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Lincoln Electric INVERTEC V300-PRO SVM105-B Service Manual

Lincoln electric welder user manual.

 
RETURN TO MAIN MENU
SVM105-B
April, 2007
INVERTEC V300-PRO
For use with machines having Code Number : 9825 THRU 10450
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 thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
SERVICE MANUAL
Copyright © 2007 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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Summary of Contents

  • Page 1

    RETURN TO MAIN MENU SVM105-B April, 2007 INVERTEC V300-PRO For use with machines having Code Number : 9825 THRU 10450 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 .

  • Page 2

    Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

  • Page 4

    WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

  • Page 5

    PRÉCAUTIONS 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.

  • Page 6

    RETURN TO MAIN MENU MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety ............i-iv Installation .

  • Page 7: Table Of Contents

    Section A-1 TABLE OF CONTENTS Section A-1 - 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 V300-PRO...

  • Page 8

    TECHNICAL SPECIFICATIONS - V300-PRO (K1349-3, K1349-4) THREE PHASE Standard Input Current Voltage at Rated Output 208/230/460/575 48/43/24/20 50/60 THREE PHASE Duty Cycle Amps 60% Duty Cycle 100% Duty Cycle THREE PHASE Welding Constant Open Current Range Circuit Voltage 5-300 Amps 60-70 VDC RECOMMENDED INPUT WIRE AND FUSE SIZES THREE PHASE...

  • Page 9

    • If voltage peaks from the engine welder are too high (380v on 230v setting), the input circuits of this machine protecting the filter capacitors, FETS and other components from damage will not be ener- gized.

  • Page 10

    POWER INPUT CONNECTION Connect terminal marked to earth ground per any existing local or national electrical codes. Single Phase Input Connect the supply lines to the upper and lower termi- nals of the line switch. Torque to 27.5in.-lbs.(3.0 Nm). Do not use center terminal of the line switch. Three Phase Input Connect the supply lines to the line switch.

  • Page 11

    LN-9 GMA Connection Instructions (Not applicable to machines with only 42V Aux.) 1. Turn the Invertec power switch “off”. 2. Connect the K596 or K1820-10 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.

  • Page 12

    OUTPUT CABLES Select the output cable size based upon the following chart. Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75° rated: Duty Length Up Cycle Current 61m (200 ft.) 100% QUICK DISCONNECT PLUGS (K852-7) A quick disconnect system is used for the welding cable connections.

  • Page 13

    Section B-1 TABLE OF CONTENTS Section B-1 - OPERATION SECTION - Operation ...Section B Operating Instructions ... B-2 Controls and Settings ... B-2, B-4 Auxillary Power ... B-4 V300-PRO...

  • Page 14

    OPERATING INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. ------------------------------------------------------------------------ FUMES AND GASES can be dangerous. •...

  • Page 15

    MODE SWITCH GTAW Optimized for both scratch start and Hi- Freq kit use. CC SOFT Best for EXX18 thru EXX28 stick elec- trodes. CC Crisp Use this mode for stick welding with EXX10 thru EXX14 electrodes. Non- welding applications such as resistive heating or output tests with resistive loads should be done in this mode with Arc Force Control set to minimum.

  • Page 16

    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 posi- tion of the electrode polarity indicated by the decal. The switch does not change the welding polarity.

  • Page 17

    Section C-1 TABLE OF CONTENTS Section C-1 - ACCESSORIES SECTION - Accessories ...Section C Options/Accessories...C-2 V300-PRO...

  • Page 18

    OPTIONS / ACCESSORIES CABLE PLUGS Cable Plug Kit for 1/0-2/0 cable (K852-70) attaches to welding cable to provide quick disconnect from machine. Cable Plug Kit for 2.0-3/0 cable (K852-95). NOTE: Two K852-70 plugs are included with the V300-I. K864 REMOTE CONTROL ADAPTER Plugs into the 14-pin receptacle on the rear panel of the Invertec.

