Lincoln Electric INVERTEC V300-PRO SVM105-B Service Manual Download Page 116

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ELECTRICAL DIAGRAMS

G-24

V300 PRO

SCHEMATIC - POWER PC BOARD (M16018)

G-24

NOTE:

This diagram is for reference only. It may not be accurate for all machines covered by this manual.

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Summary of Contents for INVERTEC V300-PRO SVM105-B

Page 1: ...ONS CON TAINED THROUGHOUT And most importantly think before you act and be careful SERVICE MANUAL For use with machines having Code Number 9825 THRU 10450 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC View Safety Info View Safety Info View Safety Info View Safety Info Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U...

Page 2: ...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 purchase 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 o...

Page 3: ...ever dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dan...

Page 4: ...a 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 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent haza...

Page 5: ...ge à l aide d écrans appropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où ...

Page 6: ...FOR ALL SECTIONS Safety i iv Installation Section A Operation Section B Accessories Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagrams Section G Parts Manual P243 Series ...

Page 7: ...n to Master TOC V300 PRO Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION Installation Section A Technical Specifications A 2 Location A 3 Electrical Installation A 3 Input Connections A 4 Wire feeder and Accessory Connections A 4 A 5 Output Connection A 6 ...

Page 8: ...8 230 460 69 62 38 9825 9936 9965 50 60 10034 10130 Volts at Rated Duty Cycle Amps Amperes 60 Duty Cycle 200 28 100 Duty Cycle 165 26 5 Welding Constant Open Auxiliary Current Range Circuit Voltage Power 5 200 Amps 60 70 VDC 42 VAC 5 5 Amps 24 VAC 1 Amp 115 VAC 2 Amps Not on all codes INPUT RECOMMENDED INPUT WIRE AND FUSE SIZES Type 75 C Type 75 C Copper Fuse Input Copper Ground Superlag Ampere Wi...

Page 9: ...AW processes It is designed to be used with the LN 25 and LN 7 semiautomatic wire feeders ELECTRIC SHOCK can kill Have an electrician install and ser vice this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts WARNING LOCATION The Invertec has been designed with many features to protect it from harsh environments Even so it is import...

Page 10: ...con nection diagram S19899 and S19309 or S19405 in Operator s Mamual 4 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 not applicable to IEC machines with only 42V Aux 1 Turn the Invertec power switch off 2 Connect th...

Page 11: ...ld pendant type GMAW Pulsing option for the V300 PRO Power Source See the Mig Pulser s IM manual IM555 for connection information 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 attachi...

Page 12: ...signed to accept a welding cable size of 1 0 to 2 0 1 Remove 1 inch 25mm of welding cable insulation 2 Slide rubber boot on to the cable end The boot end may be trimmed to match the cable diameter Soap or other lubricant will help to slide the boot over the cable 3 Slide the copper tube into the brass plug 4 Insert the cable into the copper tube 5 Tighten set screw to collapse copper tube The scre...

Page 13: ...urn to Master TOC Return to Master TOC Return to Master TOC V300 PRO Section B 1 Section B 1 TABLE OF CONTENTS OPERATION SECTION Operation Section B Operating Instructions B 2 Controls and Settings B 2 B 4 Auxillary Power B 4 ...

Page 14: ...losion 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 front of this operator s manual WARNING 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 c...

Page 15: ...gun trigger to energize the welding ter minals 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 set tings For CV modes this control will set the degree of pinch effect ...

Page 16: ... 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 limiter 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 A 110 115 VAC 2 amp supply is includ...

Page 17: ...Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC V300 PRO Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES SECTION Accessories Section C Options Accessories C 2 ...

Page 18: ...te control circuitry to a 6 pin receptacle and to a 14 pin receptacle Adapter per mits remote output control of Invertec by means of K857 Remote Control K812 Hand Amptrol or K870 Foot Amptrol Allows remote while using LN 7 K480 7 control cable K867 UNIVERSAL ADAPTER PLUG Consisting of a 14 pin plug connected to labeled wires the adapter allows user connection of any suitable accessory or wire feed...

Page 19: ...TOC Return to Master TOC V300 PRO Section D 1 Section D 1 TABLE OF CONTENTS MAINTENANCE SECTION Maintenance Section D Input Filter Capacitor Discharge Procedure D 2 Preventive maintenance D 3 Overload Thermal Protection D 3 Printed Circuit Board Replacement D 3 ...

