Page 1: Service Manual
RETURN TO MAIN INDEX RETURN TO MAIN MENU SVM199-A July, 2010 ® INVERTEC V450 PRO For use with machine code number: 11212 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety increased by proper installation...
Page 2: California Proposition 65 Warnings
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
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 and CUTTING 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 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 SAFETY Electromagnetic Compatibility (EMC) Conformance Introduction Installation and Use Assessment of Area INVERTEC® V450-PRO...
Page 7: Safety
SAFETY Electromagnetic Compatibility (EMC) Methods of Reducing Emissions Mains Supply Maintenance of the Welding Equipment Welding Cables Equipotential Bonding Earthing of the Workpiece Screening and Shielding INVERTEC® V450-PRO...
Page 8: Table Of Contents
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN MENU Page Safety ................i-iv Installation .
Page 9 TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .
Page 10: Installation
TECHNICAL SPECIFICATIONS - INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS- OUTPUT CONDITIONS FREQUENCY AMPS / VOLTS / DUTY CYCLE 450A@38V.100% 208/230/460/575V - 60HZ. 570A@43V. 60% 400A@36V.100% 200/220/440/575V - 50HZ. 500A@40V. 60% PULSE PULSE FREQUENCY VOLTAGE RANGE 0.15 - 1000 Hz 5 - 55 VDC OPEN CIRCUIT VOLTAGE 30-76...
Page 11: Safety Precautions
5.90" (150mm) beyond the equipment on all sides. ------------------------------------------------------------------------ Place the welder where clean cooling air can freely cir- culate in through the rear louvers and out through the case sides and bottom. Water, Dirt, dust, or any foreign material that can be drawn into the welder should be kept at a minimum.
Page 12: Input Fuse And Supply Wire Considerations
If the Auxiliary (A) lead is placed in a position lower than the applied line voltage, the welder will not come on, and the two circuit break- ers or fuses in the reconnect area will open. If this occurs, turn off the input voltage, properly connect the (A) lead, reset the breakers, and try again.
Page 13: Negative Electrode Polarity
CABLE INDUCTANCE, AND ITS EFFECTS ON PULSE WELDING For Pulse Welding processes, cable inductance will cause the welding performance to degrade. For the total welding loop length less than tional welding cables may be used without any effects on welding performance. For the total welding loop length greater than 15.24m), the K1796 Coaxial 50 ft.
Page 14: Connections Of Wire Feeders
CONNECTIONS OF WIRE FEEDERS TO V450-PRO LF-72, 74 Connection Instructions • Turn the Invertec® power switch "off". • Connect the K1797-[ ] control cable from the LF-72, 74 to the 14-pin MS-style connector. • Connect the electrode cable to the output terminal of the polarity required by electrode.
Page 15: Parallel Operation
LN-742 Connection Instructions • Turn the Invertec® power switch "off" • A K1819-1 Input cable assembly is required to con- nect the LN-742 to the Invertec®. • Connect the control cable from the LN-742 to the 14-pin MS-style connector. • Connect the electrode cable to the output terminal of the polarity required by electrode.
Page 16 NOTES INVERTEC® V450-PRO...
Page 17 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions .
Page 18: Operation
SAFETY PRECAUTIONS 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 19: Hidden Middle Control Panel
6. THERMAL • This status light indicates when the power source has been driven into thermal overload. If the output terminals were "ON", the "ON" light will blink indicating that the output will be turned back on once the unit cools down to an accept- able temperature level.
Page 20: Tig Gtaw
• The Arc Control regulates the Arc Force to adjust the short circuit current. The minimum setting (-10) will produce a "soft" arc and will produce minimal spat- ter. The maximum setting (+10) will produce a "crisp" arc and will minimize electrode sticking. TIG GTAW: The TIG mode features continuous control from 5 to 570 amps.
