Lincoln Electric INVERTEC IM526-B manual

INVER TEC V300-PRO OPERA TOR’S MANUAL For use with machines Code 10256 and 10257. IM526-B December,1999 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE[...]

– 2 – 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 - ANS[...]

– 3 – FOR ENGINE powered equipment. 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. --------------------------------------------------------------------------------------- 7.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes out- doors. -[...]

– 4 – PRÉCA UTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à [...]

– 5 – T ABLE OF CONTENTS P age Safety Precautions ............................................................................................................. 2-4 Introductory Information .......................................................................................................6 Product Description ................................[...]

– 6 – Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick referenc[...]

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 desig[...]

– – 8 – INPUT VOLTAGE SETUP POWER CORD CONNECTION A 10 ft. (3.0m) power cord is provided and wired into the machine. Follow the power cord connection instructions. Incorrect connection may result in equip- ment damage. Single Phase Input 1. Connect green lead to ground per U.S. National Electrical Code. 2. Connect black and white leads to pow[...]

– 9 – – 9 – remote control adapter and K857 remote control are required for remote output control). 5. Set the meter polarity switch on the rear of the Invertec to coincide with wire feeder polarity used. The wire feeder will now display the welding volt- age. 6. If K480 is not available, see connection diagram S19404 for modification of K2[...]

LN-9 GMA Connection Instructions 1. Turn the Invertec power switch “off”. 2. Connect the K596 control cable assembly from the LN-9 GMA to the Invertec control cable connector. The control cable connector is located at the rear of the Invertec. 3. Connect the electrode cable to the output terminal of polarity required by electrode. Connect the w[...]

– 11 – OPERA TING INSTR UCTIONS 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 [...]

– CV FCAW This setting has been optimized for Innershield ® and Outershield ® flux-cored electrodes. CV GMAW Short circuit, glob and spray transfer solid wire and gas welding are done in this mode. Low end procedures, less than 17V, may operate better in the FCAW mode. Voltage in the GMAW mode can become erratic when welding is attempted using [...]

– 13 – Meter Polarity Switch The wire feeder polarity switch is located at the rear of the machine. The switch provides a work connection for wire feeder voltmeters. Place the switch in the position of the electrode polarity indicated by the decal. The switch does not change the welding polarity. Auxiliary Power A 24 VAC @ 1 amp supply is inclu[...]

– 14 – PERIODIC MAINTENANCE Overload Protection The machine is electrically protected from producing high output currents. Should the output current exceed 340-360A, an electronic protection circuit will reduce the current to approximately 150A. The machine will continue to produce this low current until the protection circuit is reset. Reset o[...]

– 15 – TROUBLESHOO TING GUIDE Trouble What To Do Not output but fan operates and meter is on. Poor welding, weld settings drift, or output power is low. Main fuses open or Switch PC boards overheated. Output turns on momentarily then switches off and repeats. Machine is connected for 380 VAC or higher input voltage. OCV is normal (approx. 65-75[...]

– – 16 – TEST PROCEDURES Step 1A 1B 2 3A 3B Next Test Step 1B 2 3A 3B 4 and 5 Test Output pilot circuit (set S4 on) Protection PC board output (set S4 on) Static capacitor balance (set S4 off) 380 VAC input and higher test Dynamic capaci- tor balance (set S4 on) 380 VAC input and higher test Repair Action Replace Power and Control PC Boards R[...]

– 17 – Step 4 Next Test Step cont 5 cont 5 cont 5 cont 5 cont 5 cont 5 cont 5 cont 5 cont 5 cont 5 cont 5 cont 5 Test Switch PC Board resistance test. No dynamic test is possible. Remove leads 401/403, 1/8, 9, 12, 4/5 and 402/404. Repair Action Replace Switch PC Board Replace Switch PC Board Replace Switch PC Board Replace Switch PC Board Repla[...]

– 18 – Step 5 6 Next Test Step cont cont cont cont Test Snubber Resistors Disconnect leads 401, 402, 403 and 404 from Switch PC Board Output diodes Remove output load Repair Action Replace R4 Replace R5 Replace R6 Replace R7 Test individually Check Lead 401 to terminal 12 Lead 402 to terminal 9 Lead 403 to terminal 12 Lead 404 to terminal 9 + o[...]

Repair Action Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, inspect S1, test C1 and C2 Replace D13, ins[...]

– Matched Parts Certain parts must be replaced in matched sets. Matched sets are required in the following areas: Output diodes: D1, D2, D3, D4 and D5 Output diodes: D7, D8, D9, D10 and D11 Capacitor bleeder resistors: R1 and D9 Capacitors: C1 and C2 Capacitors: C1, C2, C14 and C15 (575 VAC only) Switch PC Board Repairs If a test indicates that a[...]

