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 can be
increased by proper installation
. . . and thoughtful operation on
your part. DOꢀNOT 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 © 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: 888.935.3877 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com
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ii
ii
SAFETY
ELECTRIC SHOCK can kill.
ARC RAYS can burn.
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.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical ven-
tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
cautions are also required when welding on galvanized
steel.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo-
sure level should be checked upon installation and periodi-
cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
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SAFETY
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.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
Remember
that
welding
sparks
and
hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
INVERTEC® V450-PRO
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SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRÉCAUTIONS DE SÛRETÉ
prévenir tout risque d’incendie dû aux étincelles.
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:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
INVERTEC® V450-PRO
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v
v
SAFETY
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work com-
plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equip-
ment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
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SAFETY
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommen-
dations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con-
nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capaci-
tance, selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
1
tions.
_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”
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I
I
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-525
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A-1
A-1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Lifting, Stacking & Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Input Fuse and Supply Wire Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Negative Electrode Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - INVERTEC® V450-PRO
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT VOLTS-
OUTPUT
CONDITIONS
AMPS / VOLTS / DUTY CYCLE
INPUT
CURRENT
AMPS
POWER FACTOR
EFFICIENCY
@ RATED
OUTPUT
IDLE
POWER
FREQUENCY
@ RATED OUTPUT
450A@38V.100%
570A@43V. 60%
58/53/25/22
82/78/37/31
208/230/460/575V - 60HZ.
200/220/440/575V - 50HZ.
88%
.95 MIN.
400 Watts
Max.
400A@36V.100%
500A@40V. 60%
49/45/23/18
67/61/31/25
OUTPUT
PULSE AND
BACKGROUND
TIME RANGE
PULSE
FREQUENCY
PULSE
VOLTAGE
RANGE
AUXILIARY POWER
(CIRCUIT BREAKER PROTECTED)
0.15 - 1000 Hz
5 - 55 VDC
100 MICRO SEC. -3.3
SEC.
24VAC
42VAC AT
10 AMPS
115VAC AT
15* AMPS
OPEN CIRCUIT VOLTAGE
30-76
PROCESS CURRENT RANGE (DC)
CURRENT
50-570 Average Amps
40-570 Average Amps
55-570 Average Amps
5-570 Average Amps
5-750 Peak Amps
MIG/MAG
FCAW
SMAW
GTAW
Pulse
76
76
18-76
76
RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT
TYPE 75°C
GROUND WIRE IN
TYPE 75°C
COPPER WIRE IN
TYPE 75°C
(SUPER LAG)
OR BREAKER
SIZE (AMPS)
INPUT
VOLTAGE /
FREQUENCY
2
2
CONDUIT AWG(MM )
SIZES
CONDUIT AWG(MM )
SIZES
100
100
50
208/50/60HZ
230/50/60HZ
460/50/60HZ
575/50/60HZ
8(10)
8(10)
10(6)
10(6)
4(25)
4(25)
8(10)
10(6)
40
PHYSICAL DIMENSIONS
HEIGHT
26.10 in
663 mm
WIDTH
19.86 in
505 mm
DEPTH
32.88 in
835 mm
WEIGHT
293 lbs.
133 kg.
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-20°C to +40°C
STORAGE TEMPERATURE RANGE
-40°C to +40°C
* Earlier models used 10 amps circuit breaker.
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A-3
A-3
INSTALLATION
LIFTING
SAFETY PRECAUTIONS
Lift the machine by the lift bail only. The lift bail is
designed to lift the power source only. Do not attempt
to lift the V450-PRO with accessories attached to it.
Read this entire installation section before you
start installation.
STACKING
WARNING
V450-PRO machines can be stacked to a maximum of
3 high.
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this installation.
• Turn the input power OFF at the
disconnect switch or fuse box
CAUTION
The bottom machine must always be placed on a
firm, secure, level surface. There is a danger of
machines toppling over if this precaution is not
taken.
before working on this equipment. Turn off the input
power to any other equipment connected to the
welding system at the disconnect switch or fuse
box before working on the equipment.
• Do not touch electrically hot parts.
• Always connect the V450-PRO grounding lug
(located inside the reconnect input access door)
to a proper safety (Earth) ground.
MACHINE GROUNDING
The frame of the welder must be grounded. A ground
----------------------------------------------------------
SELECT SUITABLE LOCATION
Do not use the Invertec® in outdoor environments with-
out appropriate protection. The V450-PRO power
source should not be subjected to falling water, nor
should any parts of it be submerged in water. Doing so
may cause improper operation as well as pose a safe-
ty hazard. The best practice is to keep the machine in a
dry, sheltered area.
terminal marked with the symbol
is located inside
the reconnect/input access door for this purpose. See
your local and national electrical codes for proper
grounding methods.
HIGH FREQUENCY PROTECTION
Locate the V450-PRO away from radio controlled
machinery.
CAUTION
WARNING
The normal operation of the V450-PRO may
adversely affect the operation of RF controlled
equipment, which may result in bodily injury or
damage to the equipment.
Do not mount the V450-PRO over combustible sur-
faces. Where there is a combustible surface direct-
ly under stationary or fixed electrical equipment,
that surface shall be covered with a steel plate at
least .060" (1.6mm) thick, which shall extend not
less than 5.90" (150mm) beyond the equipment on
all sides.
INPUT CONNECTION
WARNING
------------------------------------------------------------------------
Place the welder where clean cooling air can freely cir-
culate in through the rear louvers and out through the Only a qualified electrician should connect the
case sides and bottom. Water, Dirt, dust, or any foreign input leads to the V450-PRO. Connections should
material that can be drawn into the welder should be be made in accordance with all local and national
kept at a minimum. Failure to observe these precau- electrical codes and the connection diagram locat-
tions can result in excessive operating temperatures ed on the inside of the reconnect/input access
and nuisance shutdowns.
door of the machine. Failure to do so may result in
bodily injury or death.
Machines are equipped with F.A.N. (fan as needed) cir-
cuitry. The fan runs whenever the output is enabled, ------------------------------------------------------------------------
whether under loaded or open circuit conditions. The
Use a three-phase supply line. A 1.75 inch (45 mm)
fan also runs for a period of time (approximately 5 min-
diameter access hole for the input supply is located on
utes) after the output is disabled, to ensure all compo-
the upper left case back next to the input access door.
nents are properly cooled.
Connect L1, L2, L3 and ground according to the Input
If desired, the F.A.N. feature can be disabled (causing Supply Connection Diagram decal located on the
the fan to run whenever the power source is on). To dis- inside of the input access door or refer to Figure A.1 on
able F.A.N., connect leads 444 and X3A together at the the following page.
output of the solid state fan control relay, located on the
back of the Control PC board enclosure. (See Wiring
Diagram)
INVERTEC® V450-PRO
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A-4
A-4
INSTALLATION
FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR
4
'
2
V
'
2
5
'
L
V
T
3
o
V
T
0
0
V
A
E
I
W
N
G
W
3
V
T
0
0
INPUT SUPPLY CONNECTION DIAGRAM
=
200-208V
VOLTAGE
W/L
3
WARNING
200-208V
220-230V
440-460V
550-575V
V/L
2
CR1
.
.
.
Disconnect input power before
inspecting or servicing machine.
U/L1
'A'
'A'
Do not operate with covers
removed.
ELECTRIC
SHOCK
CAN KILL
Do not touch electrically live parts.
.
Only qualied persons should install,
use or service this equipment.
=
= 440-460V
= 550-575V
VOLTAGE
VOLTAGE
VOLTAGE
220-230V
200-208V
200-208V
220-230V
440-460V
550-575V
200-208V
220-230V
440-460V
550-575V
220-230V
440-460V
550-575V
'A'
'A'
NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to do
so will result in damage to the machine.
INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS
ELECTRODE AND WORK CABLE
CONNECTIONS
Connect a work lead of sufficient size and length (Per
Table 1) between the proper output terminal on the
power source and the work. Be sure the connection to
the work makes tight metal-to-metal electrical contact.
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work and wire feeder. Avoid
excessive lengths and do not coil excess cable.
Refer to the Technical Specifications at the beginning
of this Installation section for recommended fuse and
wire sizes. Fuse the input circuit with the recommend-
ed super lag fuse or delay type breakers (also called
“inverse time” or “thermal/magnetic” circuit breakers).
Choose an input and grounding wire size according to
local or national electrical codes. Using fuses or circuit
breakers smaller than recommended may result in
“nuisance” shut-offs from welder inrush currents, even
if the machine is not being used at high currents.
Minimum work and electrode cable sizes are as follows:
TABLE A.1
INPUT VOLTAGE CHANGE OVER (FOR
INPUT
(Current (60% Duty Cycle)
MINIMUM COPPER
WORK CABLE SIZE AWG
Up To-100 Ft. Length (30 m)
MULTIPLE
MACHINES ONLY)
VOLTAGE
2
400 Amps
500 Amps
600 Amps
2/0 (67 mm )
2
3/0 (85 mm )
2
3/0 (85 mm )
Welders are shipped connected for the highest input
voltage listed on the rating plate. To move this connec-
tion to a different input voltage, see the diagram locat-
ed on the inside of the input access door. If the main
reconnect switch or link position is placed in the wrong
position, the welder will not produce output power.
NOTE: K1796 coaxial welding cable is recommended
to reduce the cable inductance in long cable lengths.
This is especially important when Pulse welding up to
350 amps.
If the Auxiliary (A) lead is placed in the wrong position,
there are two possible results. If the lead is placed in a
position higher than the applied line voltage, the welder
may not come on at all. 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. For
machines equipped with a fuse in the reconnect area,
turn off the input voltage and replace the fuse with the
spare fuse that is attached to the reconnect switch pin.
CAUTION
When using inverter type power sources like the
V450-PRO, use the largest welding (electrode and
work) cables that are practical. At least 2/0 (67
2
mm ) copper wire - even if the average output cur-
rent would not normally require it. When pulsing,
the pulse current can reach very high levels.
