new Switch PC Board and a thinner layer 002 to the capacitor terminals Keep the heat sink compound away from the screw threads since this compound will affect the torque specifi cations 7 Carefully place the Switch PC Board onto the heat sink Be sure the mounting holes are lined up before making full contact with the heat sink 8 Caution The heat sink and the capacitor terminals are relatively soft material and it is very easy to cross thread the mounting screws Holding the Switch PC Board install the 4 socket head cap screws finger tight only Then install th
29. c Welding e American Century of John C Lincoln 55 00 AC Foundation Book Information Welding Preheat Calculator 300 WC 8 JFLF 515 Pipe Welding Charts ED39 SUB TOTAL png Costs 177172772 ee ee eee el WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pieces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden Nao toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pe a e terra o REPOR Trant OHLMPT APYORAPHRBS NTWSHRELTFSU E 945 CE EC SUE HIER ecran s Bp e HIE amp Gu gone Al oh ye 3 puni AI pally Jai DA dua Keep flammable materi
30. chine is connected for 380 VAC or higher input voltage OCV is normal approx 65 75V but output power is low less than 20V and 100A Machine makes squealing noise while under load Machine is connect ed for 230 VAC or lower input voltage Open circuit voltage is 1 2 volts Output control not functioning on remote control Local control OK Machine does not produce more than 250A output when connected to 3 phase supply Machine does not produce more than 200 A output while connected to 1 phase supply Machine operates OK at 230 VAC or lower No output at 380 VAC or higher Poor EXX10 stick electrode 5P performance Arc pops out No output or reduced output the first time power is applied to the machine What To Do Perform test steps 1A and 1B 1 Check front panel wiring and controls 2 Replace Control PC Board Perform test steps 4 and 5 for both Switch PC Boards and 7 Perform test steps 3B 4 and 5 Perform test steps 4 and 5 for both Switch PC Boards Perform test step 6 Check remote control assembly Check 53 Local Remote switch Na Replace main fuse if blown Replace Protection PC Board Replace Control PC Board Perform test step 7 BON Normal operation Perform test step 2 Check D6 and 012 11 and 12 Check reconnect panel connections and fuse CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs saf
31. coincide with wire feeder polarity used The wire feeder will now display the welding volt age 6 If K480 is not available see connection diagram 19404 for modification of K291 or K404 LN 7 input cable with K867 universal adapter plug General Instructions for Connection of Wire Feeders to Invertec Wire feeders other than LN 7 and LN 25 may be used provided that the auxiliary power supply capacity of the Invertec is not exceeded K867 universal adapter plug is required See connection diagram 19406 and 19386 at the back of this manual for more informa tion Remote Control of Invertec Remote control K857 hand amptrol K963 and foot amptrol K870 require K864 remote control adapter See 19309 instruction at the back of this manual for connection information K954 1 MIG PULSER The MIG Pulser is a hand held pendant type GMAW Pulsing option for the V300 Power Source Refer to the Mig Pulser s IM manual IM555 for connection information Parallel Operation The Invertec s are operable in parallel in both CC and CV modes For best results the currents of each machine should be reasonably well shared As an example with two machines set up in parallel for a 400 amp procedure each machine should be set to deliver approximately 200 amps not 300 amps from one and 100 amps from the other This will minimize nuisance shutdown conditions In general more than two machines in parallel will not be effective due to the
32. ders of 50 00 or more for shipment at one time to one location New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 4 700 00 lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only IPrices include shipment 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order va
33. e hex head cap screws into the capacitor finger tight only 9 Torque the 4 socket head cap screws to 44 inch lbs force 5 m Then torque the capacitor hex head cap screws to 55 inch lbs force 6 m 10 Reconnect all the leads to the board Before applying input power to the machine check all electrical connections An incorrect connection will result in machine damage when the power is switched on Test After Repair 1 Short terminals 14 and 53 of the Protection PC Board Connect an ohmmeter set for X1000 range to terminals 9 and 12 of the Switch PC Board The meter will show the capacitors charging up The meter may take a minute or so to stabilize The value must not exceed 8600 ohms Test both boards For 575V only units measure across each power capacitor 2 per switch board All four readings should be approximately 5 000 ohms 2 If OK remove the short and proceed with the power test 3 Fuse input supply with 5 amp fuses 4 Check output open circuit voltages Do not apply output load 5 Connect machine for 460 V300 PRO or 575 V300 PRO 575V or 380 415 or 440 300 1 VAC input 6 Check output open circuit voltages Do not apply output load 7 Fuse for 20 amps and test under load Replacement of Power Modules and Output Diodes Input rectifier D13 is a power module When mount ing power modules the heat sink and module mount ing surface should be clean and free of b