Page 20: ...Check voltage across terminals of all capacitors with a DC voltmeter Polarity of capacitor termi nals is marked on PC board above terminals Voltage should be zero If any voltage remains repeat this capacitor discharge procedure INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 1 Turn off input power or disconnect input power lines 2 Remove 14 5 16 hex head screws from side and top of machine 6 screws on ...

Page 21: ...blem is fixed by the new board reinstall the old board and see if the problem reoccurs If the problem does not reoccur check the wiring harness and plugs for loose connec tions PREVENTIVE MAINTENANCE 1 Perform the following preventive maintenance procedures at least once every six months It is good practice to keep a preventive maintenance record a record tag attached to the machine works best 2 R...

Page 22: ...rn to Master TOC Return to Master TOC Return to Master TOC FIGURE D 2 LOCATION OF MAINTENANCE COMPONENTS ITEM COMPONENT QTY NO PC BOARDS CONTROL 1 1 DRIVER 1 2 PROTECTION 1 3 SWITCH 2 7 POWER 1 10 INPUT RECTIFIER 1 4 POWER SWITCH 1 5 HEAT SINK FINS 2 6 MAIN TRANSFORMER 1 8 OUTPUT STUDS 1 9 INPUT FILTER CAPACITORS 2 11 1 6 2 7 3 8 4 9 5 10 11 ...

Page 23: ...DETETCTION H5 LINE SWITCH INPUT RECTIFIER AC1 AC2 AC3 A LEAD AUXILIARY TRANSFORMER TO WIREFEEDER 18VAC 24VAC POWERBOARD 24VDC PULSE TRAIN DRIVER BOARD PRE CHARGE PRE CHARGE 2ND STEP PWM 1ST STEP PWM VOLTAGE 15VDC CONTROL BOARD FUNCTION VOLTAGE 24VAC THERMOSTATS GUN TRIGGERING LOCAL REMOTE METER MODE POT POT PROTECTION BOARD 1 VDC RIGHT SWITCH BOARD FET MODULES CAP FET MODULES FAN 1 2 3 CONTROL BOA...

Page 24: ...ntrol Board and a 24v d c supply to the Driver Board to operate the Pre charge Relays E 2 E 2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1ø OR 3ø DETETCTION H5 LINE SWITCH INPUT RECTIFIER AC1 AC2 AC3 A LEAD AUXILIARY TRANSFORMER TO WIREFEEDER 18VAC 24VAC POWERBOARD 24VDC...

Page 25: ...e phase or three phase and pass that information to the Control Board The maximum output of the machine will be limited to approximately 250 amps with single phase input and 360 amps with 3 phase input E 3 E 3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE E 3 PRECHAR...

Page 26: ...er Signals from the Current Transformer insure that one switch circuit is turned off before the other is gated on Field Effect Transistor operation and Pulse Width Modulation are discussed in more detail later in this section E 4 E 4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Maste...

Page 27: ...etting determines which feedback signal voltage or current will have the most relevance However both signals are used in all modes The Control Board also monitors signals from the ther mostats and the Protection Board and if necessary shuts off the weld output The protection circuit infor mation is discussed in more detail later in this section E 5 E 5 Return to Section TOC Return to Section TOC R...

Page 28: ...e shows the FET in an active mode When the gate signal a positive DC voltage relative to the source is applied to the gate terminal of the FET it is capable of conducting current A voltage supply con nected to the drain terminal will allow the FET to con duct and henceforth supply current to downstream components Current will flow through the conducting FET to downstream components as long as the ...

Page 29: ... how much time is devoted to conduction in the positive and negative portions of the cycle Changing the pulse width is known as MODULA TION Pulse Width Modulation PWM is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine MINIMUM OUTPUT By controlling the duration of the gate signal the FET is turned on and off for different durations during a cycle...

Page 30: ... problem or air obstruction must also be corrected PROTECTIVE CIRCUITS Protective circuits are designed into the Invertec machine to sense trouble and shut down the machine before the trouble damages the internal machine components Both overload and thermal protection circuits are included OVERLOAD PROTECTION The machine is electronically protected from produc ing excessive output current Should t...

Page 31: ...Filter Capacitor Discharge Procedure F 11 Output Pilot Circuit Test F 13 Protection Board Output Test F 17 Capacitor Balance Test F 21 Switch Board Test F 25 Snubber Resistor Test F 29 Output Diode Test F 31 Input Rectifier Test F 33 OverCurrent Protection Current Trigger Test F 35 Overvoltage Protection DC Trigger Circuit Test F 38 Thermal Protection AC Trigger Circuit F 43 Power Board Test F 47 ...

Page 32: ...sts the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriat...

Page 33: ...s Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shielding bag If the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The ...