Voltage drops can become excessive, leading to
poor welding characteristics, if undersized welding
cables are used.
------------------------------------------------------------------------
INVERTEC® V450-PRO
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A-5
A-5
INSTALLATION
For additional Safety information regarding the elec-
trode and work cable set-up, See the standard "SAFE-
TY INFORMATION" located in the front of the
Instruction Manuals.
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 50 ft.(15.24m), tradi-
tional welding cables may be used without any effects
on welding performance. For the total welding loop
length greater than 50 ft. (15.24m), the K1796 Coaxial
Welding Cables are recommended. The welding loop
length is defined as the total of electrode cable length
(A) + work cable length (B) + work length (C) (See
Figure A.2).
CAUTION
Excessive voltage drops caused by poor work
piece connections often result in unsatisfactory
welding performance.
------------------------------------------------------------------------
NEGATIVE ELECTRODE POLARITY
FIGURE A.2
When negative electrode polarity is required, such as in
some Innershield applications, switch the output con-
nections at the power source (electrode cable to the
negative (-) stud, and work cable to the positive (+)
stud.
V450-PRO
A
C
WORK
B
For long work piece lengths, a sliding ground should be
considered to keep the total welding loop length less
than 50 ft.(15.24m). (See Figure A.3.)
K
6
C
I
C
L
S
A
E
F
B
I
W
B
V
-
F
R
3
C
W
A
C
FIGURE A.3
A
A
V450-PRO
C
WORK
C
B
B
SLIDING WORK
K1796 COAXIAL CABLE
MEASURE FROM END
OF OUTER JACKET OF
CABLE
Output connections on some V450-PRO are made via
1/2-13 threaded output studs located beneath the
spring-loaded output cover at the bottom of the case
front.
Most welding applications run with the electrode being
positive (+). For those applications, connect the elec-
trode cable between the wire feeder and the positive
(+) output stud on the power source (located beneath
the spring loaded output cover near the bottom of the
case front). Connect the other end of the electrode
cable to the wire drive feed plate. The electrode cable
lug must be against the feed plate. Be sure the con-
nection to the feed plate makes tight metal-to-metal
electrical contact. The electrode cable should be sized
according to the specifications given in the work cable
connections section. Connect a work lead from the
negative (-) power source output stud to the work
piece. The work piece connection must be firm and
secure, especially if pulse welding is planned.
INVERTEC® V450-PRO
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A-6
A-6
INSTALLATION
LN-15 Connection Instructions
(See Figure A.4)
CONNECTIONS OF WIRE FEEDERS TO V450-PRO
• Turn the Invertec® power switch "off".
• Connect the electrode cable to the output terminal of polar-
ity required by electrode. (See Figures below)
• Set the meter polarity switch on the front of the Invertec®
to coincide with wire feeder polarity used.
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. Connect the work lead to
the other terminal.
• If a remote control such as K857 is to be used with the
LF-72, 74 the remote can be connected directly to the 6-
pin MS-style connector on the front of the Invertec® or
use a K864 adapter to connect the LF-72, 74 and the
remote to the 14-pin MS-style connector.
LN-25 Connection Instructions
• Turn the Invertec® power switch "off".
• Connect the electrode cable to the output terminal of polar-
ity required by electrode. Connect the work lead to the
other terminal.
• LN-25 with Remote Control 6-Pin (K444-1) and 14-pin
(K444-2) remotes can be connected directly to the 6-pin &
14-pin MS-style connectors. The 42 Volt Remote Voltage
and Output Control (K624-1) Kit can be connected to the
V450’s 14-pin MS-style connector using Remote Control
Cable assembly K627- [ ]. LN-25s with a K431-1 remote kit
can be connected to the V450’s 14-pin MS-style connector
using a K432 cable and K876 adapter. (See connection
diagram S19899). Or the K432 cable could be modified
with a K867 Universal Adapter Plug (See connection dia-
gram S19405) to connect it to the V450’s 14-pin MS-style
connector.
LN-10, DH-10 Connection Instructions
•
•
Turn the Invertec® power switch "off"
Connect the K1505 control cable from the LN-10 to the
14-pin MS-style connector.
•
Connect the electrode cable to the output terminal of
polarity required by the electrode. Connect the work lead
to the other terminal.
•
•
Set the meter polarity switch on the front of the Invertec®
to coincide with wire feeder polarity used.
See the LN-10 manual for details on accessing Control
DIP Switch. Dip Switches for the V350 and the same set-
tings may be used for the V450.
FIGURE A.4
V
ST
K18
O
ABL
C
LB
LE
K
L
D
A
W
C
MBL
P
E
V
ST
O
C
ER
IN
T
M
F
E
A
B
N
ACROSS THE ARC MODEL
OUTPUT TERMINALS
ALWAYS HOT.
V450-PRO
POWER SOURCE CONTACTOR
SWITCH MUST BE IN THE
“ON” POSITION OR USE A
MAGNUM GUN
AND CABLE
ASSEMBLY
LN-15
SEMIAUTOMATIC
K848 JUMPER PLUG KIT.
WIRE FEEDER
K1870-1
14-PIN
STUD
ELECTRODE CABLE
WORK CLAMP
CONROL CABLE MODEL
V450-PRO
MAGNUM GUN
AND CABLE
ASSEMBLY
LN-15
SEMIAUTOMATIC
WIRE FEEDER
K1819-10
CONTROL CABLE
14-PIN
STUD
K1871-1 MODEL
ELECTRODE CABLE
INVERTEC® V450-PRO
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A-7
A-7
INSTALLATION
LN-742 Connection Instructions
General Instructions for Connection of Wire
Feeders to V450-Pro
• 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. Connect the
work lead to the other terminal.
Wire feeders other than those listed above may be
used provided that the auxiliary power supply rating of
the V450-Pro is not exceeded and the V450-PRO out-
put is not actively controlled by the wire feeder. (Like
an LN-9). K867 universal adapter plug is required. See
connection diagram S24985 in Operator Manual.
• Set the meter polarity switch on the front of the
Invertec® to coincide with wire feeder polarity used.
The wire feeder will now display the welding volt-
age.
REMOTE CONTROL OF INVERTEC®
Remote Control K857, Hand Amptrol K963 and Foot
Amptrol K870 may be used.
• If a remote control such as K857 is to be used with the
LN-742, the remote can be connected directly to the 6-pin
MS-style connector on the front of the Invertec® or use a
K864 adapter to connect the LN-742 and the remote to
the 14-pin MS-style connector.
PARALLEL OPERATION
The V450-Pro are operable in parallel in CC mode. For
best results, the currents of each machine should be
reasonably equally balanced. As an example, with two
machines set up in parallel for a 800 amps procedure,
each machine should be set to deliver approximately
400 amps, not 450 amps from one and 350 amps from
the other. This will minimize nuisance shutdown condi-
tions. In general, more than two machines in parallel
will not be effective due to the voltage requirements of
procedures in that power range.
Cobramatic Connection Instructions
• Turn the Invertec® power switch "off"
• Connect the control cable from the Cobramatic to
the 14-pin MS-style connector.
• Connect the electrode cable to the output terminal
of the polarity required by electrode. Connect the
work lead to the other terminal.
• Set the meter polarity switch on the front of the
Invertec® to coincide with wire feeder polarity used.
• If a remote control such as K857 is to be used with
the Cobramatic, the remote can be connected
directly to the 6-pin MS-style connector on the front
of the Invertec® or use a K864 adapter to connect
the cobramatic and the remote to the 14-pin MS-
style connector.
To set machine outputs, start with output control pots
and arc control pots in identical positions. Use the out-
put control pots to balance the currents and maintain
the desired current. The arc control pots should be
kept identical on the two machines.
TIG Module K930-2
The TIG Module connects to the Factory and Advanced
Process V450-Pro versions with a K936-1 (9-14 pin)
control cable. Connect the K936-1 to the 14-Pin MS-
style connector.
INVERTEC® V450-PRO
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A-8
A-8
NOTES
INVERTEC® V450-PRO
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B-1
B-1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Hidden Middle Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
TIG GTAW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
CV-Innershield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Weld Mode Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Pulse Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Remote Control Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10
INVERTEC® V450-PRO
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B-2
B-2
OPERATION
SAFETY PRECAUTIONS
• After welding, the meter holds the actual current
value for 5 seconds. Output adjustment while in the
"hold" period results in the "prior to operation" char-
acteristics stated above. The displays blink indicat-
ing that the machine is in the "Hold" period.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground.
3. VOLT METER
• Prior to CV operation (current flow), the meter dis-
plays desired preset voltage value (+/- .5V).
• Prior to STICK or TIG operation, the meter displays
the Open Circuit Voltage of the Power Source or four
dashes if the output has not been turned on.
• During welding, this meter displays actual average
volts.
• 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.
• After welding, the meter holds the actual voltage
value for 5 seconds. The displays blink indicating
that the machine is in the "Hold" period.
• Output adjustment while in the "hold" period results
in the "prior to operation" characteristics stated
above.
-------------------------------------------------------
-----------------
WELDINGꢀSPARKSꢀcan cause fire or
explosion.
• Keep flammable material away.
• Do not weld on closed containers.
4. OUTPUT CONTROL
• Output control is conducted via a single turn poten-
tiometer.
------------------------------------------------------------------------
ARCꢀRAYS can burn eyes and skin.
• Wear eye, ear and body
• Adjustment is indicated by the meters as stated
above.
protection.
• When in TIG modes, this control sets the maximum
welding current. Full depression of a foot or hand
Amptrol results in the preset level of current.
------------------------------------------------------------
See additional warning information at
front of this operator’s manual.
5. WELD TERMINALS-REMOTE / ON
• Two status lights indicate the location of trigger con-
trol as determined by the "WELD TERMINALS" push
button.
• If trigger control is local "weld terminals on", the ON
display will be lit.