34. ed The connection should be as close as possible to the area being welded 1 e Ground the work or metal to be welded to a good electrical earth ground 1 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 1 g Never dip the electrode in water for cooling 1 h Never simultaneously touch electrically hot parts of elec trode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 1 1 When working above floor level use a safety belt to protect yourself from a fall should you get a shock 1 j Also see Items 4 c and 6 ARC RAYS can burn 2 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 2 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 2 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal Apr 93 9 FUMES AND GASES can be dangerous 3 a Welding may produce fumes and gases haz ardous to health Avoid breathing these fumes and gases When welding keep your head out
35. ely con tact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed TEST PROCEDURES Next Test Test Step Test Check Result Conclusion Step Repair Action UJ 1A Output pilot circuit 223A to 210 24 VAC Fan thermostat choke 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 ply OK 0 VDC Check T1 and Power PC Board 2 Protection PC 313 neg to 311 pos 1 VDC Protection PC Board OK board output set S4 on 25 VDC 3A Static capacitor Compare voltage across 25 VDC C1 C2 R1 R9 OK balance set S4 terminals 9 amp 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 and higher test 440 VAC 311 VDC 415 VAC 293 VDC 380 VAC 269 VDC 575 VAC only compare 225 VDC Check above compo voltage across 9A amp 13 difference nents and 13 amp 12A then 9B amp 15 and 15 amp 12B 3B Dynamic capaci Connect as in step 3A 25 VDC tor balance set Same voltages as above S4 on 380 VAC input 225 VDC Power PC Board or and higher test Switch PC Boards are damaged Replace Power and Control PC Boards Replace Protection PC Board UJ OK 5 CAUTION If for any reason you do not understand the test procedures are unable to perf
36. hutdown was caused by excessive output or duty cycle and the fan is operating normally the Power Switch may be left on and the reset should occur within a 15 minute period If the fan is not turning or the air intake louvers were obstructed then the power must be switched off for 15 minutes in order to reset The fan problem or air obstruction must also be corrected Filter Capacitor Conditioning A protection circuit is included to monitor the voltage across filter capacitors C1 and C2 also C14 and C15 on 575 VAC units In the event that the capacitor volt age is too high the protection circuit will prevent out put The protection circuit may prevent output provid ing all these circumstances are met 1 Machine is internally connected for 380 VAC or higher input voltage 2 Machine did not have power applied for many months 3 Machine did not produce output when power was first switched on If these circumstances apply the proper action is to switch the machine on and let it idle for up to 30 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 TROUBLESHOOTING A WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the
37. input power off at the fuse box before working on equipment Do not touch electrically hot parts 27 EXPLODING PARTS cause Failed parts can explode or cause other parts to explode when power is applied Always wear a face shield and long sleeves when servicing Visual Inspection Clean interior of machine with a low pressure airstream Make a thorough inspection of all compo nents Look for signs of overheating broken leads or other obvious problems Many problems can be uncovered with a good visual inspection Open Circuit Voltage The open circuit voltage of the Invertec V300 PRO is 60 to 75 VDC and cannot be adjusted by the output control Test Conditions Perform all testing at the lowest input voltage avail able except where a higher voltage is required by a test step Make ohmmeter checks only after power has been disconnected from machine and after capacitors have been discharged Certain high voltage connections have been insulated with RTV sealant It is necessary to break through the sealant with a sharp probe in order to make voltage or resistance checks Disconnect any control cables from remote control receptacle 14 TROUBLESHOOTING GUIDE Trouble Not output but fan operates and meter is on Poor welding weld settings drift or output power is low Main fuses open or Switch PC boards overheated Output turns on momentarily then switches off and repeats Ma
