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G-19

ELECTRICAL DIAGRAMS

INVERTEC V300-I

Wiring Diagram — Invertec V300-I — Code 10133

E L E C T R I C A L   S Y M B O L S   P E R   E 1 5 3 7

B O A R D

+

H 1

1 8 V

T 1

  F A N
M O T O R

7 5

7 6

7 7 B

G N D

G

F
E
J

A
I
K
C

D

M
L

B
N

H

7 5

7 6
7 7

3 1

3 2

4 1

4 2

2

4

8 1

8 2

2 1

G N D

S P A R E

4 2
V A C

N . C .

  W I R E
F E E D E R

  R E M O T E
  C O N T R O L
R E C E P T A C L E

M I N

1 2

C 1

R 4

R 5

2 5
2 5 W

2 5
2 5 W

9

5

8

T 3

  CURRENT
TRANSFORMER

+

1 2

2 5
2 5 W

2 5
2 5 W

9

C 2

R 6

R 7

4

1

1

4

T 2

M A I N  
T R A N S F O R M E R

R 3

R1

7 5 0 0
2 5 W

9 A

O F F O N

H 1

T P 1

T P 3

T P 2

I

I

    C H O K E
T H E R M O S T A T

5

8

D 1
D 2

D 3

C H O K E

T P 5

2 2 9

B W

T P 4

C 6

L 3

C 5

2 2 0

2 0 4 A

7 6

2 0 3
2 0 6

2 2 7

2 1 3
2 1 4

2 7 5 B

2 2 6

2 7 5 D

3 0 2
3 0 5
3 0 3
3 0 4

C O N T R O L
B O A R D

W
B

2 2 9
2 2 8
2 0 7
2 0 8
2 7 6

2 1 8

7 5
7 7 A

2 0 6

2 0 4 A
2 0 4 B

2 1 3
2 1 8

1

2

3

7 7 B
7 7 A
2 7 6

2 7 5 C
2 7 5 B
2 7 5 A

2 2 8
2 0 4 B

2 0 4 C

L O C A L

R E M O T E

1 0 K
2 W

R11

2 0 7

2 0 8

1 0 K
2 W

R12

3 0 7
3 0 8
3 0 9
3 1 0

3 0 2
3 0 3
3 0 4
2 7 5 D

P O W E R
B O A R D

2 1 4

2 2 6

2 2 7
2 7 5 C

2 0 4 C

2 2 0

J 3

J 4

C O N N E C T O R   C A V I T Y   N U M B E R I N G   S E Q U E N C E

( V I E W E D   F R O M   C O M P O N E N T   S I D E   O F   B O A R D )

N O T E S :

R E M O T E
O U T P U T
C O N T R O L

T R I G G E R

}

I N P U T  
P E R  
N . A .

4 0 2 ,   4 0 4

4 0 1 ,   4 0 3

1 ,   8

W

R

W

R

R

W

R

W

4 0 1 ,   4 0 3

1 ,   8

4 ,   5

P O W E R

S 1

1

J 3

J 5

J 4

J 1

J 2

2

3

1

7
8

J 7

J 6

2 8 5

2 2 9

4 0 2 ,   4 0 4

4 2

2 1

2 1 2

2 8 5

2 2 9

+

-

C B 1

S W I T C H

+

-

+

-

S W I T C H

4 2 A

W I R E   F E E D E R
W E L D I N G
P O L A R I T Y
S W I T C H

  A U X I L I A R Y
T R A N S F O R M E R

2
4
5
6
1
3

N.E.

C W   ( M A X )

C W   ( M A X )

9

1 0

S 6

4 2 A

N . C .     W I R E   F E E D E R S   R E Q U I R I N G   2 4 V A C ,   U S E   P I N S   " N "   &   " C " .

F

F

S

S

S

T O P
O U T S I D E

B O T T O M
I N S I D E

S

S

S

S

F

F

F

T O P

T O P
I N S I D E

B O T T O M
O U T S I D E

F

S

7
6

8

4
5

4 0 0 A

S H U N T

R8

C O N T R O L   P A N E L

L A Y O U T

C C   S O F T

C C   C R I S P

C V   F C A W

C V   G M A W

    R 1 1
O U T P U T
C O N T R O L

    S 2
  M O D E
S W I T C H

          S 2
  M O D E   S W I T C H
 

          R 1 1
O U T P U T   C O N T R O L
 

V

A

          S 3
L O C A L / R E M O T E
        S W I T C H

2

1

2 1 1 A

3

7

2 2 9

2 8 6

2 1 1 B

L 2
R I G H T

L 1
L E F T

2 0 3

2 1 5

5

C C   G T A W

4

B O A R D

1

2

3

4

5 2

1 4

5 1

5 3

1 4

1 4

3 1 3

J 8

P R O T E C T I O N

5 2

5 1

5 3

2 2 0 0   F
4 5 0 V

N . G .

N . F .

N . G .