-----------------------------------------------------------
GENERAL DESCRIPTION
The Invertec® V450-Pro offers multi-process CV, CC,
and DC welding and is rated 570 amps, 43 volts at a
60% duty cycle.
• If trigger control is remote "weld terminals remotely
controlled", the REMOTE display will be lit.
• The unit will power up in "pre-determined preferred"
trigger modes.
DUTY CYCLE
The V450-Pro is rated at 570 amps, 60% duty cycle
(based on a 10 minute cycle). It is also rated at 450
amps, 100% duty cycle.
STICK = ON
OPERATIONAL FEATURES and CONTROLS:
UPPER CONTROL PANEL
CV = REMOTE
TIG = REMOTE if remote output controls are attached
to the machine.
1. ON, OFF- SWITCH
TIG = ON if remote output controls are not attached to
the machine.
2. AMPS Meter
• Prior to STICK or TIG operation (current flow), the
meter displays preset current value (either +/- 2
amps or +/- 3% (e.g. 3 amps on 100), whichever is
greater).
• Prior to CV operation, the meter displays four dash-
es indicating AMPS unable to be preset.
• During welding, this meter displays actual average
amps.
For all versions, these trigger modes can be over-ridden
(switched) with the WELD TERMINALS push button. When
changed, the unit will power up in the configuration it was in
INVERTEC® V450-PRO
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B-3
B-3
OPERATION
6. THERMAL
CC-STICK SOFT: The Stick Soft process features contin-
uous control ranging from 5 to 570 amps. This mode was
intended for most SMAW applications, and Arc Gouging.
• 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. If the unit was operating in the
"REMOTE" mode, the trigger will need to be opened
before or after the thermal has cleared and closed after the
machine has cooled down to an acceptable temperature to
establish output.
• Arc Gouging: Setting the output of the Stick Soft
mode to 570 amps or setting the arc control to maxi-
mum will enable the arc-gouging mode. The actual out-
put current will depend on the size of carbon used. The
recommended maximum size carbon is 3/8"(9.5mm).
• The Hot Start control regulates the starting current at
arc initiation. Hot Start can be adjusted from minimum
(0), with no additional current added at arc start, to
maximum (10), with double the preset current or 570
amps (max of machine) added for the first second after
arc initiation.
7. CONTROL-REMOTE / LOCAL
• Two status lights indicate the location of output control as
pre-determined by the power sources auto-configure sys-
tem.
• The Arc Control regulates the Arc Force to adjust the
short circuit current. The minimum setting (-10) will pro-
duce a "soft" arc and will produce minimal spatter. The
maximum setting (+10) will produce a "crisp" arc and
will minimize electrode sticking.
• The LOCAL display will be lit when control is at the power
source.
• The REMOTE display will be lit when a remote pot/control
is detected.
These Output Control configurations can be overridden
(switched) with the CONTROL push button. When changed,
the unit will power up in the configuration it was in when it
was last powered down.
CC-STICK CRISP:The Stick Crisp mode features contin-
uous control from 5 to 570 amps with a crisp shorting
response optimized for E6010 type electrodes.
Hidden Middle Control Panel – Process Set Up
Panel
• Arc Gouging: Setting the output of the Crisp mode to
570 amps or setting the arc control to maximum will
enable the arc-gouging mode. The actual output cur-
rent will depend on the size of carbon used. The rec-
ommended maximum size carbon is 3/8"(9.5mm).
The middle control panel is removable to allow for
upgrades (see Field Installed Options/Accessories).
Additionally, this panel is hidden by an access door to
provide protection to the controls.
• The Hot Start control regulates the starting current at
arc initiation. Hot Start can adjust starting current up or
down by 25% of the preset value. The recommended
setting for Hot Start is 5 where the initial current is
equal to the preset current.
8. WELD MODE SELECT
Figure B.1)
-
STANDARD (See
The Mode Control button selects from the following
welding modes.
FIGURE B.1
3
4
2
AMPS
VOLTS
6
OUTPUT
CONTROL
REMOTE
LOCAL
1
SELECT
7
8
5
TOUCH
START
TIG
HI-FREQ
TIG
SOFT
CRIP
10
9
12
11
13
14
15
INVERTEC® V450-PRO
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B-4
B-4
OPERATION
CV-WIRE: The CV-WIRE mode features continuous
control from 10 to 40 volts. This mode was intended for
most GMAW, FCAW, and MCAW applications.
• 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.
• The Hot Start control is not used in the CV-WIRE
mode.
TIG GTAW: The TIG mode features continuous control
from 5 to 570 amps. The TIG mode can be run in either
the TIG touch start or high frequency (optional equip-
ment required) assisted start mode.
• The Hot Start control selects the starting mode
desired. A setting of less than 5, the TIG lift start
mode is selected. The OCV is controlled below 10v
and the short circuit "TIG touch" current is main-
tained at 25 amps independent of the preset current.
• The Arc Control regulates pinch effect. At the mini-
mum setting (-10), minimizes pinch and results in a
soft arc. Low pinch settings are preferable for weld-
ing with gas mixes containing mostly inert gases. At
the maximum setting (+10), maximizes pinch effect
and results in a crisp arc. High pinch settings are
preferable for welding FCAW and GMAW with CO2.
CV-INNERSHIELD: The CV-INNERSHIELD mode
features continuous control from 10 to 45 volts. This
mode was designed for self-shielded flux cored wires
that require tight voltage control.
When the tungsten is lifted, an arc is initiated and
the output is regulated at the preset value. Hot start
settings between 0 and 5 regulate the arc initiation
current. A setting of 5 results in the most positive arc
initiation. A setting of 0 reduces hot start.
• The Hot Start control is not used in the CV-INNER-
SHIELD mode.
• Hot Start settings between 5 and 10, select high fre-
quency assisted starting TIG mode. In this range,
the OCV of the machine is controlled between 50
and 70 volts. If using the Lincoln K930-1 TIG
Module, set the Hot start to 10 for maximum OCV.
• The Arc Control regulates pinch effect. At the mini-
mum setting (-10), minimizes pinch and results in a
soft arc. At the maximum setting (+10), maximizes
pinch effect and results in a crisp arc. Most self-shield-
ed wires work well at an Arc Control setting of 5.
• The Arc Control is not used in the TIG mode.
INVERTEC® V450-PRO
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B-5
B-5
OPERATION
• Gouge Mode
The gouging mode is specifically designed for car-
bon arc gouging with electrodes up to 3/8”.
8A. WELD MODE SELECT-FOR
MACHINES EQUIPPED WITH OPTIONAL
ADVANCED PROCESS PANEL
(See Figure B.2 UPPER AND MIDDLE SECTION)
See (WELD MODE DETAILS) in this section.
• Pulsed Modes
In Pulse Modes;
The work point will be in the Amps window and
should be set close to the wire feed speed of the
wire feeder in inches per minute. The Volts window
will have SPd displayed indicating Wire Feed
Speed. Once current starts flowing and during the 5
second “Hold” feature the displays will show amps
and volts.
To program welding modes, the SELECT knob is used
to Scroll through all welding modes. The MEMORY
button is used to store and access welding modes into
locations M1 thru M8.
Modes:
In addition to the 5 welding modes described in SEC-
TION 7, the Advance Process Panel allows you to
select the Following additional modes.
Pulse Mode features that are displayed while selecting
a Welding pulse mode are listed below:
Steel - .030”, .035”, .045”, .052”, 1/16” – Argon Blends
Stainless Steel - .030”, .035”, .045” – Argon Blends &
Helium/Argon Blends
Aluminum - .035”, 3/64”, 1/16” – 4043 & 5356
Metal Core - .045”, .052”, 1/16” – Argon Blends
Nickel - .035”, .045” – Argon/Helium blends
• Constant Power mode
In the Power Mode;
The work point will be in the Volts window. The Amp
window will have CP displayed indicating Constant
Power. Once current starts flowing and during the 5
second “Hold” feature the displays will show Volts
and Amps respectively.
FIGURE B.2
A
S
L
N
O
C
E
N
L
M
L
O
ST
O
O
W
C
R
O
T
N
L
((
TH
)
N
T
U
0
N
R
C
T
A
O
UU
K
B
C
R
T
O
M
SE
C
S
I
VOLTS
AMPS
OUTPUT KNOB
CONTROL
REMOTE
LOCAL
WELD TERMINALS
REMOTE
ON
SELECT
SELECT
ADJUST
MEMORY
SELECT
SELECT
ADJUSST KNOB
(0 THRU +100 HOT START)
(-10 THRU 0 AAND 0 THRUU +10 ARC CCONTROL)
MEMORYY BUTTON
(M1 THRU M8)
SELECT KNOB
(SCOLLS WELDING PROCESSES)
SELECT BUTTON
(HOT SSTART ORR ARC COONNTROL)
ADVANCE PROCESS PANEL- MIDDLE SECTION OF WELDER (OPTIONAL)
INVERTEC® V450-PRO
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B-6
B-6
OPERATION
MEMORY SELECTIONS:
(See Figure B.2 for location of controls)
4. Start welding. If the arc length is too short, turn the
Output knob up. If the arc length is too long, turn
the Output knob down.
The MEMORY button and SELECT knob are used
together to select a welding process and store it in
memory (M1 thru M8). The SELECT knob scrolls
through the welding process modes and memory M1
thru M8. The MEMORY button stores the welding
process in memory.
The Arc Control, which is displayed in the right digi-
tal window, can be used to fine-tune the arc length
and characteristics.
• SELECT button" (The right button) selects between
the "Hot Start" or "Arc Control". The < will indicate the
active feature shown below.
5. After all adjustments have been made press and
hold the MEMORY button until the display changes.
The right and the left window will display a memory
position, for example M1 (or turn knob to select
memory of your choice). To store in M1, push the
MEMORY button again to save the Pulse Mig mode
to memory M1.
Right Digital Window
"Hot Start"
(-10 to 0 +10)
"Arc Control" (0 to 10) <
• The ADJUST knob adjusts the desired settings for
the Hot Start or Arc Control feature that is active.