38. ir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s a deux machines a souder parce que la tension entre les deux pinces peut tre le total de la tension a vide des deux machines Si on utilise la machine a souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le cable lectrode autour de n importe quelle partie du corps zones ou pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince a une endroit isol de la masse Un court circuit accidental peut provoquer un chauf fement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage cables de grue ou autres circu
39. its Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 Un coup d arc peut tre plus s v re qu un coup de soliel donc PR CAUTIONS DE S RET POUR a Utiliser un bon masque avec un verre filtrant appropri ainsi LES MACHINES SOUDER qu un verre blanc afin de se prot ger les yeux du rayon TRANSFORMATEUR ETA nement de l arc et des projections quand on soude ou quand on regarde l arc REDRESSEUR b Porter des v tements convenables afin de prot ger la peau Relier la terre le chassis du poste conformement au code de soudeur et des aides contre le rayonnement de l arc l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece a souder doit tre branch a une bonne mise a la terre
40. lue up to 49 99 510 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 For North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment IMETHOD OF PAYMENT Sorry No C O D Orders CHECK ONE Please Invoice only if order is over 50 00 I Check or Money Order Enclosed U S Funds only Credit Card LIN Le Name Address Telephone Signature as it appears on Charge Card pes No 111 LI lise THIS FORM TO ORDER Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 looks OR FREE INFORMATIVE CATALOGS Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 ILincoin Welding Schoo Tes Code Quantity ED 80 New Lessons Arc Welding L a 5 Information Procedure Handbook Twelfth Edition 15 00 PH How to Read Shop Drawings 450 H Educational Video Information Incentive Management 590 1 New Approach to Industrial Economics 5 00 NA James Lincoln Ar
41. ment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other mov ing parts when starting operating or repair ing equipment v 7 In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 7 g To prevent accidentally starting gasoline engines while turn ing the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate e 7 h To avoid scalding do not remove the radia tor pressure cap when the engine is hot ELECTRIC AND MAGNETIC FIELDS may be dangerous 8 a Electric current flowing through any con ductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 8 b EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 8 c Exposure to EMF fields in welding may have other health effects which are now not known 8d All welders sho
42. ng the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas oylin ders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 6 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s rec ommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations FOR ENGINE powered equipment Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 9 T 7 0 Operate engines in open well ventilated areas or vent the engine exhaust fumes out doors 7 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated Keep all equip
43. on 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 3 Connect the electrode cable to the output terminal din 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 the rear of the Invertec to coincide with wire feeder polarity used The wire feeder will now display the welding volt E BRASS PLUG age COPPER TUBE 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 20607 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 b
44. ont of this operator s manual DUTY CYCLE The Invertec is rated at 300 amps 60 duty cycle for 3 phase inputs based on a 10 minute cycle It is also rated at 250 amps 100 duty cycle CONTROL FUNCTION OPERATION Power Switch Place the lever in the ON position to energize the machine When the power is on the digi tal meter will activate and the fan will operate Output Control This controls the output voltage in the CV modes and output current in the CC modes Control is provided over the entire output range of the power source with 1 turn of the control knob This con trol may be adjusted while under load to change power source output OUTPUT 2 40 7 v 2 49 a o 1 10 Local Remote Switch Place the LOCAL posi tion to allow output adjustment at the machine Place in the REMOTE position to allow output adjustment at the wire feeder or with a remote control option REMOTE 1 Digital Meter Switch Select either for amps for volts to display welding current or voltage on the meter When welding current is not present the meter will display the set current for the CC modes or the set voltage for the CV modes This set reading is an indi cation of machine control setting For a more precise process reading read meter during actual welding Mode Switch GTAW Optimized for both scratch start and Hi Freq kit use CC S