Page 34: ... D2 D3 D4 and D5 Output Diodes D7 D8 D9 D10 and D11 Note On newer codes where Diode Modules are used in place of individual diodes both modules on a heat sink assembly should be replaced if one fails Capacitor Bleeder Resistors R1 R9 Capacitors C1 C2 Capacitors C1 C2 C14 C15 on 575 v a c units Switch Boards proir to L10598 F 4 F 4 Return to Section TOC Return to Section TOC Return to Section TOC R...

Page 35: ...ponent D13 3 Check for broken leads to pri mary of Auxiliary Transformer T1 4 Possible open primary coil of Auxiliary Transformer T1 No output but fan operates and the meter display is on Output Terminal Switch or Remote Trigger MUST be in ON position Local Remote Switch must be in LOCAL position unless remote con trol device is attached to remote receptacle If machine has not been used for a long...

Page 36: ...itches off and repeats cycle Check input voltages and recon nection procedures See Instal lation section Check output terminal switch S4 and or Remote Trigger Options i e wire feeders guns cables etc 1 See Thermal Protection AC Trigger Circuit test 2 See Overvoltage Protection DC Trigger Circuit test 3 See Capacitor Balance test NOTE This test is necessary only if machine is connected for 380 VAC ...

Page 37: ...ter while welding while connected to single phase supply Normal operation Nothing is wrong No test necessary The single phase operation is detected by the Protection Board and the output cur rent is limited accordingly Machine operates okay at 230 VAC or lower No output at 380 VAC or higher Check input voltage and input volt age reconnect procedures See Installation section of this manual 1 Check ...

Page 38: ... on local con trol Check input voltages and input volt age reconnect procedures See Installation section of this manual 1 Check Mode Switch S2 for dam age and continuity 2 Check for continuity between Mode Switch S2 and Control Board See Wiring Diagram in Section G 3 Check for loose or faulty con nections in heavy current carry ing leads i e choke shunt output bridge and output studs See wiring di...

Page 39: ...rect electrode for your application 1 Check for loose or burned con nections at choke shunt and output studs See wiring dia gram in Section G 2 Test and inspect D6 D12 L1 and L2 See Wiring Daigram in Section G Machine makes squealing noise while under load when welding Output power is low less than 20 VDC on meter 100 amps Input voltage 230 VAC or lower Check input lines and connections Check inpu...

Page 40: ...V300 PRO NOTES F 10 F 10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 41: ...ions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 WARNING INPUT FILTER CAPACITOR DISCHARGE PROCEDURE TEST DESCRIPTION This procedure will drain off any charge stored in the c...

Page 42: ...connect resistor leads across the two capacitor terminals Hold resistor in place for 10 seconds DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS 7 Repeat discharge procedure for capacitor on other side of machine If you are working on a 575 VAC machine repeat discharge procedure for second capacitor on each side of machine 8 Check voltage across terminals of all capacitors with a DC voltmeter...

Page 43: ...er form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 V300 PRO F 13 F 13 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WARNING TROUBLESHOOTING REPAIR OUTPUT PILOT CIRC...

Page 44: ... Perform Input Capacitor Discharge test as described in the Maintenance Section 3 Remove the four screws that hold the Control Panel to the frame 4 Move the Control Panel forward and to the left so that there is access to the Control PC Board Be careful not to stress any of the connections to the Control Panel 5 Set the Output Terminals Switch to the ON position 6 Turn the Input Power Switch ON FI...

Page 45: ...A J4 Pin 11 a If voltage is 24v a c thermostats transfor mer T1 and switch S4 are OK Go on to Step 8 b If voltage is 0v a c test the following com ponents individually Auxiliary Transformer T1 Fan Thermostat Choke Thermostat Output Terminal Switch S4 8 Measure voltage from lead 302 J1 Pin 6 to Lead 275D J1 Pin1 a If voltage is 15v d c Transformer T1 and 15 volt supply are OK Go to Protection Board...

Page 46: ...V300 PRO NOTES F 16 F 16 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 47: ... safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 WARNING PROTECTION BOARD OUTPUT TEST TEST ...

Page 48: ... Rectifier bracket Each through bolt also supports a resistor 5 Slide the through bolts toward the Control Panel until the brackets are disconnected and resistors are loose Be careful when loosening these through bolts as they secure the two resistors As the through bolts are removed carefully place the resis tors and the connected wires to the side PROTECTION BOARD OUTPUT TEST cont FIGURE F 4 REM...