6. The display in the digital windows read as follows:
M1 Pulse MIG Argon Blends
WELDING PROCESS MODES AVAILABLE
Steel .035
Arc Cntrl 1.2
Stick SMAW, TIG GTAW
Gouge CAG, CV MIG GMAW
CV Flux Core, Pulse MIG
7. To save a second welding mode to a memory posi-
tion of your choice, turn the SELECT knob until the
desired welding process mode is displayed in right
digital window. Then follow steps 2 thru 6.
ELECTRODE MATERIAL
Steel, Metal Core, Stainless, Aluminum, Nickel
8. Adjust the output control to the correct wire feed set-
ting and the V450-PRO is ready to weld again.
(NOTE: The wire feed speed setting is not stored in
memory and will need to be reset.)
EXAMPLE OF SAVING WELDING MODES TO MEM-
ORY
The following example is how to select Pulse MIG
using .035 steel and store it into memory.
9. Adjust the Arc Control and note that the M1 goes
away indicating that the V450-PRO settings no
longer match what is stored in memory. Going back
to the original settings will not bring the M1 back.
You will need to push the MEMORY button to recall
the original settings in M1.
1. Turn the SELECT knob until welding process is dis-
played.
RIGHT WINDOW
Pulse MIG
Steel .035
LEFT WINDOW
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
the memory and will read:
2. Wait two seconds and the right window will display
Arc Control on the second line on the right side.
Pulse MIG
Steel .035
Argon Blends
Arc Cntrl ### <
Save to MEM
M1 Overwrite
M1, which previously stored Pulse Mig, is now over-
written with the new welding process.
3. SPd is displayed in the upper right Volts window.
The left Amps window matches the desired wire
feed speed that is set on the wire feeder. Adjust the
OUTPUT knob until desired number is displayed.
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B-7
B-7
OPERATION
WELD MODE DETAILS:
Mode
Range
Comments
Stick Soft
55 - 570 amps The stick soft mode is the best selection for general stick
applications.
Arc Control = Arc Force
Hot Start = Initial hot start current (min = start a match set amps, Max.
= greatest hot start current) During hot start, arc force is set
at high and is fast response.
For gouging applications: Turn current up to 570 amps.
Stick Crisp
55 - 570 amps The stick crisp mode features an aggressive arc force routine well suit-
ed for Exx10, Exx11 series electrodes.
Arc Control = Arc Force
Hot Start = Initial hot start current (Mid range = welding current and will
vary up and down with knob control.) During hot start, arc
force is set at high and is fast response.
For gouging applications: Turn current up to 570 amps.
GTAW (Tig mode)
5 - 570 amps The tig mode produces a soft, steady constant current waveform for
either touch start or high frequency assisted start DC GTAW applica-
tions.
Hot Start = Min to Mid range = Touch start with low OCV
Mid to Max range = High frequency assisted starting with adjustable
OCV up to 70 volts.
GMAW - CV
FCAW-SS
10 - 45 volts
10 - 45 volts
The GMAW - CV mode is the best selection for general MIG welding,
Metal core, and gas shielded applications.
Arc Control = Pinch (Min = min pinch, softest arc),
(Max = max pinch, crispest arc)
The FCAW-SS mode is designed for Self Shielded Innershield products
that require tight voltage control. For example; the NR 203 series or NR
207)
Arc Control = Pinch (Min = min pinch, softest arc),
(Max = max pinch, crispest arc)
ADVANCED PULSE PANEL WELDING PROGRAMS
Gouging
60 - 570 amps The gouging mode is specifically designed for carbon arc gouging with
electrodes up to 3/8”.
GMAW - Power
0.1 - 20 KW
The GMAW - power mode is similar in operation to other GMAW
modes. The power mode features a very stable short arc performance,
which is especially good when welding small diameter (.025 and .030
steel and stainless) wires for low procedures. The short arc steel and
stainless applications, a fast response for spray applications, and a
drooper type spray mode characteristic for Aluminum.
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B-8
B-8
OPERATION
PULSE PROGRAMS:
MODE
IPM*
75 - 800
50 - 800
60 - 800
60 - 750
60 - 600
60 - 700
60 - 500
60 - 500
100 - 800
100 - 800
COMMENTS
.030 Steel
.035 Steel
.045 Steel
.052 Steel
1/16 Steel
The V450 pulse programs are non-synergic and allow independent
control of the wire feed speed and the arc length. The Output
Control Knob on the V450, adjusts an "SPD" value. Similar to trim,
the "SPD" value indicates the relative arc length setting. The value
of "SPD" is meant to be a starting point at which to set the arc
length relative to the wire feed speed. Depending on the applica-
tion, the "SPD" value can be adjusted to obtain the desired arc
length.
.045 Metal Core
.052 Metal Core
1/16 Metal Core
.030 Stainless Ar Blends
.030 Stainless He Ar CO2
The "SPD" value displayed on the V450 may not match the
actual wire feed speed!
.035 Stainless Ar Blends
.035 Stainless He Ar CO2
70 - 800
70 - 700
The operation of the Arc Control knob on the V450 is similar to the
Power Wave series. As Arc Control is increased, the frequency is
increased and the background reduced. Decreasing Arc Control will
reduce frequency and increase background current. Arc Control
acts to fine tune the arc plasma to the specific application.
Preferred gas selections:
.045 Stainless Ar Blends
.045 Stainless He Ar CO2
50 - 700
60 - 700
.035 Aluminum 4043
.035 Aluminum 5356
3/64 Aluminum 4043
3/64 Aluminum 5356
1/16 Aluminum 4043
1/16 Aluminum 5356
125 - 700
130 - 750
85 - 600
85 - 700
55 - 300
65 - 400
Steel Argon Blends = Argon with CO2 additions from 2 to 20
% or Oxygen additions from 2 to 5%.
Stainless Argon Blends = Argon with Oxygen additions up to 2%.
Stainless He Ar CO2 = ~ 90% Helium, 7 1/2 % Argon 2 1/2 CO2
Aluminum 100% Argon
The Nickel Alloy pulse programs are non adaptive. The operator
sets the output control knob to deliver the correct arc length at the
desired wire feed speed and stick out. While welding, the operator
manipulates the stick out to maintain the correct arc length. This
method of operation produces very stable arc performance consid-
ering the nature of nickel alloys.
.035 Nickel Alloys (Non Adaptive)
.045 Nickel Alloys (Non Adaptive)
60 - 700
60 - 600
Preferred gas: Argon/Helium Blends = for the best results add
helium to the argon base from 0-25%.
PULSE ON PULSE
.035 4043 (4x Pulse on Pulse) 125 - 600
3/64 4043 (4x Pulse on Pulse) 85 - 400
1/16 4043 (4x Pulse on Pulse) 65 - 315
.035 5356 (5x Pulse on Pulse) 140 - 700
3/64 5356 (5x Pulse on Pulse) 100 - 550
1/16 5356 (5x Pulse on Pulse) 75 - 360
Arc Control = Pulse on Pulse frequency. For faster travel
speed welds, the arc control should be increased.
For larger puddle, slower travel speeds, the arc control
should be decreased.
*IPM (INCHES PER MINUTE)
INVERTEC® V450-PRO
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B-9
B-9
OPERATION
TIG Mode
LN-10/DH-10 Wire Feeder Compatibility Note:
The LN-10 and DH-10 feeders can be used to pulse weld and
in the power mode with the panel. The displays on the LN-10
& DH-10 do not show the wire feed speed or power.
• The remote will default to the 6-pin MS-style if a
remote control is connected to the 6-pin MS-style
and to the 14-pin MS-style connector. If a remote is
not connected to the 6-pin MS-style connector, then
the remote will default to the 14-pin MS-style con-
nector if a remote is connected.
9. SERIAL PORT FOR SOFTWARE UPDATES
• If a remote control is connected to any of the MS-
style connectors, the WELD TERMINAL control will
default to REMOTE. If there are not any remote con-
trol devices attached, the WELD TERMINAL control
will default to ON.
10. HOT START and ARC CONTROL features have different
functions depending on the welding Mode that is active. Each
feature is described under the welding mode heading. (See
CC-Stick Modes
The output studs, Meter Polarity switch and remote connector
are located on the lower case front.
• The remote will default to only the 6-pin MS-style
connector if a remote is connected to it.
• The WELD TERMINAL control will default to ON with
or without a remote connected.
11. Both Output terminals are "STUD" connectors.
Types of Remote OUTPUT CONTROL
• The Invertec® V450-Pro’s Output Control can be
controlled by either a potentiometer connected
between 77 & 75 with the wiper connected to 76 or a
0V to 10V DC supply connected between 76 & 75.
(76 needs to be positive)
12. The METER POLARITY switch is located above the out-
put connectors. The switch provides a work connection for
wire feeder voltmeters. Place the switch in the position of
the electrode polarity indicated by the decal. The switch
does not change the welding polarity.
• 14-Pin Ms-style connector lead 75 is pin G, lead 76
is pin F and lead 77 is pin E.
13. 6-pin MS-style connector for remote control.
• 6-Pin Ms-style connector lead 75 is pin C, lead 76 is
pin B and lead 77 is pin A.
14. 14-PIN MS-style connector for wire and remote control.
15. AUXILIARY POWER
Potentiometer Control
• The total resistance should be between 2,000 ohms
(2K) and 10,000 ohms (10K)
• 115VAC, 42VAC and 24VAC power is available from the
14-pin MS-style connector.
• 42 VAC supply is rated at 10 amps.
• 24 VAC supply is rated at 10 amps.
• 115VAC outlet rated at 15* amps.
• The machine output will be at minimum when lead
76 (wiper) is at the end of the potentiometer that is
connected to 75. The machine’s output will increase
as the wiper of the potentiometer is moved to the end
that is connected to 77. (Note: In TIG mode, moving
the lead 76 (wiper) to lead 77 would produce the cur-
rent that has been set by the Invertec® V450-Pro’s
front panel Output Control.)