– 21 – 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 burrs and for- eign material. Apply heatsink compound (Dow 340) as a uniform layer ideally .010” thick, to eliminate all air pockets. This may be [...]

– 22 – TURN THE POWER SWITCH OF THE WELDING POWER SOURCE "OFF" BEFORE INSTALLING PLUGS ON CABLES OR WHEN CONNECTING OR DISCONNECTING PLUGS TO WELDING POWER SOURCE. STRAIGHT PLUG (14 PIN) TO POWER SOURCE CABLE RECEPTACLE (6 SOCKET) CABLE RECEPTACLE (14 SOCKET) TO: 1) LN-7 WIRE FEEDERS TO: 1) K857 REMOTE CONTROL 2) K963 HAND AMPTROL 3) [...]

– 23 – INSTALLATION INSTRUCTIONS THIS CONNECTOR IS MEANT TO BE USED WITH LINCOLN POWER SOURCES WHICH HAVE A 14-PIN TO ANY OF THE 14 CIRCUITS PRESENT IN THE WIRE FEEDER RECEPTACLE. WIRE FEEDER RECEPTACLE. IT IS DESIGNED TO ALLOW THE USER TO MAKE CONNECTIONS CONSULT THE WIRING DIAGRAM OF THE POWER SOURCE AND WIRE FEEDER THIS ADAPTER WILL BE USED [...]

– 24 – N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF", REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE. N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. ELECTRODE CABLE TO LN-7 TO WORK - + 14 PIN AMPHENOL SPARE 82 81 42 41 31 32 2 4 2[...]

– 25 – 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. TO WORK - + 14 PIN AMPHENOL N.C. ELECTRODE CABLE TO LN-25 K867 ADAPTER LN-25 WITH[...]

– 26 – 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. TO WORK - + 14 PIN AMPHENOL N.C. 76 82 K867 UNIVERSAL ADAPTER PLUG 81 SPARE 2 4 4[...]

– 27 – Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power Source Before connecting the wire feeder. ELECTRIC SHOCK CAN KILL N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.B. DIAGRAM SHOWS ELECTRODE POSITI[...]

– 28 – Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power Source Before connecting the wire feeder. ELECTRIC SHOCK CAN KILL N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.B. DIAGRAM SHOWS ELECTRODE POSITI[...]

– 29 – TO WORK + POWER SOURCE INVERTEC DC TIG STARTER - WARNING ELECTRIC SHOCK CAN KILL Only qualified persons should install, use or service this machine. Turn off input power to the Welding Power Source using the disconnect switch at the fuse box before connecting the DC Tig IN OUT K900-1 TO TIG TORCH K963 HAND AMPTROL K870 FOOT AMPTROL OR K8[...]

– 30 – Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power Source Before connecting the wire feeder. ELECTRIC SHOCK CAN KILL N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. TO WORK - + 14 PIN AMPHENOL ELECTRO[...]

– 31 – N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. TO WORK - + 14 PIN AMPHENOL SPARE 82 81 42 41 31 32 2 4 21 GND 75 76 77 31 32 2 4 21 GND N.C. K867 UNIVERSAL ADAPTER PLUG N.D. N.D. SPLICE LEADS AND INSULATE. Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input [...]

– 32 – CONTROL CONTROL PANEL ARC FORCE/INDUCTANCE 2 2W R11 227 /INDUCTANCE CONTROL TERMINAL CHOKE 10K 215 227 4 303 301 CW (MAX) METER TOP S2 C5 L3 R8 D2 SHUNT 1 211A 3 8 1 BOARD 9 CONNECTOR CAVITY NUMBERING SEQUENCE OUTPUT TERMINAL S4 R = RED 2 4 3 J2 J1 1 301 4 TP4 4 5 W L4 9D 12B 12D 9C 1 5 R5 R12 275C 204B 6 5 206 3 215 A V LAYOUT N.A. NOTE[...]

– 33 – 2 1 2 RECTIFIER 9D C2 R7 9A 9A N.F. CONTROL PANEL J11, J14 S F 9 H5 402, 404 ON OFF H1 R V C H6 12B BOTTOM 51 WIRING DIAGRAM V300-PRO CODE 10257 (575V) SHUNT R8 250 L3 L1 C1 TP2 9D S1 1, 8 POWER J12 401, 403 12B 12B 25 J13 G 25W R = RED R4 W = WHITE 1 3 2 1 J11 J9 4 5 2 6 3 F D13 317 6 9A J16 5 14 315 316 51 LAYOUT 504 4 H3 6 J5, J16 32 [...]

INVERTEC V300-PRO & V300-I NO TES[...]

INVERTEC V300-PRO & V300-I NO TES[...]

INVERTEC V300-PRO & V300-I NO TES[...]

Now A vailab le...12th Edition The Procedure Handbook of Ar c 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 contain[...]

– 38 – W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICAN[...]

– 39 – W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to rem[...]

– • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]