Page 49: ...Protection Board Make sure contact is made with conductor materi al NOTE Right angle thin gauge probes are best for this test With probes attached plug the J8 block into the PC board 9 Turn main power ON 10 Move Output Terminal Switch S4 to ON position on Control Panel 11 Test for less than 1 VDC between leads 313 and 311 a If less than 1 VDC is measured test is OK and Protection Board is function...

Page 50: ...OTECTION BOARD OUTPUT TEST cont TEST PROCEDURE 12 Open S4 and Turn Power OFF 13 Move probes to test between leads 306 and 275 See Figure F 6 14 Turn Power ON and close S4 If voltage is less than 1 VDC Protection Board is OK If voltage is greater than 14 VDC Protection Board may be defective See Overvoltage Protection DC Trigger Circuit test Step11 PROTECTION L7915 306 313 275F 311 J8 J15 FIGURE F ...

Page 51: ...k please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 WARNING CAPACITOR BALANCE TEST TEST DESCRIPTION This procedure will determine ...

Page 52: ...1 and R9 are OK Go to Dynamic Capacitor Balance Test b If more than 25 VDC difference is measured between the Switch Boards test each of the fol lowing components Capacitors C1 and C2 and Resistors R1 and R9 575 VAC only machines Capacitors C1 C2 C14 and C15 and Resistors R1 and R9 DYNAMIC CAPACITOR TEST TEST PROCEDURE 1 Move Output Terminal Switch S4 to ON position Adjust the output control to th...

Page 53: ...Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F 7 SWITCH BOARD TEST POINTS L8604 1 L8604 1 SWITCH SWITCH 9 9 R W 12 W R 401 403 1 8 4 5 402 404 12 CAPACITOR BALANCE TEST cont ...

Page 54: ...V300 PRO NOTES F 24 F 24 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 55: ...hroughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 WARNING SWITCH BOARD TEST TEST DESCRIPTION This procedure will determine if the Switch Boards are working properly This resis tance test is...

Page 56: ...t all wiring harness leads 401 403 1 8 9 12 4 5 402 404 from the Switch Boards 3 Fold the leads up so they do not interfere with the exposed PC board terminals See Figure F 8 4 Using an ohmmeter perform the Resistance Tests detailed in Table F 2 and Table F 3 If any test fails replace both Switch Boards See Switch Board replacement procedure 5 If the Switch Boards appear to be burned or over heate...

Page 57: ...ss than Shorted Replace both Snubber Test 100 ohms Switch Boards 4 5 9 Less than OK None Continue 100 ohms Greater than Open Replace both Snubber Test 1K ohm Switch Boards 1 8 9 Less than OK None Continue 100 ohms Greater than Open Replace both Snubber Test 1K ohm Switch Boards 9 1 8 Greater than OK None Continue 1K ohm Less than Shorted Replace both Snubber Test 100 ohms Switch Boards 12 4 5 Less...

Page 58: ...sion Repair Action Next Procedure Notes 12 401 403 Greater than OK None Continue 1K ohm Less than Shorted Replace both Snubber Test 100 ohms Switch Boards 401 403 12 Less than OK None Continue 100 ohms Greater than Open Replace both Snubber Test 1K ohm Switch Boards 9 402 404 Less than OK None Continue 100 ohms Greater than Open Replace both Snubber Test 1K ohm Switch Boards 402 404 9 Greater than...

Page 59: ...or and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 88...

Page 60: ...eturn to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SNUBBER RESISTOR TEST cont L8604 1 L8604 1 SWITCH SWITCH 9 R W 12 W R 401 403 1 8 4 5 402 404 FIGURE F 9 SNUBBER RESISTOR TEST POINTS Check Test Result Conclusion Next Test Step Repair Action Lead 401 to 25 ohms OK Continue Terminal 12 30 ohms R4 open...

Page 61: ...formed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or ar...

Page 62: ...100 ohms one or more Output Diode is shorted Test all Output Diodes D 1 thru D 12 or diode modules individually NOTE On codes prior to 10200 the diodes should also be tested individually to check for Open diodes An open diode may cause an imbalance condition when output is activated Be sure to per form the Input Filter Capicitor Discharge Procedure as detailed in this section F 32 F 32 Return to S...

Page 63: ...ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do n...

Page 64: ...is faulty NOTE Faulty Capacitors could be the reason for a defective Input Rectifier Visually inspect Capacitors for leakage damage etc and use appropriate test equipment to determine com ponent integrity also check test Switch Boards for damage F 34 F 34 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Mast...

Page 65: ...nvalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 TE...