2 2 0 0   F
4 5 0 V

2 2 4

T P 6

2 1 2 A
2 1 2 B

R E M O T E

O N

      S 4
  O U T P U T
  T E R M I N A L
  S W I T C H

2 1 2

2 2 3 B

2 1 2 C

1 5 0   5 W

F A N

T H E R M O S T A T

H 2

H 3

H 4

F

B O T T O M
A U X

S

F

 B O T T O M

F

S

T O P
A U X

F

2 2 3 A

2 1 2 D

5 0 1
5 0 4

2 1 2 A

W

V

U

( L E F T )

J 9 ,   J 1 0 ,   J 1 2

2 1 2 C

H 1

J 1 3

J 1 2

B O A R D

( R I G H T )

2 1 2 D

5 0 3

5 0 1

5 0 4

0 V

2 4 V

4 2 V

1

4

5

3

2

1

4

2

3

. 0 0 1 / 4 0 0

C 8

R 1 0

. 0 0 1 / 4 0 0

1 0
2 W

R 1 3

C 7

C O L O R   C O D E :

R   =   R E D

2 5 0
2 5 W

6

H 5

1

1 0

1 2

5
3
4

1 1

2
9
6
8

8

1 3
1 2

7

6

1 4

4
1 1

1 0

2 7 5 F

2
3

3 0 1

6
4
7
8

5

2 1 0

2 7 5 A

1
3

4
2

1
2

5 0 2

2 1 5

3 0 6

5
9

2 2 3 B

5 0 2

Y

3 0 1

D 6

D 4
D 5

J 6

D 1 1

D 1 2

D 1 0

D 9
D 8
D 7

N . E .

2 2 4

2 1 0

6 A M P

H 2

H 3

H 4

A

1 2 B

9 B

9 B

R9

9 A

5 3

1 2 A

H 5

3 1 1

2 7 5 F

3 0 6

W

B

G

H 5

A

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 N S U L A T I O N .

F O R   T H R E E   P H A S E   I N P U T :   G R O U N D   M A C H I N E   P E R   N A T I O N A L   A N D   L O C A L   E L E C T R I C A L   C O D E S .
C O N N E C T   T E R M I N A L S   U ,   V   &   W   T O   S U P P L Y   C I R C U I T .

C O N N E C T   T E R M I N A L S   U   &   W   T O   S U P P L Y   C I R C U I T .

N . D .     P L A C E   " A "   L E A D   O N   A P P R O P R I A T E   C O N N E C T I O N   F O R   I N P U T   V O L T A G E .

C O N N E C T I O N   S H O W N   I S   F O R   4 4 0 - 4 6 0 V   O P E R A T I O N .

C O N N E C T   B L A C K   &   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 .

5 0 3 A

F O R   S I N G L 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 .

F O R   S I N G L E   P H A S E   I N P U T :   G R O U N D   M A C H I N E   P E R   N A T I O N A L   A N D   L O C A L   E L E C T R I C A L   C O D E S .

W   =   W H I T E

B   =   B L A C K
G   =   G R E E N

Y   =   Y E L L O W

H 6

N . D .

7 5 0 0
2 5 W

N . H .

R

2 2 3 A

    T H E R M A L
  O V E R L O A D
  I N D I C A T O R
( V 3 0 0 - I   O N L Y )

    T H E R M A L
  O V E R L O A D
  I N D I C A T O R
( V 3 0 0 - I   O N L Y )

2 1 1 B

2 .   F O R   M A C H I N E S   N O T   S U P P L I E D   W I T H   I N P U T   C A B L E   ( V 3 0 0 - I )

H 1

+   A R C

-   A R C

        R 1 2
  A R C   F O R C E
/ I N D U C T A N C E
    C O N T R O L

      S 5
    M E T E R
  F U N C T I O N
    S W I T C H

1 0
2 W

C 4

. 0 0 1 / 4 0 0

5 2

H 5

H 1

H 3

H 3

2 3 0 V

4 1 5 V

4 4 0 -

4 6 0 V

2 0 0 -
2 0 8 V

2 2 0 -

3 8 0 -

5 0 3 A

5 0 3

R 2

C 3

. 0 0 1 / 4 0 0

1 0
2 W

1 0
2 W

Y

Y

Y
Y

3 0 5

1
2
3
4
5

6

3 1 4

3 1 5

3 1 7

3 1 6

J 1 5

1

2
3

4

J 1 4

3 1 1
3 1 3

N . F .

J 2 ,   J 8

A

A

3   A M P
S L O W
B L O W

1 2 A

1 2 B

N . A .

1 .   F O R   M A C H I N E S   S U P P L I E D   W I T H   I N P U T   C A B L E   ( V 3 0 0 - P R O )

N . B .     S I N C E   C O M P O N E N T S   O R   C I R C U I T R Y   O F   A   P R I N T E D   C I R C U I T   B O A R D   M A Y   C H A N G E   W I T H O U T   A F F E C T I N G

 

N . E .     D 1   T H R U   D 5   O U T P U T   D I O D E S   A R E   A   M A T C H E D   S E T .