  • Page 19

    Section D-1 TABLE OF CONTENTS Section D-1 - 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 V300-PRO...

  • Page 20

    WARNING Failure to follow this capacitor discharge procedure can result in electric shock. 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 each side and 2 screws on top) and remove wrap-around machine cover.

  • Page 21

    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. Remove the machine wrap-around cover and per- form the input filter capacitor discharge procedure (detail at the beginning of this chapter).

  • Page 22

    FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS. COMPONENT QTY, PC BOARDS CONTROL DRIVER PROTECTION SWITCH POWER INPUT RECTIFIER POWER SWITCH HEAT SINK FINS MAIN TRANSFORMER OUTPUT STUDS INPUT FILTER CAPACITORS MAINTENANCE ITEM V300-PRO...

  • Page 23

    Section E-1 - THEORY OF OPERATION SECTION - Theory of Operation ...Section E Power Supply Operation ...E-2 Pre Charge and Protection Circuitry ...E-3 Switch Board and Main Transformer...E-4 Control and Output Circuitry ...E-5 Field Effect Transistor (FET) Operation ...E-6 Pulse Width Modulation ...E-7 Protective Circuits ...E-8 FIGURE E.1 –...

  • Page 24

    THEORY OF OPERATION 1ø OR 3ø DETETCTION (H5) PRE-CHARGE INPUT DRIVER LINE RECTIFIER BOARD SWITCH PULSE TRAIN A-LEAD 24VDC PRE-CHARGE AUXILIARY TRANSFORMER 2ND STEP PWM 18VAC POWERBOARD 24VAC WIREFEEDER 15VDC-CONTROL BOARD FUNCTION VOLTAGE 24VAC-THERMOSTATS-GUN TRIGGERING INPUT LINE VOLTAGE & AUXILIARY TRANSFORMER The V300-PRO can be connected for a variety of three phase or single phase input voltages.

  • Page 25

    THEORY OF OPERATION FIGURE E-3 ---PRECHARGE & PROTECTION CIRCUITS 1ø OR 3ø DETETCTION (H5) PRE-CHARGE INPUT DRIVER LINE RECTIFIER SWITCH BOARD PULSE TRAIN A-LEAD 24VDC PRE-CHARGE AUXILIARY TRANSFORMER 2ND STEP PWM 18VAC POWERBOARD 24VAC WIREFEEDER 15VDC-CONTROL BOARD FUNCTION VOLTAGE 24VAC-THERMOSTATS-GUN TRIGGERING PRECHARGE &...

  • Page 26

    THEORY OF OPERATION FIGURE E-4 ---SWITCH CIRCUITS & TRANSFORMER 1ø OR 3ø DETETCTION (H5) PRE-CHARGE INPUT DRIVER LINE RECTIFIER SWITCH BOARD PULSE TRAIN A-LEAD 24VDC PRE-CHARGE AUXILIARY TRANSFORMER 2ND STEP PWM 18VAC POWERBOARD 24VAC WIREFEEDER 15VDC-CONTROL BOARD FUNCTION VOLTAGE 24VAC-THERMOSTATS-GUN TRIGGERING SWITCH BOARDS The Switch Boards contain the the Field Effect Transistors (FETs) which, when switched ON, supply...

  • Page 27

    THEORY OF OPERATION FIGURE E-5 --OUTPUT & CONTROL CIRCUITS 1˘ OR 3˘ DETETCTION (H5) PRE-CHARGE INPUT DRIVER LINE RECTIFIER BOARD SWITCH PULSE TRAIN A-LEAD 24VDC PRE-CHARGE AUXILIARY TRANSFORMER 2ND STEP PWM 18VAC POWERBOARD 24VAC WIREFEEDER 15VDC-CONTROL BOARD FUNCTION VOLTAGE 24VAC-THERMOSTATS-GUN TRIGGERING OUTPUT AND CONTROL CIRCUITS The AC output of the transformer is changed to DC by the Output Rectifier.