Page 21: Weld Mode Select
(M1 THRU M8) SELECT KNOB SELECT KNOB (SCOLLS WELDING PROCESSES) (SCOLLS WELDING PROCESSES) ADVANCE PROCESS PANEL- MIDDLE SECTION OF WELDER (OPTIONAL) OPERATION • Gouge Mode The gouging mode is specifically designed for car- bon arc gouging with electrodes up to 3/8”.
Page 22: Memory Selections
M1. Argon Blends NOTE: After all memory; M1 thru M8, are used and the welder needs to store another welding process, a new welding process will overwrite what was originally in Argon Blends the memory and will read: Arc Cntrl ### <...
Page 23: Weld Mode Details
WELD MODE DETAILS: Mode Range Stick Soft 55 - 570 amps The stick soft mode is the best selection for general stick Stick Crisp 55 - 570 amps The stick crisp mode features an aggressive arc force routine well suit- GTAW (Tig mode) 5 - 570 amps GMAW - CV...
Page 24: Pulse Programs
MODE IPM* .030 Steel 75 - 800 .035 Steel 50 - 800 .045 Steel 60 - 800 .052 Steel 60 - 750 1/16 Steel 60 - 600 .045 Metal Core 60 - 700 .052 Metal Core 60 - 500 1/16 Metal Core 60 - 500 .030 Stainless Ar Blends 100 - 800...
Page 25: Remote Control Selection
76 (wiper) to lead 77 would produce the cur- rent that has been set by the Invertec® V450-Pro’s front panel Output Control.) • Remotes of this type offered by Lincoln Electric are the K857, K812 and K870. Voltage Control •...
Page 26: Limitations
B-10 Types of Remote WELD TERMINAL Control • The Invertec® V450-Pro’s Weld Terminals can be controlled from each of the MS-style connectors. The circuit has a nominal OCV of 15VDC and requires a dry contact closure (less than 100 ohms) to activate the output of the Invertec®...
Page 27 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Options/Accessories .
Page 28: Accessories
OPTIONS / ACCESSORIES K857 K814 K812 K870 NOTE: All of the above remote controls connect direct- ly to the 6-pin MS-style connector, with either a K864 or K876 adapter and connect it to the 14 pin wire feed- er MS-style connector. Manual) K930-[ ] K428, K446, K449...
Page 29 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .
Page 30: Maintenance
SAFETY PRECAUTIONS 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. ------------------------------------------------------------------------ EXPLODING PARTS can cause injury. •...
Page 31 1. Case Front Assembly 2. Control Box & Horizontal Plate 3. Base, Lift Bale & Fan Assembly 4. Input Assembly 5. Transformer & Output Assembly 6. Switch Board Heatsink Assembly 7. Covers Assembly Figure D.1 - Major Component Location MAINTENANCE INVERTEC®...
Page 32 NOTES INVERTEC® V450-PRO...
Page 33 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ... Section E Block Logic Diagram ..............E-1 General Description, Input Voltage .
Page 34: Theory Of Operation
THEORY OF OPERATION FIGURE E.2 - INPUT VOLTAGE AND PRECHARGE. R E C E P T A C L E C O N T R O L S I G N A L S R E C O N N E C T A U X .
Page 35: Switch Boards And Main Transformer
F E E D B A C K V O L T A G E M O T O R S E N S E R E C E P T A C L E C A P A C I T O R D R I V E P W M C O N T R O L S I G N A L S...
Page 36 THEORY OF OPERATION FIGURE E.4 - CONTROL BOARD & MODE SELECTION BOARD R E C O N N E C T A U X . T R A N S . A U X . T R A N S . A U X .
Page 37: Output Rectifier And Choke
THEORY OF OPERATION FIGURE E.5 - OUTPUT RECTIFIER AND CHOKE F E E D B A C K S E N S E R E C O N N E C T W I R E F E E D E R V O L T A G E 4 0 V D C C O N T R O L B O A R D...