Page 66: ... 275D a If 15 VDC is present test is OK Go to step 6 b If 15 VDC is not present check Power Board and leads 302 and 275D for continuity and wire breakage F 36 F 36 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OVERCURRENT PROTECTION CURRENT TRIGGER TEST cont FIGURE F 12 GET...

Page 67: ...eadings Cleaning and sol dering the terminals to the leads may eliminate that problem If tests for steps 5 7 are OK and the machine contin ues to experience the problem the Control Board should be replaced F 37 F 37 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OVERCURRENT ...

Page 68: ...actory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION T...

Page 69: ...ot disconnect any wires The machine must be functional to perform tests 4 Arrange the PC boards and wiring so you can easi ly perform the tests NOTE Do not allow live connections to touch each other 5 Turn main power ON 6 Move the Output Terminal Switch S4 to the ON posi tion closed F 39 F 39 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master T...

Page 70: ...ep 8 b If 15 VDC is present go to step 11 F 40 F 40 OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST cont FIGURE F 17 PROTECTION BOARD TEST POINT PROTECTION L7915 306 313 275F 311 J8 J15 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 71: ...gger circuit is oper ating properly b If 15 VDC is present go to step 10 10 Test for 0 1 VDC between leads 301 and 275D on Power Board a If 0 1 VDC is present AC trigger Control Board and Power Board are operating proper ly b If 15 VDC is present go to Thermal Protection AC Trigger Circuit Test F 41 F 41 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return...

Page 72: ...er TOC Return to Master TOC Return to Master TOC Return to Master TOC FIG F 19 OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST cont THESE LEADS ARE USED FOR MONITORING CAPACITOR VOLTAGES SEE TABLE 1 BELOW 311 313 52 14 53 51 1J8 3J8 TABLE 1 INPUT VOLTS FOR 460 VOLTS AC LEADS NORMAL 52 53 51 53 14 53 14 52 325 VDC 325 VDC 14 15 VDC 315 VDC OPTOCOUPLER DEPEND...

Page 73: ...perator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call...

Page 74: ...to perform the tests Do not disconnect from wiring harness Power Board Control Board NOTE Do not disconnect any wires The machine must be functional to perform test F 44 F 44 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THERMAL PROTECTION AC TRIGGER CIRCUIT cont FIGURE F 2...

Page 75: ...S4 is in the ON position closed 8 Test for 24 VAC between leads 223A and 210 a If 24 VAC is present then AC Trigger Circuit is functioning normally b If 0 VAC is present check Choke Thermostat and Fan Thermostat F 45 F 45 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THERMA...

Page 76: ...V300 PRO NOTES F 46 F 46 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 77: ... machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you pr...

Page 78: ... control relay contacts closing is not heard Power Board could be faulty Go to Test B NOTE If the relays energize but there is still a suspicion that the Power Board is faulty go on to Test B F 48 F 48 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER BOARD TEST cont Test...

Page 79: ...ective See Fig F 24 9 Test for 24VDCfrom lead 309 to lead 313 J7pin 2 to J14 pin 2 If 24VDC is not present but 24VAC step 8 is cor rect the Power Board is defective 10 Test for 24VDC from lead 309 to lead 310 J7 pin 2 to J7 pin 4 If 24 VDC is not present check the voltage from lead 311 to lead 313 If the voltage is greater than 1VDC perform the Protection Board test If the voltage is approximately...

Page 80: ...R BOARD TEST cont FIGURE F 24 SIMPLIFIED TRIGGER CICUIT FROM PROTECTION BOARD OVERVOLTAGE PWM OUTPUTS TO POWER BOARD 7J6 2J6 11J4 3J4 13J36 5J36 8J33 6J34 9J4 12J4 3J31 6J22 6J4 POWER BOARD CONTROL BOARD REMOTE PROTECTION BOARD STT ONLY 14 AMPHENOL 301 305 503A 224 210 212 223 212C 413 405 C D T1 AUXILIARY TRANSFORMER 2 4 V A C P W M SIMPLIFIED TRIGGER CIRCUIT 5J4 TO POWER BOARD 2J31 3 5 ohms 3 5 ...

Page 81: ...ine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed...

Page 82: ...located on top of the fan shroud See Figure F 25 F 52 F 52 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAPACITOR REMOVAL AND REPLACEMENT cont FIGURE F 25 REMOVING HEX NUTS 3 Turn the machine on it s side as shown in Figure F 26 Slide the plastic insulators that go through...

Page 83: ...mp ring and remove the Capacitor from the clamp ring See Figure F 28 F 53 F 53 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F 27 REMOVING CAPACITOR NUTS FIGURE F 28 LOOSENING THE CLAMP RING SET SCREW CAPACITOR REMOVAL AND REPLACEMENT cont ...