N . F .     R 1 ,   R 9   B L E E D E R   R E S I S T O R S   A R E   A   M A T C H E D   S E T .
 N.G.  C1, C2 CAPACITORS ARE A MATCHED SET.
 N.H.  PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.

T H E   I N T E R C H A N G E A B I L I T Y   O F   A   C O M P L E T E   B O A R D ,   T H I S   D I A G R A M   M A Y   N O T   S H O W   T H E   E X A C T
C O M P O N E N T S   O R   C I R C U I T R Y   H A V I N G   A   C O M M O N   C O D E   N U M B E R .

D 7   T H R U   D 1 1   O U T P U T   D I O D E S   A R E   A   M A T C H E D   S E T .

C O N N E C T I O N   S H O W N   I S   F O R   3 8 0 - 4 6 0 V   O P E R A T I O N .

J 1 ,   J 7

5 1

5

3 0 8

3 0 7

4 , 5

D R I V E R

B O A R D

4

1

6

3

J 1 0

2 5

N . H .

9 C

1 2 C

9 B

1 2 A

9 B

1 2 A

1 2 A

9 B

S 7

R E C O N N E C T

3 0 9

3 1 0

4

1

3

2

J 1 1

7

3

2

1

8 1 2 1 3 1 4

J 1 6

3 1 4

3 1 5

3 1 6

3 1 7

9 D

3

6

4

1

J 9

2 5

5 2

1 2 B

1 2 D

9 A

9 D

1 2 D

1 2 B

3 1 0

3 0 9

C R 1

C R 2

J 5 ,   J 1 6

J 1 3 ,   J 1 5

2 1 2

2 1 2

3 2

J 1 1 ,   J 1 4

2 1 1 A

2 1 2 B

CLEVELAND, OHIO U.S.A.

  

            

R

WIRING DIAGRAM - (CODE 10133)                    

                R 1 2
A R C   F O R C E / I N D U C T A N C E  
            C O N T R O L

            S 5
M E T E R   F U N C T I O N
        S W I T C H

            S 4
  O U T P U T   T E R M I N A L
        S W I T C H  

        S 3
L O C A L / R E M O T E
    S W I T C H

    2 - 1 1 - 9 4 F    

        L 9 5 6 8      

A

B

C

 

1 2 C

9 C 9D

1 2 D

D   +

F   -

9 D

1 2 D

P A N E L
M E T E R

1
2
3
4
5
6

1
2
3
4
5
6

Retur

n to Section TOC

Retur

n to Section TOC

Retur

n to Section TOC

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n to Section TOC

Retur

n to Master TOC

Retur

n to Master TOC

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n to Master TOC

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n to Master TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific
diagram for a particular code is pasted inside the machine on one of the enclosure panels.

Содержание INVERTEC V300-I

Страница 1: ...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 TH...

Страница 2: ...g head nozzle or semiautomatic welding gun are also electrically hot 1 d Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close...

Страница 3: ...g 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 readi...

Страница 4: ..._____________________________ 7 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from va...

Страница 5: ...es 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 pantalons sans revers et chaussures mont...

Страница 6: ...cedure D 1 Preventive maintenance D 2 Theory of Operation Section E Power Supply Operation E 1 Field Effect Transistor FET Operation E 5 Pulse Width Modulation E 6 Protective Circuits E 7 Troubleshoot...

Страница 7: ...Ground Connections A 3 Input Power Cord Connection A 3 Input Power Connection A 3 Input Fuse and Supply Wires A 3 Input Voltage Reconnect Procedure A 3 Output Connections A 4 Work and Electrode Cable...

Страница 8: ...0133 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...

Страница 9: ...unding terminal located on the bottom of the input connection box to a good electrical earth ground TILTING Place machine directly on a secure level surface or on a recommended undercarriage The machi...

Страница 10: ...able sizes Fuse input circuit with recommended super lag fuses or delay type circuit breakers Install proper fuse in fuse holder in reconnect panel See Specifications at beginning of this chapter INPU...

Страница 11: ...ug included with the machine is designed to accept a welding cable size of 1 0 to 2 0 1 Remove 1 in 25mm of welding cable insulation 2 Slide rubber boot onto cable end Boot end may be trimmed to match...

Страница 12: ...ational Features and Controls B 2 Welding Capability B 2 Limitations B 2 Controls and Settings B 2 Welding Operation B 4 Auxillary Power B 5 Overload Protection B 5 Section B TABLE OF CONTENTS OPERATI...

Страница 13: ...und Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explo...

Страница 14: ...or constant current outputs The V300 I is designed for 50 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 w...

Страница 15: ...tests with resistive loads should be done in this mode with Arc Force Control set to minimum CV FCAW This setting has been optimized for Innershield and Outershield flux cored elec trodes 1 XX refers...

Страница 16: ...0 1 DC TIG starter An electrode cable work cable TIG torch and gas sup ply are required Refer to Accessories section of this manual METER POLARITY SWITCH The switch is located on the control panel at...

Страница 17: ...by a 2 5 amp circuit breaker with a reset button locat ed on the rear control panel The 24 42 and 115 VAC supplies must not be loaded at the same time NOTE 110 115 VAC is not available on Codes 9827...