Page 38: Protective Circuits
THEORY OF OPERATION THERMAL PROTECTION Two normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are con- nected to the control board. One of the thermostats is located on the heat sink of the output rectifier and the other is located near the fan.
Page 39 THEORY OF OPERATION A . P A S S I V E B . A C T I V E D R A I N G A T E D R A I N D R I F T R E G I O N B U F F E R L A Y E R I N J E C T I N G L A Y E R B O D Y R E G I O N...
Page 40: Pulse Width Modulation
THEORY OF OPERATION FIGURE E.7 - TYPICAL IGBT OUTPUTS 2 4 μ s e c 2 μ s e c M A X I M U M O U T P U T 5 0 μ s e c 1 μ s e c ( + ) M I N I M U M O U T P U T 4 8 μ...
Page 41 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .
Page 42: How To Use Troubleshooting Guide
TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 43: Pc Board Troubleshooting Procedures
- 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 prop- er failure analysis.
Page 44: Troubleshooting And Repair
CR-1 contactor closes If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
Page 45 No 120VAC present. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
Page 46 Service Navigator. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS 1.
Page 47 “overheats.” If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
Page 48 General degradation of weld performance. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF MISADJUSTMENT(S) 1.
Page 49 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF MISADJUSTMENT(S) 1.
Page 50 “####” presently loaded in the machine. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.
Page 51 5 second period, the display will revert to the above mode. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. CAUTION INVERTEC®...
Page 52 NOTES F-12 F-12 INVERTEC® V450-PRO...
Page 53: Input Filter Capacitor Discharge Procedure
F-13 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 54 TROUBLESHOOTING AND REPAIR F-14 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.1 – CAPACITOR TERMINAL LOCATION T E R M I N A L S C A P A C I T O R R E S I S T O R R E S I S T O R C A P A C I T O R T E R M I N A L S...
Page 55: Voltage And Current Calibration Procedure
F-15 VOLTAGE AND CURRENT CALIBRATION PROCEDURE Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 56 TROUBLESHOOTING AND REPAIR F-16 VOLTAGE AND CURRENT CALIBRATION PROCEDURE (continued) CALIBRATION CHECK The calibration of the V450-PRO can be checked using a resistive load bank with the V450-PRO in mode 200. Mode 200 is a constant current test mode. NOTE: Before attempting to calibrate the voltage or current setting of the V450-PRO, be sure to read the entire voltage or current calibration section.
Page 57 TROUBLESHOOTING AND REPAIR F-17 VOLTAGE AND CURRENT CALIBRATION PROCEDURE (continued) CURRENT CALIBRATION PROCEDURE NOTE: If the Mode SELECT/MEMORY button is not pressed within 30 seconds after adjusting the Output Control knob the machine will leave the calibration mode and use the previous calibration settings. 1.
Page 58 NOTES F-18 F-18 INVERTEC® V450-PRO...
Page 59: Main Switch Board Test
F-19 MAIN SWITCH BOARD TEST PROCEDURE Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 60 TROUBLESHOOTING AND REPAIR F-20 MAIN SWITCH BOARD TEST PROCEDURE (continued) FIGURE F.2 - CAPACITOR TERMINAL LOCATIONS T E R M I N A L S T E R M I N A L S C A P A C I T O R R E S I S T O R C A P A C I T O R R E S I S T O R...
Page 61: Input Rectifier Test
F-21 INPUT RECTIFIER TEST PROCEDURE Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 62 TROUBLESHOOTING AND REPAIR F-22 INPUT RECTIFIER TEST PROCEDURE (continued) PROCEDURE 1. Remove input power to the INVERTEC® V450-PRO. 2. Using the 3/8” nut driver, remove the case top. 3. Perform the Capacitor Discharge Procedure. 4. Locate the Input Rectifier and lead locations. Refer to Figure F.3.
Page 63 TROUBLESHOOTING AND REPAIR F-23 INPUT RECTIFIER TEST PROCEDURE (continued) 6. Use the analog ohmmeter to perform the tests detailed in Table F.1. 7. If the input rectifier does not meet the accept- able readings outlined in the table, the compo- nent may be faulty.