* Earlier models used a 10 amp circuit breaker.
REMOTE CONTROL SELECTION
• Remotes of this type offered by Lincoln Electric are
the K857, K812 and K870.
The Invertec® V450-Pro has auto sensing of remote output
controls. If after connecting or removing a remote, the
Invertec® V450-Pro did not configure the way you would like
the local or remote control settings can be changed by push-
ing the OUTPUT CONTROL or WELD TERMINAL button. (A
user cannot select between the 6 and 14 pin MS-style con-
nectors.)
Voltage Control
• The supply should be an isolated supply. (Not refer-
enced to earth ground, any auxiliary power from the
Invertec® V450-Pro or the welding output) The sup-
ply should be capable of supplying at least 20mA.
• 0 volts supplied to 76 will set the Invertec® V450-Pro
to minimum output for the mode that has been
selected while 10 volts supplied to 76 will set the
Invertec® V450-Pro to the maximum output for the
mode. (NOTE: In TIG mode, 10 volts supplied to
lead 76 would produce the current that has been set
by the Invertec® V450-Pro’s front panel Output
Control.)
CV modes
• The remote will default to the 14-pin MS-style connector if a
remote is connected. If no remote is connected to the 14-pin
MS-style connector, then the remote will default to the 6-pin
MS-style connector if a remote is connected to it.
• In all of the CV modes, the WELD TERMINAL control will
default to REMOTE.
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B-10
B-10
OPERATION
Types of Remote WELD TERMINAL Control
LIMITATIONS
• The V450-Pro is not recommended for processes
other than those listed.
• The V450-Pro can only be used with the recom-
mended equipment and options.
• 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® V450-Pro.
• 14-Pin MS-style connector, the Weld Terminals are
controlled from pin C (lead 2) and pin D (lead 4). Pin
C is positive.
RECOMMENDED PROCESSES
Properly equipped, the Invertec® V450-Pro sup-
ports GMAW-P, FCAW, SMAW, GTAW and CAC-A
processes for a variety of materials, including mild
steel, stainless steel, cored wires, and aluminum.
• 6-Pin MS-style connector, the Weld Terminals are
controlled from pin D (lead 2) and pin E (lead 4). In
the 6-pin MS-style connector pin D is positive.
INVERTEC® V450-PRO
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C-1
C-1
TABLE OF CONTENTS - ACCESSORIES SECTION
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
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C-2
C-2
ACCESSORIES
OPTIONS / ACCESSORIES
K857
K814
K812
K870
Remote Output Control
Arc Start Switch
Hand Operated Amptrol
Foot Operated Amptrol
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. (See Diagram in Operator
Manual)
K930-[ ] TIG Module
K428, K446, K449 LN-25 *
K617 (-1 or -2) K618 (-1 or -2) LN-742
K2327-[ ]
K2426-[ ]
LF-72
LF-74
K1559-1, K1564-1
K1499-1, K1521-1
K1587-1
LN-10
DH-10
Cobramatic
*Not recommended for pulse welding
FIELD INSTALLED OPTION (ALL VERSIONS)
• K1763-1
Advanced Process Panel
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D-1
D-1
TABLE OF CONTENTS - MAINTENANCE SECTION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
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D-2
D-2
MAINTENANCE
VISUAL INSPECTION
SAFETY PRECAUTIONS
Clean interior of machine with a low-pressure air
stream. Make a thorough inspection of all compo-
nents. Look for signs of overheating, broken leads or
other obvious problems. Many problems can be
uncovered with a good visual inspection.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
ROUTINE MAINTENANCE
• Always wear dry insulating gloves.
------------------------------------------------------------------------
EXPLODING PARTS can cause
1. Every 6 months or so, the machine should be
cleaned with a low pressure airstream. Keeping
the machine clean will result in cooler operation
and higher reliability. Be sure to clean these
areas:
injury.
•
Failed parts can explode or cause other
parts to explode when power is applied.
•
Always wear a face shield and long
sleeves when servicing.
• All printed circuit boards
• Power switch
• Main transformer
------------------------------------------------------------------------
See additional warning information
throughout this Operator’s Manual
-----------------------------------------------------------
• Input rectifier
• Auxiliary Transformer
• Reconnect Switch Area
• Fan (Blow air through the rear louvers)
CAPACITOR DISCHARGE PROCEDURE
1. Obtain a power resistor (25 ohms, 25 watts).
2. Examine the sheet metal case for dents or breakage.
Repair the case as required. Keep the case in good
condition to insure that high voltage parts are protected
and correct spacings are maintained. All external sheet
metal screws must be in place to insure case strength
and electrical ground continuity.
2. Hold resistor body with electrically insulated glove.
DOꢀNOTꢀTOUCHꢀTERMINALS. Connect the resis-
tor terminals across the two studs in the position
shown. Hold in each position for 1 second.
Repeat for all three capacitors.
C
M
O
C
M
L
OVERLOAD PROTECTION
The machine is electrically protected from producing
high output currents. Should the output current exceed
570A, an electronic protection circuit will reduce the
current to approximately 100A. The machine will con-
tinue to produce this low current until the protection cir-
cuit is reset. Reset occurs when the output load is
removed.
RESISTOR
RESISTOR
CAPACITOR
TERMINALS
THERMAL PROTECTION
CAPACITOR
TERMINALS
Thermostats protect the machine from excessive oper-
ating temperatures. Excessive temperatures may be
caused by a lack of cooling air or operating the
machine beyond the duty cycle and output rating. If
excessive operating temperature should occur, the
thermostat will prevent output voltage or current. The
meter will remain energized during this time.
3. Use a DC voltmeter to check that voltage is not
present across the terminals on three capacitors.
Thermostats are self-resetting once the machine
cools sufficiently. If the thermostat shutdown was
caused by excessive output or duty cycle and the fan
is operating normally, the Power Switch may be left
on and the reset should occur within a 15 minute
period.
INVERTEC® V450-PRO
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D-3
D-3
MAINTENANCE
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
3
6
2
5
1
7
4
7
1
4
5
2
3
6
INVERTEC® V450-PRO
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D-4
D-4
NOTES
INVERTEC® V450-PRO
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E-1
E-1
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
Theory of Operation ................................................................................................................................. Section E
Block Logic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description, Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Switch Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Output Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
IGBTꢀOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
FIGURE E.1 BLOCK LOGIC DIAGRAM
MAIN
R
5
L
P
E
4
C
E
ON
E
THE
A
S
R
A
#
ER
D
E
OL
O
C
E
F
K
O
I
CONT
F
S
R
C
E
T
P
R
C
C
R
F
D
E
B
S
R
T
A
T
M
M
C
N
TRANSFORMER
CURRENT
SENSOR
LEFT
SWITCH
BOARD
OUTPUT
TERMINAL
PWM
DRIVE
INPUT
INPUT
CONTACTOR
RECTIFIER
R
E
C
O
N
N
E
C
T
S
W
I
PRIMARY
CURRENT
SENSOR
T
C
H
CAPACITOR
VOLTAGE
FEEDBACK
S
W
I
P
O
W
E
T
C
H
CHOKE
RIGHT
SWITCH
BOARD
R
I
B
O
A
R
D
N
P
U
T
OUTPUT
TERMINAL
CAPACITOR
VOLTAGE
CONTROL SIGNALS
PWM
DRIVE
THERMOSTATS
FEEDBACK
#1
AUX.
RECTIFIER
65VDC
TRANS.
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CONTROL BOARD
AUX.
RECONNECT
#2
AUX.
TRANS.
FAN
MOTOR
POWER
BOARD
40VDC
STATUS
LIGHT
THERMAL
LIGHT
VOLTAGE
SENSE
WIRE FEEDER RS232
RECEPTACLE CONN.
115VAC
RECEPTACLE
RECEPTACLE
INVERTEC® V450-PRO
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 - INPUT VOLTAGE AND PRECHARGE.
R
5V
B
D
40V
P
E
R
R
P
T
E
R
S
U
R
N
T
S
R
F
5VD
O
R
C
T
C
E
E
C
W
T
C
TR
A
D
E
A
C
K
T
I
F
C
A
R
R
D
B
O
U
T
M
M
CU
R
MAIN
TRANSFORMER
CURRENT
SENSOR
LEFT
SWITCH
BOARD
OUTPUT
TERMINAL
PWM
DRIVE
INPUT
INPUT
CONTACTOR
RECTIFIER
R
E
C
O
N
N
E
C
T
S
W
I
T
C
H
PRIMARY
CURRENT
SENSOR
CAPACITOR
VOLTAGE
FEEDBACK
S
W
I
P
O
W
E
T
C
H
CHOKE
RIGHT
R
I
B
O
A
R
D
SWITCH
BOARD
N
P
U
T
OUTPUT
TERMINAL
CAPACITOR
VOLTAGE
CONTROL SIGNALS
PWM
DRIVE
THERMOSTATS
FEEDBACK
#1
AUX.
RECTIFIER
65VDC
TRANS.
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CONTROL BOARD
AUX.
RECONNECT
#2
AUX.
TRANS.
FAN
MOTOR
POWER
BOARD
40VDC
WIRE FEEDER RS232
STATUS
LIGHT
THERMAL
LIGHT
VOLTAGE
SENSE
115VAC
RECEPTACLE
RECEPTACLE CONN.
RECEPTACLE
POWER ꢀSOURCE
GENERAL DESCRIPTION
The INVERTEC® V450-PRO is an inverter based
welding power source that is designed to be a multi-
process welding system. It is a high performance, dig-
itally controlled inverter capable of complex, high-
speed waveform control. With the appropriate modu-
lar components it can support constant current, con-
stant voltage and pulse welding processes. The output
rating is 450 amps at 36 volts with a 100% duty cycle.
The 65 VDC produced from the power board rectifier is
utilized by the power board to provide various DC volt-
ages for the control board and wire feeder.