Страница 18: ...C Return to Master TOC Return to Master TOC Accessories Section C Options Accessories C 1 Connecting a LN 25 Wire Feeder C 2 Connecting a LN 7 Wire Feeder C 4 Connecting a LN 9 GMA Wire Feeder C 6 Con...

Страница 19: ...its remote control circuitry to a 6 pin receptacle and to a 14 pin receptacle Adapter permits remote output control of Invertec by means of K857 Remote Control K812 Hand Amptrol or K870 Foot Amptrol A...

Страница 20: ...d 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 SHO...

Страница 21: ...S I Z E D F O R C U R R E N T A N D D U T Y C Y C L E O F A P P L I C A T I O N N B D I A G R A M S H O W S E L E C T R O D E P O S I T I V E T O C H A N G E P O L A R I T Y T U R N P O W E R O F F R...

Страница 22: ...ified 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...

Страница 23: ...Y E L E C T R O D E C A B L E T O L N 7 T O W O R K 1 4 P I N A M P H E N O L S P A R E 8 2 8 1 4 2 4 1 3 1 3 2 2 4 2 1 G N D 7 5 7 6 7 7 3 1 3 2 2 4 2 1 G N D N C K 2 9 1 O R K 4 0 4 I N P U T C A B...

Страница 24: ...ING Turn off input power to the Welding Power Source Before connecting the wire feeder ELECTRIC SHOCK CAN KILL N A W E L D I N G C A B L E M U S T B E S I Z E D F O R C U R R E N T A N D D U T Y C Y C...

Страница 25: ...N P O W E R O F F R E V E R S E E L E C T R O D E A N D W O R K C A B L E A T P O W E R S O U R C E S E T M E T E R P O L A R I T Y S W I T C H O N R E A R O F I N V E R T E C T O C O I N C I D E W I...

Страница 26: ...5 5 A M P 1 1 5 V A C 2 A M P I N V E R T E C F R A M E C O N N E C T I O N N D N D F O R W I R E F E E D E R S T H A T R E T U R N A S I G N A L F O R W E L D I N G O U T P U T U S E I S O L A T I O...

Страница 27: ...A L L I N G P L U G S O N C A B L E S O R W H E N C O N N E C T I N G O R D I S C O N N E C T I N G P L U G S T O W E L D I N G P O W E R S O U R C E S T R A I G H T P L U G 1 4 P I N T O P O W E R S...

Страница 28: ...ssories K867 K775 K843 and K812 or K870 are required In this configuration K775 remote control sets the upper current limit of K812 hand Amptrol or K870 foot Amptrol See connection diagram S19432 3 Co...

Страница 29: ...se 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 I N O U T K 9 0 0 1 T O T I G T O R C H K 8 1 2 H A...

Страница 30: ...the other This will minimize nuisance feed back conditions In general more than two machines in parallel will not be effective due to voltage requirements of procedures in that power range 1 Set machi...

Страница 31: ...performing preventative maintenance perform the follow ing capacitor discharge procedure to avoid electric shock Only qualified personnel should perform this maintenance Turn the input power OFF at th...

Страница 32: ...capaci tor on each side of machine 8 Check voltage across terminals of all capacitors with a DC voltmeter Polarity of capacitor terminals is marked on PC board above terminals Voltage should be zero...

Страница 33: ...ding should be 500 000 ohms or more If meter reading is less than 500 000 ohms check for electrical com ponents that are not properly insulated from the case Correct insulation if need ed 7 Replace ma...

Страница 34: ...C Return to Master TOC Return to Master TOC D 3 MAINTENANCE 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 IN...

Страница 35: ...r TOC Return to Master TOC INVERTEC V300 I Theory of Operation Section Section E Power Supply Operation E 1 Field Effect Transistor FET Operation E 5 Pulse Width Modulation E 6 Protective Circuits E 7...

Страница 36: ...and connect the auxil POWER SUPPLY OPERATION FIGURE E 1 INPUT POWER CIRCUITS 1 OR 3 DETETCTION H5 LINE SWITCH INPUT RECTIFIER AC1 AC2 AC3 A LEAD AUXILIARY TRANSFORMER TO WIREFEEDER 18VAC 24VAC POWERBO...

Страница 37: ...nput filter capacitors The Protection Board monitors the capacitors for voltage balance and or overvoltage and will de energize the input relays and precharge circuitry if either occurs The machine ou...

Страница 38: ...nt flow through the main transformer primary and the offset timing of the Switch Boards induce an AC square wave output signal at the secondary of the main trans former The DC current flow through eac...

Страница 39: ...t terminals and fed to the Control Board The Control Board also monitors the panel controls to deter mine which weld process is being employed and how the output should be controlled to optimize weldi...

Страница 40: ...s as long as the gate signal is present This is similar to turning on a light switch An FET is a type of transistor FETs are semiconductors well suited for high fre quency switching Drawing A above sh...