45. oot 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 520608 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 10096 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 OPERATING INSTRUCTIONS A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be danger ous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or 3 TA ST explosion Keep flammable material away Do not weld on closed containers ARC RAYS can burn eyes and skin Wear eye ear and body protection See additional warning information at fr
46. orm the tests repairs safely tact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed Test 4 Switch PC Board resistance test No dynamic test is possible Remove leads 401 403 1 8 9 12 4 5 and 402 404 Check Terminals on Switch PC Board 1 8 pos to 12 neg 1 8 neg to 12 pos 9 pos to 4 5 neg 9 neg to 4 5 pos 1 8 pos to 9 neg 1 8 neg to 9 pos 12 pos to 4 5 neg 12 pos to 401 403 neg 12 neg to 401 403 pos 9 pos to 402 404 neg 9 neg to 402 404 pos Test Result gt 1K ohms OK lt 100 ohms Short gt 1K ohms gt 1K ohms Open gt 1K ohms OK lt 100 ohms Short A CAUTION Conclusion Next Test Step cont MN CAE eet Ro Dem m LEM cont e cont Repair Action Replace Switch PC Board Replace Switch PC Board Replace Switch PC Board Replace Switch PC Board Replace Switch PC Board Replace Switch PC Board Replace Switch PC Board Replace Switch PC Board Replace Switch PC Board Replace Switch PC Board Replace Switch PC Board Replace Switch PC Board 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 Test Test S
47. oved ELECTRIC SHOCK CAN KILI not touch electrically live parts 440 460V Only qualified persons should install 380 415V use or service this equipment 220 230V IF MACHINE CEASES TO OPERATE NO METER NO FAN AND THERE IS NO OTHER KNOWN FAILURE CHECK FUSE REPLACE WITH A 3 AMP SLOW BLOW ONLY 200 208V POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE has THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A POWER CORD CONNECTION A 10 ft 3 0m power cord is provided and wired into the machine Follow the power cord connection instructions Incorrect connection may result in equip ment damage GREEN A WHITE Single Phase Input 1 Connect green lead to ground per U S National Electrical Code 2 Connect black and white leads to power 3 Wrap red lead with tape to provide 600V insula tion Three Phase Input 1 Connect green lead to ground per U S National Electrical Code 2 Connect black red and white leads to power Install in accordance with all local and national electric codes Recommended Fuse Sizes Based On The U S National Electrical Code And Maximum Machine Outputs Fuse Size in Amps Input Volts Time Delay Fuses 208 230 460 3 phase 50 60 Hz 2089 2300 460 1 phase 50 60 Hz 575 3 phase 60 Hz Input voltage must be within 10 of rated value When operating on these inputs at outputs exceeding 200A 60 o
48. r A 42 VAC 5 5 amp supply is included for use with other wire feeders This supply is protected by a 6 amp breaker located on the rear of the machine 110 115 VAC 2 amp supply is included for use with the LN 7 or LN 9 GMA wire feeders This supply is protected by a 2 5 amp breaker located on the rear of the machine It is NOT available on IEC units All three supplies are not to be loaded simultaneously MAINTENANCE A WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts 27 EXPLODING PARTS can cause Lg Failed parts can explode or cause other parts to explode when power is applied Always wear a face shield and long sleeves when servicing Capacitor Discharge Procedure 1 Obtain a power resistor 25 ohms 25 watts 2 Hold resistor body with electrically insulated glove DO NOT TOUCH TERMINALS Connect the resis tor terminals across the two hex head cap screws in the position shown Hold in each position for 1 second For 575 VAC only repeat for second capacitor Repeat for the capacitor s on the other side of the machine RESISTOR 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 airst
49. r 165A 100 the input line cord should be changed to an input conductor of 6 AWG or larger CONNECTION OF WIRE FEEDERS TO THE INVERTEC Note IEC units do not have 110 VAC auxiliary power LN 25 Connection Instructions 1 Turn the Invertec power switch off 2 Connect the electrode cable to the output terminal of polarity required by electrode Connect the work lead to the other terminal LN 25 with remote control options K431 and K432 Use K876 adapter with K432 cable or modify K432 cable with K867 universal adapter plug See con nection diagram 519899 and 19309 or 19405 at the back of this manual Place the local remote switch in the remote posi tion if output control is desired at the wire feeder rather than the Invertec LN 25 must have K431 and K432 options for remote output control opera tion LN 7 Connection Instructions Turn the Invertec power switch off Connect the K480 control cable from the LN 7 to the Invertec control cable connector The control cable connector is located at the rear of the Invertec Connect the electrode cable to the output terminal of polarity required by electrode Connect the work lead to the other terminal Place the local remote switch in the local posi tion to allow output control at the Invertec K864 remote control adapter and K857 remote control are required for remote output control 5 Set the meter polarity switch on the rear of the Invertec to