The two phases, which are connected to the input
board through the power switch, are connected to the
input rectifier. During precharge or “soft start” these
two phases are current limited by the input board. This
AC input voltage is rectified, and the resultant DC volt-
age is applied through the reconnect switches to the
input capacitors located on the switch boards. The
control board monitors the voltage across the capaci-
tors. When the capacitors have charged to an accept-
able level, the control board signals the input board to
energize the main input contactor making all three
phases of input power, without current limiting, avail-
able to the input capacitors. At this point, the
INVERTEC® V450-PRO is in the “Run Mode” of oper-
ation. If the capacitors become under or overvoltage,
the control board will signal the input board to de-
energize the main input contactor, and the
INVERTEC® V450-PRO will be disabled.
INPUT VOLTAGE AND
PRECHARGE
The INVERTEC® V450-PRO can be connected for a
variety of three phase voltages. Refer to Figure E.2.
The initial input power is applied to the INVERTEC®
V450-PRO through a line switch located on the front of
the machine. Two phases of the three-phase input
power is applied to the input board and both auxiliary
transformers. The various secondary voltages devel-
oped by the #1 auxiliary transformer are applied to the
input board, the power board rectifier and the fan
motor. The 115 VAC secondary voltage developed by
the No. 2 auxiliary transformer is applied to the 115
VAC receptacle.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
INVERTEC® V450-PRO
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3 — SWITCH BOARDS AND MAIN TRANSFORMER
MAIN
TRANSFORMER
CURRENT
SENSOR
LEFT
SWITCH
BOARD
OUTPUT
TERMINAL
PWM
DRIVE
INPUT
INPUT
CONTACTOR
RECTIFIER
R
E
C
O
N
N
E
C
T
S
W
I
T
C
H
PRIMARY
CURRENT
SENSOR
CAPACITOR
VOLTAGE
FEEDBACK
S
W
I
P
O
W
E
T
C
H
CHOKE
RIGHT
R
I
B
O
A
R
D
SWITCH
BOARD
N
P
U
T
OUTPUT
TERMINAL
CAPACITOR
VOLTAGE
CONTROL SIGNALS
PWM
DRIVE
THERMOSTATS
FEEDBACK
#1
AUX.
RECTIFIER
65VDC
TRANS.
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CONTROL BOARD
AUX.
RECONNECT
#2
AUX.
TRANS.
FAN
MOTOR
POWER
BOARD
40VDC
WIRE FEEDER RS232
STATUS
LIGHT
THERMAL
LIGHT
VOLTAGE
SENSE
115VAC
RECEPTACLE
RECEPTACLE CONN.
RECEPTACLE
SWITCH BOARDS AND MAIN
TRANSFORMER
Each switch board feeds current to a separate, oppo-
sitely wound primary winding of the main transformer.
The reverse directions of current flow through the main
transformer primaries and the offset timing of the IGBT
switch boards induce an AC square wave output signal
at the secondary of the main transformer. These pri-
mary currents are monitored by the current transformer
(CT). If the primary currents become abnormally high,
the control board will shut off the IGBTs, thus disabling
machine output. The DC current flow through each pri-
mary winding is clamped back to each respective input
capacitor when the IGBTs are turned off. This is need-
ed due to the inductance of the transformer primary
winding. The firing of the two switch boards occurs
during halves of a 50 microsecond interval, creating a
constant 20 kHz output.
There are two switch boards in the INVERTEC® V450-
PRO, each containing an input capacitor and insulated
gate bipolar transistor (IGBT) switching circuitry. Refer
to Figure E.3. When the machine reconnect switches
are configured for a lower input voltage (below 300
VAC) the input capacitors are connected in parallel.
When the machine is configured for higher input volt-
ages (300 VAC and above) the input capacitors are
connected in series.
When the input capacitors are fully charged they act as
power supplies for the IGBT switching circuit. The
Insulated Gate Bipolar Transistors switch the DC
power, from the input capacitors, “on and off” thus sup-
plying pulsed DC current to the main transformer pri-
Diagrams in this section.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
INVERTEC® V450-PRO
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 - CONTROL BOARD &ꢀMODE SELECTION BOARD
R
5V
B
D
40V
F
E
O
R
P
A
E
R
S
T
R
A
C
#
S
R
M
OR
6
O
C
T
B
C
R
E
D
W
T
O
O
A
D
E
R
BAL CT KE AED GE
C
K
T
I
ECONNECT
ITCH
F
GE
C
R
C
R
B
T
M
M
CU
R
MAIN
TRANSFORMER
CURRENT
SENSOR
LEFT
SWITCH
BOARD
OUTPUT
TERMINAL
PWM
DRIVE
INPUT
INPUT
CONTACTOR
RECTIFIER
R
E
C
O
N
N
E
C
T
S
W
I
T
C
H
PRIMARY
CURRENT
SENSOR
CAPACITOR
VOLTAGE
FEEDBACK
S
W
I
P
O
W
E
T
C
H
CHOKE
RIGHT
R
I
B
O
A
R
D
SWITCH
BOARD
N
P
U
T
OUTPUT
TERMINAL
CAPACITOR
VOLTAGE
CONTROL SIGNALS
PWM
DRIVE
THERMOSTATS
FEEDBACK
#1
AUX.
RECTIFIER
65VDC
TRANS.
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CONTROL BOARD
AUX.
RECONNECT
#2
AUX.
TRANS.
FAN
MOTOR
POWER
BOARD
MODE BOARD OR
ADVANCED MODE
BOARD
40VDC
WIRE FEEDER RS232
STATUS
LIGHT
THERMAL
LIGHT
VOLTAGE
SENSE
115VAC
RECEPTACLE
RECEPTACLE CONN.
RECEPTACLE
CONTROL BOARD & MODE
SELECTION
The control board performs the primary interfacing
functions to establish and maintain output control of the
INVERTEC® V450-PRO. Refer to Figure E.4. The
control board sends and receives digital command
information through the wire feeder receptacle and or
the RS232 connector. The software that is contained
within the control board processes and compares
these commands with the voltage and current feed-
back information it receives from the current sensor
and voltage sensing leads. The appropriate pulse
width modulation (PWM) signal (See Pulse Width
Modulation in this section) is sent to the switch board
IGBTs. In this manner, the digitally controlled high-
speed welding waveform is created.
The control board also monitors the thermostats, main
transformer primary current, and capacitor voltage,
and activates either the thermal light and/or the status
light. Dependent upon the fault situation, the control
board will either disable or reduce machine output, or
de-energize the main input contactor.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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E-5
E-5
THEORY OF OPERATION
FIGURE E.5 - OUTPUT RECTIFIER AND CHOKE
R
5V
40V
F
E
O
R
P
A
E
R
S
U
R
N
#
#
S
R
OR
F
6
C
C
R
B
C
R
E
D
W
T
S
A
D
E
R
BAL CT KE AED GE
C
K
T
I
C
T
O
F
GE
C
R
R
T
R
D
B
O
T
M
M
CU
R
MAIN
TRANSFORMER
CURRENT
SENSOR
LEFT
SWITCH
BOARD
OUTPUT
TERMINAL
PWM
DRIVE
INPUT
INPUT
CONTACTOR
RECTIFIER
R
E
C
O
N
N
E
C
T
S
W
I
T
C
H
PRIMARY
CURRENT
SENSOR
CAPACITOR
VOLTAGE
FEEDBACK
S
W
I
P
O
W
E
T
C
H
CHOKE
RIGHT
R
I
B
O
A
R
D
SWITCH
BOARD
N
P
U
T
OUTPUT
TERMINAL
CAPACITOR
VOLTAGE
CONTROL SIGNALS
PWM
DRIVE
THERMOSTATS
FEEDBACK
#1
AUX.
RECTIFIER
65VDC
TRANS.
CURRENT FEEDBACK
VOLTAGE FEEDBACK
CONTROL BOARD
AUX.
RECONNECT
#2
AUX.
TRANS.
FAN
MOTOR
POWER
BOARD
40VDC
WIRE FEEDER RS232
STATUS
LIGHT
THERMAL
LIGHT
VOLTAGE
SENSE
115VAC
RECEPTACLE
RECEPTACLE CONN.
RECEPTACLE
OUTPUT RECTIFIER
AND CHOKE
The output rectifier receives the AC output from the
main transformer secondary and rectifies it to a DC
voltage level. Since the output choke is in series with
the negative leg of the output rectifier and also in series
with the welding load, a filtered DC output is applied to
the machine output terminals. See Figure E.5.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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E-6
E-6
THEORY OF OPERATION
OVER CURRENT
PROTECTION
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. (On later production
machines this thermostat is located on the output
choke) Excessive temperatures may be caused by a
lack of cooling air or operating the machine beyond its
duty cycle or output rating. If excessive operating tem-
peratures should occur, the thermostats will prevent
output from the machine. The yellow thermal light,
located on the front of the machine, will be illuminated.
The thermostats are self-resetting once the machine
cools sufficiently. If the thermostat shutdown was
caused by excessive output or duty cycle and the fan
is operating normally, the power switch may be left on
and the reset should occur within a 15-minute period.
If the fan is not turning or the air intake louvers are
obstructed, then the power must be removed from the
machine, and the fan problem or air obstruction cor-
rected. The F.A.N. (fan as needed) system is con-
trolled by the control board via a solid-state relay.
If the average current exceeds 590 amps, then the
peak current will be limited to 100 amps until the aver-
age current decreases to fewer than 50 amps.
UNDER/OVER VOLTAGE PROTEC-
TION
A
protective
control board to monitor the voltage across
the input capacitors. In the event that
circuit
is
included
on
the
a
capacitor voltage is too high, or too low, the protection
circuit will de-energize the input contactor. Machine
output will be disabled and the “soft start” mode will be
repeated. The protection circuit will prevent output if
any of the following circumstances occur.
1. Capacitor conditioning is required. (May be
required if machine has been off for a long period
of time and is connected for high input voltage
operation.)