Страница 41: ...he more dark area under the curve the more power is present The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the positive and negative portions of the cycl...

Страница 42: ...The fan 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...

Страница 43: ...rigger Circuit Test F 35 Thermal Protection AC Trigger Circuit Test F 41 Control Board Test F 46 Power Board Test F 47 Capacitor Replacement F 50 Switch PC Board Replacement F 54 Test After Repair of...

Страница 44: ...ur problem All the needed test specifications and repair procedures are described in detail on the referenced pages All the needed electrical test points terminal strips junctions etc can be found on...

Страница 45: ...hot parts WARNING 4 Test the machine to determine if the fail ure symptom has been corrected by the replacement PC board NOTE Allow the machine to heat up so that all electrical components can reach...

Страница 46: ...eing used Check continuity of 3 amp slow blow fuse located on reconnect panel Output Terminal Switch or Remote Trigger MUST be in ON position Local Remote Switch must be in LOCAL position unless remot...

Страница 47: ...ltages 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 Test or replace Output Remote Control Devic...

Страница 48: ...and input voltage reconnect proce dures See Installation section of this manual Normal operation Nothing is wrong Check input voltage and input volt age reconnect procedures See Installation section...

Страница 49: ...2 VDC and output is extremely low or no output POSSIBLE AREAS OF MISADJUSTMENT S Local Remote Switch must be in LOCAL position unless Remote Control device is attached to remote receptacle POSSIBLE AR...

Страница 50: ...DRY Try welding with another electrode from a different container Make sure you have the correct electrode for your application Check input lines and connections Check input voltage and reconnec tion...

Страница 51: ...four screws that attach the Control Panel to the frame TEST DESCRIPTION The Output Pilot Circuit Test determines if the Fan Thermostat Choke Thermostat Transformer T1 and Output Terminal Switch S4 are...

Страница 52: ...itch S4 Go to step 8 b If 0 VAC is measured test is not OK Test each of the following compo nents Fan Thermostat Choke Thermostat Transformer T1 and Output Terminal Switch S4 4 Position the Control Pa...

Страница 53: ...ter TOC F 10 TROUBLESHOOTING REPAIR 8 Test for 15 VDC between leads 302 and 275D a If 15 VDC is measured test is OK for 15 VDC Power Supply and Trans former T1 Go to Protection Board Output Test b If...

Страница 54: ...resistors As the through bolts are removed care fully place the resistors and the connect ed wires to the side TEST PROCEDURE 1 Turn main power OFF 2 Perform Input Filter Capacitor Discharge procedur...

Страница 55: ...ter TOC Return to Master TOC F 12 TROUBLESHOOTING REPAIR 5 Remove the two screws attaching the Protection Board Input Rectifier bracket to main assembly bracket 6 Tilt the top of the Protection Board...

Страница 56: ...position on Control Panel 7 With power OFF disconnect J8 and attach voltage probes into back of wire harness lead junction block J8 See Figure F 7 Insert probes into back of the connec tion cavities...

Страница 57: ...ction Board is OK If voltage is greater than 14 VDC Protection Board is faulty See Figure F 28 10 Test for less than 1 VDC between leads 313 and 311 a If less than 1 VDC is measured test is OK and Pro...

Страница 58: ...ve Output Terminal Switch S4 to REMOTE OFF position NOTE This test should only be conducted when the machine reconnect switch and jumper are set for high voltage above 380 VAC and the proper line volt...

Страница 59: ...16 TROUBLESHOOTING REPAIR 2 Test VDC across terminals 9 and 12 of one Switch Board and repeat the test for the other Switch Board See Table F 1 in this procedure for expected voltage readings NOTE Fo...

Страница 60: ...s C1 C2 C14 and C15 and Resistors R1 and R9 3 Record VDC measured for each Switch Board and determine the difference in VDC NOTE The following measurements should result based on VAC input TABLE F 1 E...

Страница 61: ...just the output control to the minimum setting Place the mode control at the SMAW soft position NOTE This test should only be conducted when the machine reconnect switch and jumper are set for high vo...

Страница 62: ...st these PC boards and replace if needed 2 Test VDC across terminals 9 and 12 of one Switch Board and repeat the test for the other Switch Board NOTE For 575 VAC ONLY compare voltage across 9A and 13...

Страница 63: ...ly In addition it is dangerous to work on these boards with machine power ON LOCATION There are two Switch Boards One is located on each side of the machine FUNCTION The Switch Boards are designed to...

Страница 64: ...lacement procedure 5 If the Switch Boards appear to be burned or overheated or if the machine was supplied by a 380 VAC or higher voltage supply when the failure occurred replace the Capacitors and th...

Страница 65: ...than Open Replace both Snubber Test 1K ohm Switch Boards 9 4 5 Greater than OK None Continue 1K ohm Less than Shorted Replace both Snubber Test 100 ohms Switch Boards 4 5 9 Less than OK None Continue...

Страница 66: ...ult Conclusion 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 Contin...