Page 84: ...increments of 10 inch pounds alternating between the two See Figure F 27 7 Tighten the set screw of the clamping ring 8 Perform the Test After Repair of Switch Boards and or Capacitors F 54 F 54 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F 29 COMPLETE SWITCH BOARD...

Page 85: ... warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedu...

Page 86: ...the mounting sur faces of the new PC board and to the Capacitor terminals DO NOT allow the compound to enter the mounting screw holes because it can distort the torque values 8 Prepare to mount the new PC board on the heat sink by first lining up the mounting holes Then press the PC board into place 9 Insert each of the four socket head screws into the mounting holes and thread finger tight The th...

Page 87: ...safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test MUST be performed afte...

Page 88: ...ut supply fuse holders NOTE These fuses should be installed to protect against excessive current flow caused by a short circuit during the procedure 8 Turn on the machine 9 With the output free of a load check the open cir cuit voltages of the output 10 Connect the machine for 440 or 575 volt opera tion 11 With the output free of a load check open circuit voltages of the output Voltage should be 7...

Page 89: ...all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid in the relpacement of the Output Diodes MATERIALS NEEDED Mi...

Page 90: ...mounting bracket 8 Mount the replacement diodes to the heat sink IMPORTANT The replacement diodes will come with an instruction sheet that addresses surface preparation and torque values Failure to follow these instructions may result in subsequent break down 9 Carefully resolder the leads to the new diodes 10 Reassemble the unit being careful to use all of the insulating materials Also make certa...

Page 91: ...sink 7 Mount the new module and re connect the leads IMPORTANT The replacement module will come with an instruction sheet that addresses surface preparation torque values and hardware changes Failure to follow these instructions may result in subsequent breakdown 8 Reassemble the unit being careful to use all of the insulating materials Also make certain to replace all disconnected leads in their ...

Page 92: ...0 450 440 50 or 60 1 38 425 460 60 1 50 450 380 50 or 60 1 67 425 575 60 OCV at rated INPUT V300 PRO V300 I 60 75V MAXIMUM ACCEPTABLE OUTPUT AMPS AT MINIMUM OUTPUT SETTINGS Output Min Max acceptable all machines CC modes 12A 10V GTAW SOFT CRISP CV modes 20A 19V FCAW GMAW OUTPUT MINIMUM ACCEPTABLE VOLTS AT MAXIMUM OUTPUT SETTINGS WITH FULL LOAD Min Acceptable Max All Modes V300 I V300 PRO 1 phase 2...

Page 93: ...257 G 9 Entire Machine Schematic G 10 Driver PC Board Schematic S20216 G 11 Driver PC Board Assembly L8660 G 12 Driver PC Board Schematic S20799 G 13 Driver PC Board Assembly L9134 G 14 Switch Board Schematic L8440 G 15 Switch Board Assembly L8441 G 16 Switch Board Schematic L10956 G 17 Switch Board Assembly L10958 1 G 18 Control PC Board Schematic G2525 G 19 Control Board Assembly G2527 3 G 20 G ...

Page 94: ... 6 14 4 11 10 275F 2 3 301 6 4 7 8 5 210 275A 1 3 4 2 1 2 502 215 306 5 9 223B 502 Y S5 METER FUNCTION SWITCH 301 D6 D4 D5 J5 J6 D11 D12 D10 D9 D8 D7 N E 224 210 2AMP 6AMP 110 115 VAC H2 H3 H4 A 12B 9B 9B R 9 12C 9A 53 12A 9C H5 311 275F 306 W B G H5 A FOR THREE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE CONNECT BLACK RED WHITE LEADS TO SUPPLY CIRCUIT WRAP RED LEAD WITH TA...

Page 95: ... 6 D 1 1 D 1 2 D 1 0 D 9 D 8 D 7 N E 2 2 4 2 1 0 2 A M P 6 A M P 1 1 0 1 1 5 V A C H3 1 2 B 9 B R 9 1 2 D 9 D W B G H 5 H 6 F O R T H R E E P H A S E I N P U T C O N N E C T G R E E N L E A D T O G R O U N D P E R N A T I O N A L E L E C T R I C C O D E C O N N E C T B L A C K R E D W H I T E L E A D S T O S U P P L Y C I R C U I T W R A P R E D L E A D W I T H T A P E T O P R O V I D E 6 0 0 V I ...