2. Voltage across a capacitor exceeds 390 volts.
(High line surges or improper input voltage con-
nections.)
PROTECTIVE CIRCUITS
Protective circuits are designed into the INVERTEC®
V450-PRO to sense trouble and shut down the
machine before damage occurs to the machine's inter-
nal components.
3. Voltage across a capacitor is under 70 volts. (Due
to improper input voltage connections.)
4. Internal component damage.
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E-7
E-7
THEORY OF OPERATION
FIGURE E.6 - IGBT OPERATION
A
P
S
I
E
B
D
IV
P
B
F
R
T
G
N
P
I
IN
G
A
ER
N
n+
P
n+
E
B
D
E
N
n+
P
URC
E
Y
E
IO
GATE
GATE
A
P
E
POSITIVE
VOLTAGE
APPLIED
GATE
GATE
SOURCE
SOURCE
n+
n+
n+
n+
BODY REGION
BODY REGION
P
P
n-
n-
DRAIN DRIFT REGION
DRAIN DRIFT REGION
n+
n+
BUFFER LAYER
BUFFER LAYER
P+
P+
INJECTING LAYER
INJECTING LAYER
DRAIN
A. PASSIVE
DRAIN
B. ACTIVE
INSULATED GATE BIPOLAR
TRANSISTOR (IGBT)
OPERATION
An IGBT is a type of transistor. IGBT are semiconduc-
tors well suited for high frequency switching and high
current applications.
Example B shows the IGBT in an active mode. When
the gate signals a positive DC voltage relative to the
source, is applied to the gate terminal of the IGBT, it is
capable of conducting current. A voltage supply con-
nected to the drain terminal will allow the IGBT to con-
duct and supply current to the circuit components cou-
pled to the source. Current will flow through the con-
ducting IGBT to downstream components as long as
the positive gate signal is present. This is similar to
turning ON a light switch.
Example A in Figure E.6 shows an IGBT in passive
mode. There is no gate signal, zero volts relative to the
source, and therefore, no current flow. The drain termi-
nal of the IGBT may be connected to a voltage supply;
but since there is no conduction, the circuit will not sup-
ply current to components connected to the source.
The circuit is turned OFF like a light switch.
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E-8
E-8
THEORY OF OPERATION
FIGURE E.7 - TYPICAL IGBT OUTPUTS
(
2
μ
c
2
se
5
sec
O
T
UT
24
μ
c
(
1
sec
(
s
(
(+)
(-)
1 μsec
1 μsec
48 μsec
50 μsec
MINIMUM OUTPUT
(+)
(-)
24 μsec
2 μsec
24 μsec
50 μsec
MAXIMUM OUTPUT
PULSE WIDTH
MODULATION
1
The negative portion is the other IGBT group . The
dwell time (off time) is 48 microseconds (both IGBT
groups off). Since only two microseconds of the 50-
microsecond time period is devoted to conducting, the
output power is minimized.
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 modulation. Pulse Width Modulation
(PWM) is the varying of the pulse width over the
allowed range of a cycle to affect the output of the
machine.
MAXIMUM OUTPUT
By holding the gate signal on for 24 microseconds
each, and allowing only two microseconds of dwell
time (off time) during the 50-microsecond cycle, the
output is maximized. The darkened area under the top
curve can be compared to the area under the bottom
curve. The more dark area that is under the curve indi-
cates that more power is present.
MINIMUM OUTPUT
By controlling the duration of the gate signal, the IGBT
is turned on and off for different durations during the
cycle. The top drawing in Figure E.7 shows the mini-
mum output signal possible over a 50-microsecond
time period.
1
An IGBT group consists of two IGBT modules feeding one trans-
former primary winding.
The positive portion of the signal represents one IGBT
1
group conducting for one microsecond.
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F-1
F-1
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Voltage and Current Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19
Main Switch Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19
Input Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-21
Input Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25
Input Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29
Aux. Transformer No.2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33
Aux. Transformer No.1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-35
Power Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-39
Current Transducer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-43
Thermostat Test - Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47
Fan Control and Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-49
Output Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-51
Choke Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-53
Control Board Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-55
SPI Cable Resistance and Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-57
Control or Power Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-59
Input Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-65
Current Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-77
Switch Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-81
Retest and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-84
INVERTEC® V450-PRO
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F-2
F-2
TROUBLESHOOTING AND REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
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 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.
---------------------------------------------------------------------------------------------------------------------------
Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
Course of Action” lists the most likely com-
procedure listed below.
ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject com-
ponent is either good or bad. If there are a
number of possible components, check the
components in the order listed to eliminate
one possibility at a time until you locate the
cause of your problem.
Step 1. LOCATE PROBLEMꢀ(SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos-
sible symptoms that the machine may exhib-
it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems and welding
problems.
All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
CAUTION
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.
-----------------------------------------------------------------------------------------------------------------------------------
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F-3
F-3
TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shield-
ing bag.
WARNING
ELECTRIC SHOCK
can kill.
•
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
- 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.
CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems when troubleshooting and replacing PC boards,
please use the following procedure:
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board
to assure that the PC board is properly
connected.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:
a. If the original problem does not reappear by
substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal strips.
PC board can be damaged by static electricity.
b. If the original problem is recreated by the
substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.
- Remove your body’s static
charge before opening the static-
shielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
to
a
equipment frame.
grounded part of the
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.
- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
INVERTEC® V450-PRO
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F-4
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical
damage is evident when the
sheet metal covers are removed.
Contact the Lincoln Electric
Service Department at 1-888-
935-3877.
The input fuses repeatedly fail or
the input circuit breakers keep
tripping.
1. Check the reconnect panel
connections and associated
wiring. See the Wiring
1. Input fuses or breakers may be
improperly sized.
2. The reconnect panel may not
be configured properly for the
applied voltage.
Diagram and Input
Information in Section A for
the proper input voltage.
Check the input voltage and
make sure it is correct.
1. Check the re-connect panel
connections and associated
wiring. See the Wiring
1. Input fuses or breakers may be
improperly sized.
The input fuses fail or input
breakers trip after the CR-1
contactor closes
2. The reconnect panel may not
be configured properly for the
applied voltage.
Diagram and Input
Information in Section A.
2. Perform the Input Rectifier
Test. If the Input Rectifier is
3. A component in the input
circuitry has failed.
defective, perform tests 3 and
4.
3. Perform the IGBT Switch
4. Perform the Input Board Test
CAUTION
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.
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F-5
Observe Safety Guidelines detailed in the beginning of this manual.
F-5
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The machine is dead - - no lights
- - no output - - the machine
appears to have no power.
1. Check the input power switch
SW1 for proper operation.
Also check the associated
leads for loose or faulty
1. Make sure the input power
switch SW1 is in the ON
position.
2. Check the main input fuses or
breakers and make sure all
three phases are present.
connections. See the Wiring
Diagram or Machine Diagram
3. Check the CB3 breaker
(located in the reconnect
area). Reset if tripped.
2. Replace or reset input fuses
or breaker.
3. If CB-3 opens repeatedly,
perform the Auxiliary
4. The power board rectifier may
be faulty. Check the rectifier
and associated wiring. See
the Wiring Diagram or
Machine Diagram for the
welder in Section G.
5. Perform the Power Board
6. Perform the Control Board
Check. The Control Board
may be faulty.
1. Check the receptacle and asso-
ciated wiring. See the Wiring
Diagram or Machine Diagram in
The Auxiliary Receptacle is “dead”. 1. Check CB-2 on the case front.
Reset if necessary.
No 120VAC present.
2. Check CB-3 in the reconnect
area. Reset if necessary.
2. Perform the Auxiliary
3. Make sure all three input phases
are present
CAUTION
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.
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F-6
Observe Safety Guidelines detailed in the beginning of this manual.
F-6
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The INVERTEC® V450-PRO
does not have welding output.
The main input contactor (CR1) is
not activating.
1. Make certain that the input
voltage is proper, according
1. The input voltage may be too
high or too low or reconnect
panel may be incorrectly
connected
to the Rating Plate located on
the rear of the machine. See
Installation Section of this
manual.
NOTE: This
problem
will
normally be accompanied
by an error code.
2. May be a thermal shutdown.
Check to see if the Thermal
LED is ON
this section.
The Diagnostic Utility is also
available on the Service
Navigator.
3. Possible short in output
circuit. Turn machine off.
Remove all leads from the
output of the machine.
3. The primary current limit has
been exceeded (CR1 drops out
when the output is initiated).
4. Perform the Input Contactor
4. The power source (upper
section) has failed. If nothing
is evident from a visual
inspection, perform tests as
shown.
5. Perform the Input Board
6. Perform the Auxiliary
NOTE: Error codes as indicated
by LED 9 and 10 on the
Control Board.
7. Preform the Input Rectifier
8. Perform the IGBT Switch
9. Perform the Power Board
10. Perform the Control Board
may be faulty.
CAUTION
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.
INVERTEC® V450-PRO
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F-7
Observe Safety Guidelines detailed in the beginning of this manual.
F-7
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Thermal light is ON. The
machine regularly “overheats.”
1. One of the thermostats may
be faulty. Also check
1. The welding application may
be exceeding the
associated wiring for loose or
faulty connections. See the
Wiring Diagram or the
Machine Diagram in Section
G. There are a total of 2
thermostats in the system.
recommended duty cycle
and/or limits of the machine.
2. Dirt and dust may have
clogged the cooling channels
inside the machine. Refer to
this manual.
2. Temporarily jumper out the
thermostat circuit at the
Control Board. See the
Machine Diagram in this
manual to jump this circuit
function for test only. If the
machine does not reset, the
Control Board is defective. If
it does reset, perform the
3. Air intake and exhaust louvers
may be blocked due to
inadequate clearance around
the machine. Check the upper
section of the machine and
AC/DC switch lower section
intakes.