Страница 67: ...m Input Filter Capacitor Discharge procedure detailed in Maintenance sec tion 3 Locate and gain access to the Switch Board 4 Remove leads from terminals 401 402 403 and 404 on Switch Board MATERIALS N...

Страница 68: ...esistor R4 is OK b If 30 ohms or more is measured Resistor R4 is faulty and must be replaced SNUBBER RESISTORS TEST continued FIGURE F 14 SWITCH BOARD TEST POINTS L8604 1 SWITCH 401 12 Check Test Resu...

Страница 69: ...SHOOTING REPAIR TEST PROCEDURE 1 Perform Input Filter Capacitor Discharge procedure detailed in Maintenace sec tion ELECTRIC SHOCK can kill Observe all safety precautions detailed throughout this manu...

Страница 70: ...Output Diodes are OK b If less than 100 ohms measured an Output Diode is shorted Test all Output Diodes D 1 thru D 12 indi vidually 3 Remove any output load 4 Test for more than 200 ohms resistance be...

Страница 71: ...I wiring diagrams TEST PROCEDURE 1 Perform Input Filter Capacitor Discharge procedure detailed in Maintenance sec tion 2 Locate Input Rectifier Component D 13 3 Locate leads needed to perform tests s...

Страница 72: ...nent D13 when any of tests A L are not OK NOTE When installing new Input Rectifier torque mounting nuts in a cross tightening pattern to 6 inch pounds 7 Nm Torque terminals to 26 inch pounds 3 Nm ALWA...

Страница 73: ...n 225 275 amps for single phase The functioning circuit will reduce the output amperage to approximately 200 amps in three phase operation 100 190 amps sin gle phase when overcurrent loading is detect...

Страница 74: ...urn to Master TOC F 31 TROUBLESHOOTING REPAIR TEST PROCEDURE 1 Perform Input Filter Capacitor Discharge procedure detailed in Maintenance sec tion 2 Remove front panel from machine to access Control B...

Страница 75: ...TOC F 32 TROUBLESHOOTING REPAIR 4 Turn main power ON 5 Test for 15 VDC between leads 302 and 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...

Страница 76: ...erform Input Filter Capacitor Discharge procedure detailed in Maintenance sec tion Test resistance between pin 1J3 and black lead from Control Board to shunt See Figure F 22 a If zero ohms resistance...

Страница 77: ...Board should be replaced 8 Test resistance between pin 2J3 to white lead from Control Board to shunt a If zero ohms resistance continuity is shown test is OK See note below b If resistance of any val...

Страница 78: ...lied to the Input Filter Capacitors If an overvoltage is sensed from conditions such as misconnections or line surges the Output Trigger Circuit and the Input Power Relays are opened caus ing the mach...

Страница 79: ...main power ON 6 Move the Output Terminal Switch S4 to the ON position closed TEST PROCEDURE 1 Turn main power OFF 2 Perform Input Filter Capacitor Discharge procedure detailed in Maintenance sec tion...

Страница 80: ...o Master TOC Return to Master TOC F 37 TROUBLESHOOTING REPAIR 7 Test for 0 VDC between leads 311 and 313 on Protection Board a If 0 1 VDC is present the Protection Board is OK Go to step 8 b If 15 VDC...

Страница 81: ...operly b If 15 VDC is present go to step 10 8 Test for 15 VDC supply voltage between leads 302 and 275D on Power Board a If 15 VDC is present test is OK Go to step 9 b If 15 VDC is not present the Pow...

Страница 82: ...TOC F 39 TROUBLESHOOTING REPAIR 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 properly b If 15 VDC is pre...

Страница 83: ...test Capacitor balance Refer to Static and Dynamic Capacitor Balance Tests OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST continued FIGURE F 28 OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT THESE LEADS AR...

Страница 84: ...e choke thermostat will open the normally closed output trigger circuit if overheating occurs due to excessive output loading and or excessive duty cycle The fan thermostat will open the normally clos...

Страница 85: ...Turn main power OFF 2 Perform Input Filter Capacitor Discharge procedure detailed in Maintenance sec tion 3 Detach the following PC boards so you can gain access to and have ample room to perform the...

Страница 86: ...T1 and leads used for test See Figure F 30 5 Turn main power ON THERMAL PROTECTION AC TRIGGER CIRCUIT TEST continued FIGURE F 30 THERMAL PROTECTION AC TRIGGER CIRCUIT CONTROL BOARD POWER BOARD T1 11J...

Страница 87: ...VAC is present test input voltage to Auxiliary Transformer c If input voltage to Auxiliary Transfor mer is correct replace Auxiliary Transformer d If input voltage to Auxiliary Transfor mer is not co...

Страница 88: ...32 THERMAL PROTECTION AC TRIGGER CIRCUIT CONTROL BOARD POWER BOARD T1 11J4 EXTERNAL TRIGGER S4 OUTPUT TERMINAL SWITCH FAN THERMOSTAT CHOKE THERMOSTAT PART OF 14 PIN AMPHENOL NORMALLY CLOSED NOTE WHEN...