Page 96: ...T O P A U X F 223A 212D 501 504 212A W V U LEFT J9 J10 J12 212C H1 J13 J12 BOARD RIGHT 212D 503 501 504 0V 24V 42V 110V 1 4 6 5 3 2 1 4 2 3 001 400 C8 R10 001 400 10 2W R13 C7 COLOR CODE R RED 250 25W 6 H5 1 10 12 5 3 4 11 2 9 6 8 8 13 12 7 6 14 4 11 10 275F 2 3 301 6 4 7 8 5 210 275A 1 3 4 2 1 2 502 215 306 5 9 223B 502 Y 301 D6 D 4 D 5 J6 D 1 1 D12 D 1 0 D 9 D 8 D 7 N E 224 210 2AMP 6AMP 110 115...

Page 97: ... J10 J12 212C H1 J13 J12 BOARD RIGHT 212D 503 501 504 0V 24V 42V 110V 1 4 6 5 3 2 1 2 0 0 1 4 0 0 C 8 R10 0 0 1 4 0 0 1 0 2 W R13 C 7 COLOR CODE R RED 250 25W 6 H5 1 10 12 5 3 4 11 2 9 6 8 8 13 12 7 6 14 4 11 10 275F 2 3 301 6 4 7 8 5 210 275A 1 3 4 2 1 2 502 215 306 5 9 223B 502 Y 301 D6 D 4 D 5 J6 D 1 1 D12 D 1 0 D 9 D 8 D 7 N E 224 210 2AMP 6AMP 110 115 VAC H 3 12B 9B R 9 9D W B G H5 H6 FOR THR...

Page 98: ...y not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 99: ...y not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 100: ...y not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 101: ...y not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 102: ...229 400A SHUNT R 8 229 286 TP6 250 25W ARC ARC 4 5 6 7 8 1 3 2 275F J1 1 3 4 2 1 2 B W TP4 C6 J2 J3 1 2 3 4 5 6 7 8 9 10 11 12 J4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 J5 220 204A 76 203 206 227 213 214 225 226 229 228 207 208 276 218 75 77A 211A 210 275A 502 215 306 223A Y 212C 150 5W FAN THERMOSTAT 212A 224 210 THERMOSTAT CHOKE 75 76 77B GND G F E J A I K C D M L B N H 75 76 77 31 32 41 42 2 4 81 82 ...

Page 103: ...or reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FROM RIGHT SWITCH BOARD TO INPUT RECTIFIER ...

Page 104: ...0 PRO PC BOARD ASSEMBLY DRIVER L8660 G 12 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC R13 R14 DZ1 DZ2 Q1 Q2 J16 Item Identification CR1 CR2 CR3 CR4 RELAY SPNO 24VDC 6000 ohms AG CDO D1 DIODE AXLDS 1A 400V DZ1 DZ2 DIODE Zener 1W 12V 5 1N4742A J9 J10 J16 CONNECTOR Molex min...

Page 105: ...NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 106: ...in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ELECTRICAL DIAGRAMS G 14 V300 PRO PC BOARD ASSEMBLY DRIVER 9134 G 14 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DRIVER XXXXXXX XXXXXXX XXXX XXXX XXXXX XXXXX XX...

Page 107: ...D7 1W 6 2V DZ9 47 5 R 3 6 BYT12P600 C1 A1 A1 39 2K R39 221 R 2 1 00K R 2 1 20 R 3 1 1 50K R 3 0 100 R 1 1N4936 D6 600mA 40V Q11 1W 3 3V DZ8 1N4936 D1 1 00K R 2 0 C A P A C I T O R S B G E N E R A L I N F O R M A T I O N 1 4 W 0 2 2 5 0 V L A B E L S U N L E S S O T H E R W I S E S P E C I F I E D U N L E S S O T H E R W I S E S P E C I F I E D R E S I S T O R S O h m s 1 A 4 0 0 V 8 4 4 0 C D 8 S ...

Page 108: ...3 B4 B5 B6 CONNECTOR tab QC edge offset B7 B8 B9 B10 B11 1 4 B12 C1 C5 C6 C7 CAPACITOR CEMO 022 50V 20 C2 C8 CAPACITOR CEMO 2700P 50V 5 C3 C4 CAPACITOR PPF 047 1200V 5 D1 D2 D3 D4 D5 D6 DIODE AXLDS 1A 400V FR 1N4936 D7 D8 D9 D10 DZ1 DZ2 DZ3 DZ12 DIODE Zener 1W 10V 5 1N4740A DZ4 DZ7 DIODE Zener 1W 15V 5 1N4744A DZ5 DZ6 DZ8 DZ9 DIODE Zener 1W 6 2V 5 1N4735A Q1 Q2 Q3 Q10 TRANSISTOR NMF 4PDIP 1A 100V ...