50. re environ ments Sealant must be applied to connections which have been opened or otherwise lost their protection A noncorrosive electronic grade sealant such as Dow Corning 3140 3145 738 Columbus Adhesives 0172 or GE RTV 162 is recommended Sealant may also be purchased from Lincoln Electric order E2519 Silicone Rubber RTV Coating Apply sealant after machine is repaired and tested High voltage areas which require sealant are as listed Input rectifier D13 all 5 terminals Printed Circuit Board Replacement 1 Handle PC Boards by edges only 2 Store PC Boards only in the bags that disperse static charges 3 Inspect PC Board for burned conductors or com ponents If damage is visible inspect the machine wiring for grounds or shorts to avoid damaging a new PC Board 4 lf there is no visible damage to the PC Board install a new PC Board and see if the problem is fixed If the problem is fixed by the new board reinstall the old board and see if the problem reoc curs If the problem does not reoccur check the wiring harness and plugs for loose connections LHH90S 9 LHHDOS PT LHH90S 9 5 HAIM SC NT OL HAIM L NT OL 1 0 8 t 96 c TOULNOD HALOWEA 686 I OL H IDVLdHOHN ATED HOUNOS AAMOd DNIG ISM OL 5001
51. ream 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 Heatsink 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 Overload Protection The machine is electrically protected from producing high output currents Should the output current exceed 340 360A an electronic protection circuit will reduce the current to approximately 150A The machine will continue to produce this low current until the protection circuit is reset Reset occurs when the output load is removed Thermal Protection Thermostats protect the machine from excessive operating temperatures Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating If excessive operating temperature should occur the thermostat will prevent output voltage or current The meter will remain energized during this time Thermostats are self resetting once the machine cools sufficiently If the thermostat s
52. rt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a weld ing area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 4 h Also see item 7c CYLINDER may explode if damaged 5 a Use only compressed gas cylinders contain ing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located 5 e 54 5 9 7 a Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when openi
53. s off No operar con panel abierto guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas QUNRIPHI MNUALE S CHMBTELEUTEEU CRRRIARRARS SHR Ro 20 Sel AE AREY e gt WARNING AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO it ie BIR Chinese LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SRM OBHOX AD OHRBEE lt K HA CL TRHORERMEI HES TE Rr de MART 7 09 0 ALS 4 iT src Saal 01 Jub al olg Gail giall lasted LINCOLN 8 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 216 486 1751 WEB SITE www lincolnelectric com
54. tep Test Check Result Conclusion Step Repair Action 5 Snubber Lead 401 to terminal cont Resistors 12 R4 open R4 shorted Disconnect leads cont 401 402 403 and Lead 402 to terminal 404 from Switch 9 R5 open PC Board R5 shorted Lead 403 to terminal gt 30 ohms R6 open 12 lt 20 ohms R6 shorted R7 open Lead 404 to terminal R7 shorted 9 Replace R4 Replace R5 Replace R6 Replace R7 lt 100 ohms Shorted output Test individually 6 Output diodes diode D1 thru output plug pos D12 to output plug neg gt 200 ohms Output diodes OK Remove output load CAUTION If for reason you do not understand the test procedures or are unable to perform the tests repairs safely tact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed 18 7 013 Input Rectifier Check 9 pos to H1 neg 9 pos to A neg 9 pos to H5 neg 12 neg to H1 pos 12 neg to A pos 12 neg to 5 pos 9 neg to H1 pos 9 neg to A pos 9 neg to 5 pos 12 pos to H1 neg 12 pos to A neg Test Result gt 1K ohms lt 100 ohms lt 100 ohms Shorted lt 100 ohms Shorted lt 100 ohms Shorted lt 100 ohms Shorted lt 100 ohms Shorted gt 1K ohms Conclusion Shorted Open Next Test Step 4 5 ont 4 5 Repair Action D13 inspect 1 test