  • Page 28

    THEORY OF OPERATION FIELD EFFECT TRANSISTOR OPERATION SOURCE TERMINAL SOURCE (N) SOURCE (N) An FET is a type of transistor. FETs are semiconduc- tors well suited for high-frequency switching because they are capable of going from full off to full on much more quicklfy than other types of semi-conductors.

  • Page 29

    THEORY OF OPERATION PULSE WIDTH MODULATION FIGURE E.6 — TYPICAL FET OUTPUTS. The term PULSE WIDTH MODULATION is used to describe 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.

  • Page 30

    340 to 360 amps, an electronic protec- tion circuit will reduce the current to approximately 150 amps. Lincoln Electric refers to this current reduction as “Fold Back.” The machine will continue to produce this low current until the protection circuit is reset by removing the load.

  • Page 31

    Section F-1 - TROUBLESHOOTING & REPAIR SECTION - Troubleshooting & Repair Section ...Section F How to Use Troubleshooting Guide...F-2 PC Board Troubleshooting Procedures and Replacement...F-3 Additional Troubleshooting Procedures ...F-4 Troubleshooting Guide ...F-5 Test Procedures Input Filter Capacitor Discharge Procedure ...F-11 Output Pilot Circuit Test ...F-13 Protection Board Output Test...F-17 Capacitor Balance Test ...F-21...

  • Page 32

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION Step 3.

  • Page 33

    - If the PC board uses protective shorting jumpers, don’t remove them until installation is complete. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static- shielding bag. This will prevent further damage and allow proper failure analysis.

  • Page 34

    TROUBLESHOOTING & REPAIR ADDITIONAL INFORMATION OSCILLOSCOPE WARNING Do not use oscilloscopes and other pieces of test equipment that are powered by 115 VAC. This equipment should not be used with inverter-type machines, such as Invertec V300-PRO. There are high voltages present, which are “floating” off case ground (floating ground). Connecting the ground lead of a test probe (which may be connected to the case of the test equipment) to a high voltage potential presents a shock hazard as well as the possibility of damage to the equip- ment in question.

  • Page 35

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. detailed in the beginning of this manual.

  • Page 36

    LOCAL control. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. detailed in the beginning of this manual.

  • Page 37

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. detailed in the beginning of this manual.

  • Page 38

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. detailed in the beginning of this manual.

  • Page 39

    230 VAC or lower. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 40

    F-10 NOTES F-10 V300-PRO...

  • Page 41

    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.

  • Page 42

    F-12 TROUBLESHOOTING & REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (cont.) WARNING Failure to follow this capacitor discharge procedure can result in electric shock. 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 each side and 2 screws on top) and remove wrap-around machine cover.

  • Page 43

    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.

  • Page 44

    F-14 TROUBLESHOOTING & REPAIR OUTPUT PILOT CIRCUIT TEST(cont.) TEST PROCEDURE 1. Turn Input Power Switch OFF 2. 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.

  • Page 45

    F-15 TROUBLESHOOTING & REPAIR OUTPUT PILOT CIRCUIT TEST (cont.) FIGURE F.3 – CONTROL BOARD TEST POINTS G2527 7. Measure voltage from Lead #210 (J2/Pin 4) to Lead # 223A (J4/Pin 11). a. If voltage is 24v.a.c., thermostats, transfor mer T1 and switch (S4) are OK. Go on to Step 8.

  • Page 46

    F-16 NOTES F-16 V300-PRO...

  • Page 47

    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.

  • Page 48

    F-18 TROUBLESHOOTING & REPAIR PROTECTION BOARD OUTPUT TEST(cont.) TEST PROCEDURE 1. TURN POWER SWITCH OFF 2. Remove sheetmetal wraparound. 3. Perform Input Filter Capacitor Discharge procedure detailed in Maintenance section 4. Remove the two through bolts that attach the Power/Driver Board bracket to Protection/Input Rectifier bracket.