Page 64 NOTES F-24 F-24 INVERTEC® V450-PRO...
Page 65: Input Contactor Test
F-25 INPUT CONTACTOR TEST PROCEDURE Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 66 TROUBLESHOOTING AND REPAIR F-26 INPUT CONTACTOR TEST PROCEDURE (continued) FIGURE F.4 – INPUT CONTACTOR COIL 6 0 1 I N P U T C O N T A C T O R PROCEDURE 1. Remove input power to the INVERTEC® V450-PRO.
Page 67 TROUBLESHOOTING AND REPAIR F-27 INPUT CONTACTOR TEST PROCEDURE (continued) FIGURE F.5 – INPUT CONTACTOR TEST POINTS 5. With the input contactor activated, check the continuity across the three sets of contacts. (Zero ohms or very low resistance is normal.) See Figure F.5. If the resistance is high, the input contactor is faulty.
Page 68 NOTES F-28 F-28 INVERTEC® V450-PRO...
Page 69: Input Board Test
F-29 INPUT BOARD TEST PROCEDURE Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 70 TROUBLESHOOTING AND REPAIR F-30 INPUT BOARD TEST PROCEDURE (continued) FIGURE F.6 – INPUT CONTACTOR CR1 5 6 7 8 1 2 3 4 1 2 3 4 5 6 7 8 9 1 0 J 6 0 J 6 1 J 6 0 J 6 1 I N P U T...
Page 71 TROUBLESHOOTING AND REPAIR F-31 INPUT BOARD TEST PROCEDURE (continued) 6. Remove input power to the INVERTEC® V- 450 PRO. If any of the voltages are low or not present, perform the Input Contactor Test. If that checks out, the Input Board may by faulty.
Page 72 TROUBLESHOOTING AND REPAIR F-32 INPUT BOARD TEST PROCEDURE (continued) TABLE F.2 – INPUT BOARD VOLTAGE CHECKS LEAD TEST POINTS NUMBERS PLUG J61 PIN 8 (H1D) PLUG J61 PIN 2 (612) #612 PLUG J61 PIN 10 (T3) PLUG J61 PIN 2 (T1) PLUG J60 PIN 3 (238) PLUG J60 PIN 4 (604) PLUG J60 PIN 3 (238)
Page 73 F-33 AUXILIARY TRANSFORMER NO. 2 TEST Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 74 TROUBLESHOOTING AND REPAIR F-34 AUXILIARY TRANSFORMER NO. 2 TEST (continued) T R A N S F O R M E R # 2 P 5 1 P 5 2 S C R E W S ( 2 ) 3 / 8 ” M O U N T I N G P 5 0 PROCEDURE 1.
Page 75 F-35 AUXILIARY TRANSFORMER NO. 1 TEST Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 76 TROUBLESHOOTING AND REPAIR F-36 AUXILIARY TRANSFORMER NO. 1 TEST (continued) FIGURE F.8 – TEST LEAD LOCATIONS P L U G T R A N S F O R M E R # 1 P 5 9 S C R E W S ( 2 ) 3 / 8 ”...
Page 77 TROUBLESHOOTING AND REPAIR F-37 AUXILIARY TRANSFORMER NO. 1 TEST (continued) LEAD IDENTIFICATION X8 to 41B X3 to X5 X3 to X4 X6 to X7 X6 to X9 TABLE F.3 NORMAL EXPECTED VOLTAGE 28 VAC 115 VAC 24 VAC 24 VAC 42 VAC INVERTEC®...
Page 78 NOTES F-38 F-38 INVERTEC® V450-PRO...