Страница 89: ...ction problems FUNCTION The Control Board monitors the panel controls to determine which weld process is being employed and how the out put should be controlled to optimize welding results The Control...

Страница 90: ...er Board is probably OK NOTE If there is still a possibility that the Power Board is faulty go to Test B b If audible click of control relay con tacts closing is not heard Power Board could be faulty...

Страница 91: ...C Return to Master TOC F 48 TROUBLESHOOTING REPAIR 4 Detach Control Panel by removing the four mounting screws Move the panel to the left to gain access to the Power Board 5 Turn main power ON Test B...

Страница 92: ...red Power Board is OK b If 15 VDC output is not measured replace Power Board 6 Test for 18 VAC input from Auxiliary Transformer between leads 504 and 501 J7 on Power Board a If 18 VAC is measured inpu...

Страница 93: ...ust always be replaced in matched sets C1 and C2 as a set or C1 C2 C14 and C15 as a set on 575 VAC machines When replacing Capacitors remove the entire FET heat sink assembly including Capacitors and...

Страница 94: ...o Master TOC F 51 TROUBLESHOOTING REPAIR 2 Place the machine on its side as shown in Figure F 38 Slide the plastic insula tors that go through the base of the machine to one side Pull the through bolt...

Страница 95: ...C Return to Master TOC F 52 TROUBLESHOOTING REPAIR 4 Loosen the set screw of the Capacitor clamp ring and remove the Capacitor from the clamp ring See Figure F 40 3 Remove the two 7 16 hex nuts that h...

Страница 96: ...ity must be noted when attaching the capacitor to the Switch Board assembly 5 Install the new Capacitor and tighten the two 7 16 hex nuts to a torque of 55 inch pounds 6 Nm Tighten these nuts in incre...

Страница 97: ...rd is defective both Switch Boards must be replaced at the same time In addition to replacing the Switch Boards Capacitors C1 and C2 plus C14 and C15 on 575 VAC models must also be replaced if the fol...

Страница 98: ...lways make sure that Switch Boards are changed in matched pairs Never mix an old style different part num ber Switch Board with a new style new part number 3 Remove the two 7 16 head Capacitor screws...

Страница 99: ...nd 12 of one Switch Board The meter will show the Capacitors charging up and may take a minute or so to stabilize The final meter reading should not exceed 8600 ohms 8 6 on the scale TEST AFTER REPAIR...

Страница 100: ...ly fuse holders 13 Install 20 amp fuses and test under load NOTE A resistive type grid load bank is recommended 14 Perform Retest After Repair 8 Turn on the machine 9 With the output free of a load ch...

Страница 101: ...o a torque of 25 inch pounds 3 Nm 1 Turn main power OFF 2 Perform Input Filter Capacitor Discharge procedure detailed in Maintenance sec tion 3 Detach and remove both Switch Boards and attached capaci...

Страница 102: ...for a long period of time many months Then The Input Filter Capacitor Protection Circuit could have been activated and prevented output This means the Input Filter Capacitors must be conditioned The I...

Страница 103: ...5 460 60 1 50 450 380 50 or 60 1 67 425 575 60 INPUT IDLE AMPS AND IDLE WATTS Min Acceptable Max All Modes V300 I V300 PRO 1 phase 200A 380V 220 440V 208V 230 460V 575V 38V 38V 36V 3 phase 300A 32V 36...

Страница 104: ...INVERTEC V300 I 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 F 61 NOTES...

Страница 105: ...oard G 4 Switch Board G 8 Power Board G 10 Driver Board L8660 1 G 12 Driver Board L9134 1 G 13 Wiring Diagrams Code 9826 G 14 Code 9827 G 15 Code 10036 G 16 Code 10037 G 17 Code 10132 G 18 Code 10133...

Страница 106: ...ty for liabilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not avail able from Lincoln Electri...

Страница 107: ...rmet trmr 25W 1 5K ohm R14 RESISTOR MF 25W 1 100K ohm R15 RESISTOR MF 25W 1 475 ohm R18 R26 R28 R32 RESISTOR MF 25W 1 10K ohm R19 RESISTOR MF 25W 1 3 32K ohm R21 R23 R24 R25 RESISTOR MF 25W 1 15K R29...

Страница 108: ...no responsibility for liabilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not avail able from...

Страница 109: ...3V 5 1N4755A J1 RECEPTACLE Molex mini 8 pin J2 RECEPTACLE Molex mini 4 pin J3 RECEPTACLE Molex mini 2 pin J4 RECEPTACLE Molex mini 12 pin J5 RECEPTACLE Molex mini 14 pin OCI1 OPTOCOUPLER Photo Q 70V C...

Страница 110: ...ISTOR MF 25W 1 24 3K R82 R120 R128 RESISTOR MF 25W 1 301 R83 RESISTOR MF 25W 1 267K R95 TRIMMER ST 50W 10 10K linear R96 RESISTOR MF 25W1 825 R131 RESISTOR MF 25W 1 68 1K R146 RESISTOR MF 25W 1 28 0K...

Страница 111: ...G 7 NOTES INVERTEC V300 I 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...