  • Page 49

    F-19 TROUBLESHOOTING & REPAIR PROTECTION BOARD OUTPUT TEST(cont.) TEST PROCEDURE 8. With power OFF, disconnect J8 and attach voltage probes into back of wire harness lead junction block (J8). See Figure F.5. Insert probes into back of the connection cavities for leads 313 (-) and 311 (+) of Protection Board.

  • Page 50

    F-20 TROUBLESHOOTING & REPAIR PROTECTION BOARD OUTPUT TEST(cont.) 275F 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.

  • Page 51

    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.

  • Page 52

    F-22 TROUBLESHOOTING & REPAIR CAPACITOR BALANCE TEST (cont.) STATIC CAPACITOR TEST TEST PROCEDURE: 1. With Output Terminal Switch S4 in REMOTE (OFF) position, turn Power Switch ON. 2. Test VDC across terminals 9 and 12 of one Switch Board (see Fig F.7). Repeat the test for the other Switch Board.

  • Page 53

    F-23 TROUBLESHOOTING & REPAIR CAPACITOR BALANCE TEST (cont.) FIGURE F.7 - SWITCH BOARD TEST POINTS 401/ L 8604-1 L8604-1 SWITCH SWITCH V300-PRO F-23 402/...

  • Page 54

    F-24 NOTES F-24 V300-PRO...

  • Page 55

    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.

  • Page 56

    F-26 TROUBLESHOOTING & REPAIR SWITCH BOARD TEST (cont.) TEST PROCEDURE 1. Disconnect power to the machine and perform Input Filter Capacitor Discharge Procedure as described in Section F. 2. Disconnect all wiring harness leads (401/403, 1/8, 9, 12, 4/5, 402/404) from the Switch Boards. 3.

  • Page 57

    F-27 TROUBLESHOOTING & REPAIR SWITCH BOARD TEST (CONT.) SWITCH BOARD RESISTANCE CHECKS Apply Positive Apply Negative Test Probe to Test Probe to Terminal Terminal NOTE: K ohm = ohm reading multiplied by 1000. NOTE: Always make sure that Switch Boards are changed in matched pairs. Never mix an old style (different part number) Switch Board with a newer style.

  • Page 58

    F-28 TROUBLESHOOTING & REPAIR SWITCH BOARD TEST (CONT.) SWITCH BOARD RESISTANCE CHECKS Apply Positive Apply Negative Test Prove to Test Probe to Terminal Terminal 401/403 401/403 402/404 402/404 TABLE F.3 Test Result Conclusion Repair Action Greater than OK None 1K ohm Less than Shorted Replace both...

  • Page 59

    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.

  • Page 60

    F-30 TROUBLESHOOTING & REPAIR SNUBBER RESISTOR TEST (cont.) FIGURE F.9 - SNUBBER RESISTOR TEST POINTS 401/ 1. Turn main Power off. 2. Perform Input Filter Capacitor Discharge proce- dure. 3. Remove leads 401,402 403 & 404 from theSwitch Boards. 4. Test for 25 ohms resistance from lead 401 to termi- nal 12 on Switch Board.

  • Page 61

    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.

  • Page 62

    F-32 TROUBLESHOOTING & REPAIR OUTPUT DIODE TEST (cont.) TEST PROCEDURE 1. Locate the Output Terminals on front panel. 2. Remove any cables from Output Terminals. 3. Test for more than 200 ohms resistance between positive and negative Output Terminals: meter lead to the positive terminal, negative meter lead to the negative terminal.

  • Page 63

    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.

  • Page 64

    F-34 TROUBLESHOOTING & REPAIR FIGURE F.11 - INPUT RECTIFIER LOCATION TEST PROCEDURE 1. Perform Input Filter Capacitor Procedure as detailed in this section. 2. Locate Input Rectifier (Component D-13). 3. Locate leads needed to perform tests shown in Figure F.11. 4.

  • Page 65

    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.