Page 79: Power Board Test
TROUBLESHOOTING AND REPAIR F-39 Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 80 TROUBLESHOOTING AND REPAIR F-40 POWER BOARD TEST (continued) J 4 2 4 5 6 1 2 3 7 8 9 1 0 1 1 1 2 1 2 3 4 5 6 J 4 3 J 4 1 J 4 2 J 4 3 J 4 1 PROCEDURE...
Page 81 TROUBLESHOOTING AND REPAIR F-41 POWER BOARD TEST (continued) TABLE F.4 – POWER BOARD VOLTAGE CHECKS CHECK POINT TEST LOCATION DESCRIPTION POWER BOARD CHECK 40 VDC CONNECTOR INPUT FROM PLUG J41 DC BUS BOARD POWER BOARD CHECK +15 CONNECTOR VDC SUPPLY FROM PLUG J42 POWER BOARD POWER BOARD...
Page 82 NOTES F-42 F-42 INVERTEC® V450-PRO...
Page 83: Current Transducer Test
F-43 CURRENT TRANSDUCER TEST Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 84 TROUBLESHOOTING AND REPAIR F-44 CURRENT TRANSDUCER TEST (continued) FIGURE F.10 – CURRENT TRANSDUCER TEST 1 2 3 4 P 9 1 T R A N S D U C E R C U R R E N T 2 1 6 2 1 1 2 1 2 2 1 3 C O N T R O L B O A R D CONTROL BOARD...
Page 85 TROUBLESHOOTING AND REPAIR F-45 CURRENT TRANSDUCER TEST (continued) 5. Turn on the V-450 PRO. Check for the correct DC supply voltage to the current transducer at plug J8. See Figure F.10. A. Pin 2 (lead 212+) to pin 6 (lead 216-) should read +15 VDC.
Page 86 NOTES F-46 F-46 INVERTEC® V450-PRO...
Page 87: Thermostat Test - Thermal Protection
F-47 THERMOSTAT TEST – THERMAL PROTECTION Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 88 TROUBLESHOOTING AND REPAIR F-48 THERMOSTAT TEST – THERMAL PROTECTION (continued) FIGURE F.11 – THERMOSTAT CIRCUIT ( B O L T E D C O N N E C T I O N ) O U T P U T R E C T I F I E R 2 2 0 2 2 4 2 2 4 A...
Page 89: Fan Control And Motor Test
F-49 FAN CONTROL AND MOTOR TEST Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 90 TROUBLESHOOTING AND REPAIR F-50 FAN CONTROL AND MOTOR TEST (continued) TEST PROCEDURE 1. Remove the input power to the V450-PRO machine. 2. Using the 3/8” nut driver, remove the case top and control box cover. 4 4 4 F A N L o c a t e d i n R e a r o f P o w e r S o u r c e R E L A Y...
Page 91: Output Rectifier Test
F-51 OUTPUT RECTIFIER TEST PROCEDURE Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 92 TROUBLESHOOTING AND REPAIR F-52 OUTPUT RECTIFIER TEST PROCEDURE (continued) FIGURE F.13 - OUTPUT TERMINAL LOCATION T E R M I N A L O U T P U T N E G A T I V E ( - ) P O S I T I V E ( + ) O U T P U T T E R M I N A L...
Page 93: Choke Test
CHOKE TEST PROCEDURE WARNING Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 94 TROUBLESHOOTING AND REPAIR F-54 CHOKE TEST PROCEDURE (continued) C H O K E / I R O N CHOKE/IRON PROCEDURE 1. Using an Ohmmeter, make sure that the choke windings are not grounded to the lamination (> 1megohm). FIGURE F.14 – CHOKE ASSEMBLY No windings or terminal connections should look burned or over-heated.
Page 95: Control Board Check
TROUBLESHOOTING AND REPAIR F-55 CONTROL BOARD CHECK Since the functions of the Control Board are primarily software related, there are not very many tests to be per- formed that will help in diagnosing a problem with the board itself. Elimination of problems in the areas where loss of function is taking place will help decide by process of elimination if the Control Board is the defective component.