Страница 112: ...abilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not avail able from Lincoln Electric This in...

Страница 113: ...hm R2 R4 RESISTOR MF 25W 1 221 ohm R6 R8 R9 R17 R19 RESISTOR MF 25W 1 10 0 ohm R25 R26 R27 R33 R34 R7 R30 RESISTOR MF 25W 1 1 50K ohm R10 R32 RESISTOR MF 25W 1 15 0K ohm R11 R15 R22 R28 RESISTOR CC 50...

Страница 114: ...responsibility for liabilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not avail able from Li...

Страница 115: ...R27 10K 1 4W R5 R6 R10 R22 100K 1 4W R4 1 5K 1 4W R14 R41 15K 1 4W R9 1150K 1 4W R21 2 21K 1 4W R3 243 1 4W R7 R8 R24 267 1 4W R2 2 67K 1 4W R18 26 7K 1 4W R20 267K 1 4W R13 R15 R16 R17 33 2K 1 4W R23...

Страница 116: ...WW 20W 5 250K R3 R4 R5 R6 R8 R9 RESISTOR MF 25W 1 150K R7 R12 RESISTOR MF 25W 1 100K T1 TRANSFORMER PCB NOTE Individual parts listed are not available from Lincoln Electric DRIVER BOARD L8660 R 1 3 R...

Страница 117: ...X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X L 9 1 3 4 NOTE Lincoln Electric assumes no responsibility for liabilities resulting from board...

Страница 118: ...2 1 0 2 7 5 A 1 3 4 2 1 2 5 0 2 2 1 5 3 0 6 5 9 2 2 3 B 5 0 2 Y S 5 M E T E R F U N C T I O N S W I T C H 3 0 1 D 6 D 4 D 5 J 5 J 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...

Страница 119: ...5 M E T E R F U N C T I O N S W I T C H 3 0 1 D 6 D 4 D 5 J 5 J 6 D 1 1 D 1 2 D 1 0 D 9 D 8 D 7 N E 2 2 4 2 1 0 6 A M P H 2 H 3 H 4 A 1 2 B 9 B 9 B R 9 1 2 C 9 A 5 3 1 2 A 9 C H 5 3 1 1 2 7 5 F 3 0 6...

Страница 120: ...4 5 0 V N G N F N G 2 2 0 0 F 4 5 0 V 224 T P 6 2 1 2 A 2 1 2 B R E M O T E O N S 4 O U T P U T T E R M I N A L S W I T C H 2 1 2 B 2 1 2 2 2 3 B 2 1 2 C 1 5 0 5 W F A N T H E R M O S T A T H 2 H 3 H...

Страница 121: ...2 1 2 A 2 1 2 B R E M O T E O N S 4 O U T P U T T E R M I N A L S W I T C H 2 1 2 2 2 3 B 2 1 2 C 1 5 0 5 W F A N T H E R M O S T A T H 2 H 3 H 4 F B O T T O M A U X S F B O T T O M F S T O P A U X F...

Страница 122: ...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 N S U L A T I O N F O R T H R E E P...

Страница 123: ...D W I T H T A P E T O P R O V I D E 6 0 0 V I N S U L A T I O N F O R T H R E E P H A S E I N P U T G R O U N D M A C H I N E P E R N A T I O N A L A N D L O C A L E L E C T R I C A L C O D E S C O N...

Страница 124: ...G F E J A I K C D M L B N H 7 5 7 6 7 7 3 1 3 2 4 1 4 2 2 4 8 1 8 2 2 1 4 2 V A C R E M O T E C O N T R O L R E C E P T A C L E T R I G G E R 2 1 2 2 1 2 3 2 4 2 2 1 2 1 2 C B 1 C B 2 2 2 3 B 2 1 2 C...

Страница 125: ...roubleshooting PC Board repairs will invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s specific PC...

Страница 126: ...roubleshooting PC Board repairs will invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s specific PC...

Страница 127: ...C O N N E C T I O N I N V E R T E C V 3 0 0 L 4 2 1 0 M F D 4 4 0 2 4 0 4 POSITIVE 1N4936 D 4 1W 15V D Z 4 4 7 5 R 1 8 10 0 R 9 10 0 R 8 10 0 R17 10 0 R 3 3 C 7 10 0 R 6 RESISTOR S N U B B E R P O W E...

Страница 128: ...t 5 6 R15 1W 4 3 V DZ11 1W 3 9 0 R 3 5 J 4 11 CIRCUIT D12 CNY17 3 OCI1 4 2 1 6 5 22 1K R12 5 0 0 m W 3 V DZ1 5 0 V 2 0 C11 2 6 7 R11 47 5K R 7 2 67K R144 15V B B O A R D D14 22 1K R133 100 2 0 V C 7...

Страница 129: ...ubleshooting PC Board repairs will invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s specific PC b...

Страница 130: ...leshooting PC Board repairs will invalidate your factory warranty This Printed Circuit Board schematic is provided for reference only It may not be totally applicable to your machine s specific PC boa...

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