55. ty 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 kill 1 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 1 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous condi tions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaf folds when in cramped positions such as sitting kneel ing or lying if there is a high risk of unavoidable or acci dental contact with the workpiece or ground use the fol lowing equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic weld ing gun are also electrically hot Always be sure the work cable makes a good electrical con nection with the metal being weld
56. uld use the following procedures in order to minimize exposure to EMF fields from the welding circuit 8 d 1 Route the electrode and work cables together Secure them with tape when possible 8 d 2 Never coil the electrode lead around your body 8 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source Mar 93 PRECAUTIONS SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Mainten
57. urrs and for eign material Apply heatsink compound Dow 340 as a uniform layer ideally 010 thick to eliminate all air pockets This may be verified by mounting and then removing the module When removed the compound on both surfaces will appear textured as if a vacuum had created veinlike ridges when the parts were 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 Torque 10 Component Switch Board The compound should be applied to the heat sink in a very thin layer less than 0 001 in DO NOT apply on diode stud and mounting nut threads Components must have proper torque applied to mounting screws and to electrical terminals Torque the modules according to the following Terminal Torque 10 Module 44 Inch Lbs EN m Capacitor N A 55 Inch Lbs 6 3 N m Input Rectifier 6 Inch Lbs 26 Inch Lbs M15454 1 0 7 N m 3 N m Output Diode 25 Inch Lbs N A M15482 2 3 N m 9 Retorque after 3 hours to allow for spread of compound 9 Tighten in staggered fashion one quarter turn at a time Environment Protection High voltage connections are covered with an RTV sealant to prevent malfunction in seve
58. utput Terminals Switch to ds Recommended Arc Force Inductance Settings ON position For Selected Applications Set to the REMOTE OFF position when using LN 25 with K431 and K432 options or LN 7 which will allow the gun trigger to energize the welding terminals Full Range Is 1 10 1 Very Soft 10 Is Very Crisp ON Nominal Process Setting Recommended OUTPUT Adjustment Range TERMINALS 18 thru 28 stick 1 gentle may stick to 9 forceful more spatter EXX10 thru 3 to 10 EXX14 stick REMOTE Air Carbon Arc None Cutting CV FCAW Innershield or None Outershield Air Carbon Arc None Cutting CV GMAW or 25 CO 5 to 10 or similar gas mixes 98 Ar 2 OoAr 90 He 7 5 Ar 2 5 2 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 The wire feeder polarity switch is located at the rear of the machine The switch provides a work connection for wire feeder voltmeters Place the switch in the position of the electrode polarity indicated by the decal The switch does not change the welding polarity Auxiliary Power A 24 VAC 1 amp supply is included for use with the LN 25 wire feeder 24 volts needed for K431 and K432 options This supply is protected by a self resetting current limite
59. voltage requirements of procedures in that power range To set machine outputs start with output control pots and arc force pinch pots in identical positions If run ning ina CC mode adjust outputs and arc forces to maintain current sharing while establishing the proper output current In CV modes the pots in identical positions Then switch the machine meters to amps and adjust one of the output control pots for current balance Check the voltage and if readjustment is necessary repeat the current balancing step Pinch settings should also be kept identical on the machines K900 1 DC TIG Starter Connection This versatile new kit was made to mate with the Invertec A control cable assembly is supplied with the kit to connect the kit to an Invertec The cable can be con nected either end at the DC TIG Starter kit and at the Invertec by attaching to the 14 pin Amphenols on the backs of each unit Refer to diagram 520405 at the back of this manual A negative output cable assembly is also supplied with the DC TIG Starter kit to connect the kit with the Invertec s negative output terminal All Magnum one and two piece water cooled 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 MAR97 LN 9 Connecti
60. y Pr cautions ess anne es edidere daa 11 Controls Description and Function ss 11 13 Maintenance coe a rtt ep dn dee 13 14 Capacitor Discharge Procedure 13 Routine Maintenance 13 Periodic Maintenance see 14 Troubleshooting ceto 14 20 Matched Parts in 20 Switch P C Board Replacement Procedure 20 Replacement of Power Modules and Output Diodes 20 21 Connection DIAGKAIMNS Fe T Oe ads 22 31 Wiring Diagrams en dele Aa ended 32 33 Parts Lists EDD appendix for selecting a QUALITY product by Lincoln Electric We want you hank You to take pride in operating this Lincoln Electric Company product 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 amp Number Code amp
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