  • Page 66

    F-36 TROUBLESHOOTING & REPAIR OVERCURRENT PROTECTION CURRENT TRIGGER TEST (cont.) FIGURE F.12 - GETTING ACCESS TO CONTROL BOARD TEST PROCEDURE 1. Perform Input Filter Capacitor Procedure detailed in this section. 2. Remove front panel from machine to access Control Board. 3.

  • Page 67

    F-37 TROUBLESHOOTING & REPAIR OVERCURRENT PROTECTION CURRENT TRIGGER TEST (cont.) FIGURE F.14 - CONTROL BOARD TEST POINTS G2527 6. Turn main power OFF. 7. Perform Input Filter Capacitor Procedure detailed in this section. Test resistance of the Black and White leads from 1J3 and 2J3 to the shunt.

  • Page 68

    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.

  • Page 69

    F-39 TROUBLESHOOTING & REPAIR OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST (cont.) FIGURE F.16 - PC BOARDS REMOVED TEST PROCEDURE 1. Turn main power OFF. 2. Perform Input Filter Capacitor Discharge proce- dure detailed in Maintenance section. 3. Detach the following PC boards so you can gain access to and have ample room to perform the tests: (Do not disconnect from wiring harness.) •...

  • Page 70

    F-40 TROUBLESHOOTING & REPAIR OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST (cont.) FIGURE F.17 — PROTECTION BOARD TEST POINT 275F 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.

  • Page 71

    F-41 TROUBLESHOOTING & REPAIR OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST (cont.) FIGURE F.18 - POWER BOARD TEST POINTS 309 310 8. Test for 15 VDC supply voltage between leads 302 and 275D on Power Board. If 15 VDC is present, test is OK. Go to step 9. If 15 VDC is not present, the Power Board may be faulty.

  • Page 72

    F-42 TROUBLESHOOTING & REPAIR OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST (cont.) FIG. F.19 - OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT THESE LEADS ARE USED FOR MONITORING CAPACITOR VOLTAGES SEE TABLE 1 BELOW TABLE 1:INPUT VOLTS FOR 460 VOLTS AC LEADS NORMAL 325 VDC 52-53 325 VDC...

  • Page 73

    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.

  • Page 74

    F-44 TROUBLESHOOTING & REPAIR THERMAL PROTECTION AC TRIGGER CIRCUIT (cont.) FIGURE F.20 - PC BOARDS MOVED FOR ACCESS TEST PROCEDURE 1. Turn main power OFF. 2. Perform Input Filter Capacitor Discharge proce- dure detailed in this section. 3. Detach the following PC boards so you can gain access to and have ample room to perform the tests.

  • Page 75

    F-45 TROUBLESHOOTING & REPAIR THERMAL PROTECTION AC TRIGGER CIRCUIT (cont.) FIGURE F.21 - THERMAL PROTECTION AC TRIGGER CIRCUIT VOLTS #212D EXTERNAL #212B TRIGGER #212C #212A S4 OUTPUT TERMINAL SWITCH #223B PART OF 14 PIN AMPHENOL 4. Locate the Auxiliary Transformer T1 and leads used for test.

  • Page 76

    F-46 NOTES F-46 V300-PRO...

  • Page 77

    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.

  • Page 78

    F-48 TROUBLESHOOTING & REPAIR POWER BOARD TEST (cont.) TEST PROCEDURE NOTE: Perform Test A before disassembling the unit Test A 1. Turn main power OFF. 2. Position yourself at Switch Board area of the machine (near Case Back) so as to hear the oper- ation of the control relays.

  • Page 79

    F-49 TROUBLESHOOTING & REPAIR POWER BOARD TEST (cont.) FIGURE F.23 - POWER BOARD TEST POINTS 309 310 6. Test for 18 VAC input from Auxiliary Transformer between leads 504 and 501 (J7-pin 5 & pin 6) on Power Board. If 18 VAC is not correct, check the 3 amp fuse, the Auxiliary Transformer and associated wires.