Page 109: ...NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 110: ...R7 R5 R4 R32 R2 R24 R31 R30 R20 R23 R21 R18 R3 R1 R29 R17 R8 R6 R9 R33 R34 R27 R25 R26 R19 C8 C2 C5 C6 C1 C7 DZ8 DZ5 D6 D1 DZ9 D7 DZ12 DZ7 D8 DZ3 DZ4 DZ6 D2 D3 D4 D5 D10 D9 DZ1 DZ2 Q2 Q3 Q1 Q10 B8 B4 Q11 Q12 Q8 Q9 Q4 Q5 Q6 Q7 L10958 1 B1 B2 B5 B6 B7 B3 B9 B10 B11 B12 A2 A1 ITEM REQ D PART NO IDENTIFICATION R27 R33 R34 R45 R46 C1 C5 C6 C7 4 S16668 5 022 50 C2 C8 2 S16668 4 2700pF 50 C3 C4 2 S13490 ...

Page 111: ...022 C3 X3 8 9 10 50V 022 C15 AMPS OCV C VOLTS D VI DPC A ACTUAL B AMPS ARC TIG VOLTS 50V 022 C54 50V 022 C35 J4 8 1W 5 1V DZ9 35V 4 7 C48 22 1K R 9 8 150K R 9 1 50V 022 C67 35V 4 7 C39 301 R 8 2 2 67K R73 J4 1 4 75K R 9 7 150K R 8 5 50V 022 C50 X8 12 11 10 10K CW R 9 5 X8 6 8 9 33 2K R136 X9 8 9 6 C74 26 7K R70 t 60V 13 R17 D51 10K R 2 X3 14 12 13 50V 022 C27 47 5K R 9 100V 150p C4 47 5K R30 50V 0...

Page 112: ...urages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ELECTRICAL DIAGRAMS G 20 V300 PRO PC BOARD ASSEMBLY CONTROL G2527 3 G 20 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master...

Page 113: ...HOUSING Molex 8 pin P2 plugs into J2 PLUG HOUSING Molex 4 pin P3 plugs into J3 PLUG HOUSING Molex 2 pin P4 plugs into J4 PLUG HOUSING Molex 12 pin P5 plugs into J5 PLUG HOUSING Molex 14 pin Q1 Q2 TRANSISTOR N T226 0 5A 40V 2N4401 R2 R4 R8 R20 R23 RESISTOR MF 25W 1 10 0K R32 R38 R43 R45 R46 R51 R57 R64 R68 R87 R109 R125 R139 R141 R143 R151 R3 R10 R26 R42 R129 RESISTOR MF 25W 1 475K R5 R6 RESISTOR C...

Page 114: ... Master TOC ELECTRICAL DIAGRAMS G 22 V300 PRO SCHEMATIC PROTECTION PC BOARD M16097 G 22 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 115: ...51 B52 B53 CONNECTOR tab 1 4 C1 C3 C4 C5 C6 CAPACITOR ceramic C2 CAPACITOR tantlm etc 27µf 35VDC D1 D3 D4 D5 D6 D7 DIODE 1A 400V D8 DIODE 1A 1000V DZ1 DIODE IN4740 Zener 10V 1W J8 RECEPTACLE Molex mini 4 pin J15 RECEPTACLE Molex mini 6 pin OCI1 OCI2 OCI3 OCI4 OPTO Isolator CNY17 3 P8 plugs into J8 PLUG HOUSING Molex mini 4 pin P15 plugs into J15 PLUG HOUSING Molex mini 6 pin R1 R2 RESISTOR MF 25W ...

Page 116: ...OTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 117: ...eturn to Master TOC D C A B F E POWER BOARD L8033 4 Item Identification X1 REGULATOR ASBLY C2 C7 C11 022 50 J7 CONNECTOR X5 VOLT REG HEAT SINK ASBLY C3 150 50 D1 D2 D3 D4 D5 D8 D9 1N4004 D10 D11 D12 D13 C6 1 8 20 C4 4 7 35 C5 39uF 20VDC C1 3300 50 OCI1 OPTO ISOLATOR X2 X3 8 PIN I C SS C8 C9 C12 C13 1 50 J6 HEADER C10 500 50 DZ1 1N4744A DZ2 DZ3 1N4746A Q1 Q3 3A 60V TRANSISTOR Q2 Q4 3A 60V PNP TRANS...

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