Page 96 NOTES F-56 F-56 INVERTEC® V450-PRO...
Page 97: Spi Cable Resistance And Voltage Test
F-57 SPI CABLE RESISTANCE AND VOLTAGE TEST PROCEDURE Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 98 TROUBLESHOOTING AND REPAIR F-58 SPI CABLE RESISTANCE AND VOLTAGE TEST PROCEDURE (continued) TEST PROCEDURE 1. Remove the input power to the V450-PRO. 2. Using the #2 Phillips screwdriver, remove the case front panel. 5. Locate and remove plug J33 from the control board.
Page 99: Removal And Replacement Procedures
CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 100 TROUBLESHOOTING AND REPAIR F-60 CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) C O N T R O L B O A R D C O V E R C O M P A R T M E N T P O W E R B O A R D COMPARTMENT COVER...
Page 101 TROUBLESHOOTING AND REPAIR F-61 CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) INSTALLATION PROCEDURE 1. Install either the power or control board to the PC board assembly and secure it in place. 2. Carefully slide the power and control PC board assembly into place, making sure to clear the lead harnesses on the right and left side of the PC board compartment.
Page 102 NOTES F-62 F-62 INVERTEC® V450-PRO...
Page 103 F-63 INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 104: Input Rectifier
TROUBLESHOOTING AND REPAIR F-64 REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.17 – INPUT RECTIFIER LOCATION P O S ( + ) N E G ( - ) R E C T I F I E R I N P U T REMOVAL PROCEDURE 1.
Page 105 F-65 INPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 106: Input Contactor
TROUBLESHOOTING AND REPAIR F-66 REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.18 – INPUT CONTACTOR LOCATION I N P U T C O N T A C T O R 6 0 1 REMOVAL PROCEDURE 1. Remove input power to the V450-PRO. 2.
Page 107: Replacement Procedure
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT PROCEDURE Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 108 TROUBLESHOOTING AND REPAIR F-68 AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.19 – TRANSFORMER AND PLUG LOCATIONS P 5 1 P 5 0 T R A N S F O R M E R # 2 3 / 8 ” M O U N T I N G P 5 2 S C R E W S ( 2 ) REMOVAL PROCEDURE...
Page 109 TROUBLESHOOTING AND REPAIR F-69 AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully place the transformer into the V450- PRO. 2. Install the two mounting screws that hold the transformer to the machine base using the 3/8” nut driver.
Page 110 NOTES F-70 F-70 INVERTEC® V450-PRO...
Page 111 AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 112 TROUBLESHOOTING AND REPAIR F-72 AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE (continued) T R A N S F O R M E R # 1 P L U G P 5 9 S C R E W S ( 2 ) 3 / 8 ”...
Page 113 TROUBLESHOOTING AND REPAIR F-73 AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE (continued) 8. Cut any necessary cable ties and clear the leads. 9. Using the 3/8” nut driver, remove the two mounting screws that hold the transformer to the fan baffle and the machine base. 10.
Page 114 NOTES F-74 F-74 INVERTEC® V450-PRO...
Page 115: Control, Remote, Mode Or Display
CONTROL, REMOTE, MODE OR DISPLAY PC BOARD REMOVAL AND REPLACEMENT Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 116 TROUBLESHOOTING AND REPAIR F-76 CONTROL, REMOTE, MODE OR DISPLAY PC BOARD REMOVAL AND REPLACEMENT (continued) C O N T R O L B O A R D B O L T S ( 4 ) B O A R D 3 / 8 ”...
Page 117: Current Transducer
F-77 REMOVAL AND REPLACEMENT PROCEDURE Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 118 TROUBLESHOOTING AND REPAIR F-78 REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.22 – CURRENT TRANSDUCER LOCATION B O T T O M O F B O L T E D C O N N E C T I O N 3 / 8 ” S C R E W S A T H E A V Y L E A D C A S E F R O N T ( 3 ) ( B E H I N D C A S E F R O N T )
Page 119 TROUBLESHOOTING AND REPAIR F-79 REMOVAL AND REPLACEMENT PROCEDURE (continued) 9. Using the Phillips head screwdriver, remove the screws and lock washers that hold the transducer to the front panel. 10. Remove the Current Transducer. 11. Remove the standoffs from the transducer and save them for reassembly with the new transducer.