  • Page 80

    F-50 TROUBLESHOOTING & REPAIR POWER BOARD TEST (cont.) FIGURE F.24 - SIMPLIFIED TRIGGER CICUIT POWER BOARD FROM PROTECTION BOARD OVERVOLTAGE STT II Only T1 AUXILIARY TRANSFORMER #379 #224 3J31 6J22 #503A POWER BOARD #212 2J31 SIMPLIFIED TRIGGER CIRCUIT CONTROL BOARD #301 11J4 #305...

  • Page 81

    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.

  • Page 82

    F-52 TROUBLESHOOTING & REPAIR CAPACITOR REMOVAL AND REPLACEMENT (cont.) PROCEDURE NOTE: When replacing capacitors, remove the entire FET Heat Sink Assembly as a unit. Remove and reassemble one side at a time, using the other side as a model to insure that all parts are reinstalled prop erly FIGURE F.25 - REMOVING HEX NUTS...

  • Page 83

    F-53 TROUBLESHOOTING & REPAIR CAPACITOR REMOVAL AND REPLACEMENT (cont.) FIGURE F.27 -- REMOVING CAPACITOR NUTS 4. Remove the two 1/4-28 hex head bolts that hold the Capacitor to the PC board. See Figure F.27. FIGURE F.28 — LOOSENING THE CLAMP RING SET SCREW. 5.

  • Page 84

    F-54 TROUBLESHOOTING & REPAIR CAPACITOR REMOVAL AND REPLACEMENT (cont.) FIGURE F.29 -- COMPLETE SWITCH BOARD ASSEMBLY READY FOR INSTALLATION NOTE: Proper capacitor polarity must be noted when attaching the capacitor to the Switch Board assembly. 6. Install the new Capacitor and tighten the two bolts to a torque of 55 inch-pounds (6 Nm).

  • Page 85

    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.

  • Page 86

    F-56 TROUBLESHOOTING & REPAIR SWITCH BOARD REPLACEMENT (cont.) NOTE: If a test indicates that a Switch Board is defec- tive, unless their part number is L10958-[ ] 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 following conditions exist: a.

  • Page 87

    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.

  • Page 88

    F-58 TROUBLESHOOTING & REPAIR TEST AFTER SWITCH BOARD OR CAPACITOR REPLACEMENT (cont.) TEST PROCEDURE 1. Turn main power OFF. 2. Perform Input Filter Capacitor Dis-charge proce- dure detailed in Mainten-ance section.. 3. Connect a shorting conductor across terminals 14 and 53 of Protection Board. 4.

  • Page 89

    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.

  • Page 90

    F-60 TROUBLESHOOTING & REPAIR OUTPUT DIODE REPLACEMENT PROCEDURE (cont.) FIGURE F.31 - RECTIFIER ASSEMBLY WITH PARALLELED DIODES PROCEDURE (Paralleled IndividualDiodes) 1. Turn main power OFF. 2. Perform Input Filter Capacitor Discharge proce- dure detailed in Maintenance section.. 3. Detach and remove both Switch Board assemblies and attached capacitors.

  • Page 91

    F-61 TROUBLESHOOTING & REPAIR OUTPUT DIODE REPLACEMENT PROCEDURE (cont.) FIGURE F.32 - RECTIFIER ASSEMBLY WITH DIODE MODULES PROCEDURE (Diode Modules) 1. Turn main power OFF. 2. Perform Input Filter Capacitor Discharge proce- dure detailed in Maintenance section.. 3. Detach and remove both Switch Board assemblies and attached capacitors.

  • Page 92

    F-62 TROUBLESHOOTING & REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested. NOTE: 50 Hz machines may be tested using 60 Hz power.

  • Page 93

    Section G-1 - ELECTRICAL DIAGRAMS SECTION - Electrical Diagrams ...Section G Wiring Diagram (L8657 for Code 9825 & 9965) ......G-2 Wiring Diagram (L8841 for Code 9934) .

  • Page 94

    ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODE 9825 & 9965 (L8657) NOTE: This diagram is for reference only. It may 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. V300 PRO...

  • Page 95

    WIRING DIAGRAM - ENTIRE MACHINE CODE 9934 (L8841) 3 1 1 3 1 3 2 7 5 F 3 0 6 P R O T E C T I O N 3 1 4 1 0 K B O A R D 2 5 W 3 1 6 J 1 5...

  • Page 96

    WIRING DIAGRAM - ENTIRE MACHINE CODE 10034 (L9299) 3 1 1 3 1 3 2 7 5 F 3 0 6 P R O T E C T I O N 3 1 4 B O A R D 3 1 6 J 1 5 3 1 5 3 1 7...

  • Page 97

    WIRING DIAGRAM - ENTIRE MACHINE CODE 10035 (L9301) 3 1 1 3 1 3 2 7 5 F 3 0 6 P R O T E C T I O N 3 1 4 B O A R D 3 1 6 J 1 5 3 1 5 3 1 7...

  • Page 98

    ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE CODE 10130 (L9567) NOTE: This diagram is for reference only. It may 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. V300 PRO...

  • Page 99

    ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE CODE 10131 (L9569) NOTE: This diagram is for reference only. It may 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. V300 PRO...

  • Page 100

    ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE CODE 10256 (L10189) NOTE: This diagram is for reference only. It may 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. V300 PRO...

  • Page 101

    ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODE 10257 (L10191) NOTE: This diagram is for reference only. It may 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. V300 PRO...

  • Page 102

    G-10 SCHEMATIC - ENTIRE MACHINE PROTECTION BOARD ELECTRICAL DIAGRAMS SWITCH BOARD (LEFT) DRIVER BOARD SWITCH BOARD (RIGHT) POWER BOARD CONTROL BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. G-10 V300 PRO...

  • Page 103

    G-11 G-11 ELECTRICAL DIAGRAMS SCHEMATIC - DRIVER PC BOARD - (S20216) FROM (-) RIGHT SWITCH BOARD TO (-) INPUT RECTIFIER NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V300 PRO...

  • Page 104

    Lincoln Electric discourages 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.

  • Page 105

    G-13 G-13 ELECTRICAL DIAGRAMS SCHEMATIC - DRIVER PC BOARD (S20799) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V300 PRO...

  • Page 106

    Lincoln Electric discourages 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.

  • Page 107

    G-15 G-15 ELECTRICAL DIAGRAMS SCHEMATIC - SWITCH PC BOARD (L8440) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V300 PRO...

  • Page 108

    Lincoln Electric discourages 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.

  • Page 109

    G-17 G-17 ELECTRICAL DIAGRAMS SCHEMATIC - SWITCH PC BOARD (L10956) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V300 PRO...

  • Page 110

    Lincoln Electric discourages 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.

  • Page 111

    G-19 G-19 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD (G2525) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V300 PRO...

  • Page 112

    Lincoln Electric discourages 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.

  • Page 113

    QUAD, IC-OP-AMP. gen. purpose 224J CONTROLLER, IC-PWM I-mode 3847 QUAD, IC-OP-AMP high-perf 1014 X5, X6, X8, X9, X10 SWITCH, IC-CMOS analog quad 4066 INVERTER,IC-CMOS Schmitt h ex 4584 NOTE: Individual parts listed are not available from Lincoln Electric. G-21 V300 PRO...

  • Page 114

    G-22 G-22 ELECTRICAL DIAGRAMS SCHEMATIC - PROTECTION PC BOARD (M16097) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V300 PRO...

  • Page 115

    Lincoln Electric discourages 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.

  • Page 116

    G-24 G-24 ELECTRICAL DIAGRAMS SCHEMATIC - POWER PC BOARD (M16018) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V300 PRO...

  • Page 117

    Lincoln Electric discourages 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.

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