Page 120 NOTES F-80 F-80 INVERTEC® V450-PRO...
Page 121 SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT Service and repair should only be performed by 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 precautions detailed throughout this manual.
Page 122: Switch Board
TROUBLESHOOTING AND REPAIR F-82 SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.23 – SWITCH BOARD LOCATION S W I T C H B O A R D REMOVAL PROCEDURE NOTE: Observe all static electricity precautions. Lead and plug references below use a slash (/) to indicate machine right side/left side wire number differences.
Page 123 TROUBLESHOOTING AND REPAIR F-83 SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE 1. If the filter capacitor is to be replaced, careful- ly slide the new capacitor into the mounting bracket. Position the capacitor so the correct polarity terminal is lined up with the correct hole on the switch board.
Page 124: Retest After Repair
TROUBLESHOOTING AND REPAIR F-84 Retest a machine: If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. If you repair or replace any electrical components. Input Volts/Hertz 208/60 230/60 400/60...
Page 125 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram - Complete Machine - (G4923) .
Page 126 INVERTEC V450-PRO SPI FLEX CIRCUIT SPI EXTENSION CIRCUIT 5 10 3316 3315 3314 3305 3313 3304 3312 DISPLAY 3303 J60A J333 3301 J60B 3304 3216 3312 3207 OUTPUT 3215 3315 3206 3303 CONTROL 3205 5 13 3213 LED SELECT 3204 LED SELECT 3212 3203...
Page 127 G4875 ENGINEERING CONTROLLED CHANGE DETAIL: CB2 AND FUSE, REVISED AMPS REVISED NOTE N.B. MANUFACTURER: Heatsink isolated from Switch Boards SWITCH BOARD #1 Undervoltage = 200V Schematic: L11385 Overvoltage = 467V (Located on left side of Machine) 3500uF Top Rear 500V RECONNECT N.B.
Page 128 G4875 ENGINEERING CONTROLLED CB2 AND FUSE, REVISED AMPS CHANGE DETAIL: MANUFACTURER: REVISED NOTE N.B. CONTROL BOARD Additional input / outputs are illustrated on schematic # 1. Positive 206D Output Studs See page 1 202C Polarity Switch for wire feeder meter Negative Located next to 14 pin amphenol See page 1...
Page 129 G4875 ENGINEERING CONTROLLED CHANGE DETAIL: CB2 AND FUSE, REVISED AMPS REVISED NOTE N.B. MANUFACTURER: 1. STD DISPLAY PC BOARD ASSEMBLY 2. SPI ASSEMBLY 3. REMOTE PC BOARD ASSEMBLY 4. LED SELECT PC BOARD ASSEMBLY 5. FACTORY MODE PANEL ASSEMBLY Control Panel Factory Mode Panel RS232 WELD MODE...
Page 130 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE INVERTER WELDER DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE:...
Page 131 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE INVERTER WELDER DESIGN INFORMATION REFERENCE:...
Page 132 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE INVERTER WELDER DESIGN INFORMATION REFERENCE:...
Page 133 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE INVERTER WELDER DESIGN INFORMATION REFERENCE:...
Page 134 This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Page 135 This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Page 136 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 137 L11385-2D1 ENGINEERING CONTROLLED CHANGE DETAIL: NEW. MANUFACTURER: This diagram is for reference only. It may not be accurate for all machines covered by this manual. THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY &...
Page 138 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 139 This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Page 140 This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Page 141 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 142 This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Page 143 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 144 This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Page 145 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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Lincoln Electric INVERTEC SVM199-A Service Manual

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