4. Make sure the fan is
functioning correctly. Machines
are equipped with F.A.N. (fan
as needed) circuitry. The fans
run whenever the output is
enabled and will continue
running for a period of time
(approximately 5 minutes) after
the output is disabled.
3. Temporarily jump around the
fan relay contacts to test fan
relay function. See the
Machine Diagram in Section
G to test the fan relay
function.
CAUTION: 120VAC is used
to run the fan.
CAUTION
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.
INVERTEC® V450-PRO
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F-8
Observe Safety Guidelines detailed in the beginning of this manual.
F-8
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELD AND ARC QUALITY PROBLEMS
General degradation of weld
performance.
1. Check for proper wire speed
and consistent feeding.
1. Wire feed problem.
2. Check for poor connections
and/or excessive loops in the
weld cables.
2. Cabling problems.
NOTE: The presence of heat in
external welding circuits
indicates poor
3. Verify weld mode is correct for
process.
connections or
undersized weld cables.
4. Machine calibration.
3. Select the correct weld mode
for the application. Refer to
the Instruction Manual.
4. Perform Choke Test.
5. Perform Current Transducer
Test and Check Sense Lead
Routing.
CAUTION
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.
INVERTEC® V450-PRO
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F-9
Observe Safety Guidelines detailed in the beginning of this manual.
F-9
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELD AND ARC QUALITY PROBLEMS
Machine shuts down during a weld.
1. Secondary over-current
occurred.
1. Adjust parameters to minimize
momentary shorting of the arc.
NOTE: The Diagnostic Utility can
be used to check the
2. Check for single phase input,
(loss of L2) which will reduce
the secondary current limit.
Check input fuses or current in
all three phases for balance (+/-
5 amps).
‘event log’ to determine
cause of shut-down.
CAUTION
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.
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F-10
F-10
TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
STATUS LIGHTS ARE LED’S 9 AND 10 ON CENTER TOP OF CONTROL BOARD
Fault Codes
Code Description
31
Corrective Action
Primary over current.
If condition persists
contact an authorized
Lincoln Field Service
Shop
The machine needs to
be turned off and back
on to reset the machine.
32
33
34
35
37
39
CAP bank A under voltage.
CAP bank B under voltage.
CAP bank A over voltage.
CAP bank B over voltage.
Soft start Failed.
Glitch on the primary over
current fault interrupt; possibly
caused by noise or a signal level
(misc. hardware fault #1)
Check input power
Self-clearing as
reconnect to make sure condition ceases.
the machine
is connected for the input
power being supplied.
Check the machine
ground.
If problem persists
contact an authorized
Lincoln Field Service
Shop
Cycle power.
Self-clearing as
condition ceases.
43
CAP delta; CAP A and B are out
of balance.
Check input power
reconnect to make sure
the machine is
connected for the input
power being supplied.
Check the machine
ground.
44
47
Main CPU problem. The DSP
has detected a problem with the
CPU.
Possible erroneous electrical
noise on Voltage/Frequence
capacitor feed back circuit.
If problem persists
contact an authorized
Lincoln Field Service
Shop
(misc. hardware fault #2)
The main contactor opened
unexpectedly. (misc. hardware
fault #3)
48
If condition persist
contact an authorized
Lincoln Field Service
Shop
Self-clearing
"bad The selected weld mode does
node’ not exist in the weld table that is
“####” presently loaded in the machine.
If condition persists
contact an authorized
Lincoln Field Service
Shop
Press the Mode
Select button to
select a different
mode
CAUTION
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.
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F-11
F-11
TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
Displays
Description
Scrolling dash
Appears at power up while the machine is going through its self con-
figuration
"Err" "####"
Fault code display. The first fault to occur will be displayed for
three seconds. The display will cycle through fault codes for all
faults that persist after the initial three-second period are displayed
for 1 second each.
"----" "----"
Weld mode is changing
"----" "####"
A constant voltage weld mode is selected, machine output is off.
The numeric value in the right display is the work point.
"####" "----"
A constant current weld mode is selected, machine output is off.
The numeric value in the left display is either the work point or a
work point limit, depending on the weld mode and remote configu-
ration.
"####" "####"(on steady) Machine output is on. Left display is current, right display is volt-
age. If actively welding, the displays are arc current and arc volt-
age. If not actively welding, the display will show work point.
"####" "####" (blinking) Weld just finished – the average arc voltage and current will be
blinked for 5 seconds following a weld. If the work point changes
during this 5 second period, the display will revert to the above
mode.
CAUTION
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.
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F-12
F-12
NOTES
INVERTEC® V450-PRO
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F-13
F-13
TROUBLESHOOTING AND REPAIR
INPUT FILTER CAPACITOR DISCHARGE 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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will drain off any charge stored in the four large capacitors that are part
of the switch board assembly. This procedure MUST be performed as a safety precau-
tion before conducting any test or repair procedure that requires you to touch internal
components of the machine.
MATERIALS NEEDED
5/16” Nut Driver
Insulated Pliers
Insulated Gloves
High Wattage Resistor (25-1000 ohms and 25 watts minimum)
DC Volt Meter
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F-14
F-14
TROUBLESHOOTING AND REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)
FIGURE F.1 – CAPACITOR TERMINAL LOCATION
T
R
I
A
S
C
R
R
S
I
A
T
S
R
R
S
I
O
RESISTOR
RESISTOR
CAPACITOR
TERMINALS
CAPACITOR
TERMINALS
PROCEDURE
6. Using the high wattage resistor (25-1000 ohms
@ 25 watts (minimum), electrically insulated
gloves and pliers, connect the resistor across
the two capacitor terminals. Hold the resistor in
place for 10 seconds. DO NOT TOUCH THE
CAPACITOR TERMI-NALS WITH YOUR BARE
HANDS. NEVER USE A SOLID CONDUCTOR
W/LESS THAN 25 OHM RESISTANCE FOR
THIS PROCEDURE.
1. Remove input power to the INVERTEC® V450-
PRO.
2. Using the 3/8” nut driver, remove the left and
right case sides.
3. Be careful not to make contact with the capaci-
tor terminals that are located in the bottom cen-
ter of the left and right side switch boards. See
Figure F.1.
7. Repeat procedure for the other capacitor.
4. Carefully check for a DC voltage at the capaci-
tor terminals on both boards. Note the polarity
is marked on the PC board and also lead #19 is
positive.
8. Recheck the voltage across the capacitor termi-
nals. The voltage should be zero. If any volt-
age remains, repeat the discharge procedure.
5. If any voltage is present, proceed to Step #6. If
no voltage is present, the capacitors are dis-
charged.
NOTE: Normally the capacitors discharge in about
two minutes after input power is removed.
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F-15
F-15
TROUBLESHOOTING AND REPAIR
VOLTAGE AND CURRENT CALIBRATION 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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the machine is capable of producing welding output and to
check and adjust, if necessary, the voltage and or current calibration.
MATERIALS NEEDED
Resistive Load Bank
Calibrated Test Voltmeter
Calibrated Test Ammeter
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F-16
F-16
TROUBLESHOOTING AND REPAIR
VOLTAGE AND CURRENT CALIBRATION PROCEDURE (continued)
CALIBRATION CHECK
VOLTAGE CALIBRATION
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: 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.
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. If the steps are not
completed quickly, the machine will auto-
matically leave the calibration mode with-
out changing the calibration settings. The
voltage and current calibration settings of
the V450-PRO are completely indepen-
dent of each other. Adjusting one will not
affect the other.
1. Connect the resistive load band (approximate-
ly .087 ohms) and test voltmeter to the welding
output terminals.
2. Press and hold in the Mode SELECT/MEMO-
RY button.
3. Turn on the V450-PRO.
4. Rotate the Output Control knob until the dis-
play reads “vol cAL”.
1. Press and hold in the Mode SELECT button.
5. Release the Mode SELECT/MEMORY but-
2. Turn on the V450-PRO.
ton.
3. Rotate the Output Knob, while still holding the
mode select button in, until the displays read
“mode 200”.
6. Adjust the Output Control knob until the actu-
al output voltage reading on the test voltmeter
is 20volts +/- .5 volts.
7. Wait for the machine’s output to be automati-
cally turned off and then back on.
NOTE: Machines with an Advanced Process
Panels do not have a mode select button.
Use the same procedure except hold in
the Memory button on the advanced
process panel instead of the mode select
button.
8. Adjust the Output Control knob again if nec-
essary to make the actual voltage output 20
volts +/- .5 volts.
9. Wait for the machine’s output to be automati-
cally turned off and then back on.
4. Release the Mode SELECT/MEMORY but-
ton and the machine will be in mode 200.
10. Repeat the above two steps if necessary.
5. With the machine in mode 200 apply a resis-
tive load to the welding output terminals
(approximately .087 ohms) set the machine
output to 300 amps and enable the Weld
Terminals. (Weld Terminals Select ON).
11. Press and release the Mode SELECT/MEM-
ORY button to save the calibration.
6. Using the test meters note the output voltage
and current.
7. The V450-PRO voltmeter must match the test
meter reading to within +/- 1 volt.
8. The V450-PRO ammeter must match the test
meter within +/- 5 amps.
9. If the voltmeter does not meet the specification
then proceed to the Voltage Calibration
10. If the ammeter does not meet the specification
then proceed to the Current Calibration
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F-17
F-17
TROUBLESHOOTING AND REPAIR
VOLTAGE AND CURRENT CALIBRATION PROCEDURE (continued)
7. The right display will scroll the following mes-
sage: Adj oCP SorEAL cur-300A.
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
8. Adjust the Output Control knob until the actual
output current reading on the test ammeter is
300amps +/-2A.
9. Wait for the machine’s output to be
automatically turned off and then back on.
and use the previous calibration settings.
1. Connect the resistive load band (approximate-
ly .087 ohms) and test ammeter to the welding
output terminals.
10. Adjust the Output Control knob again if nec-
essary to make the actual output current read-
ing on the test ammeter 300 amps +/-2A.
2. Press and hold in the Mode SELECT/MEMO-
11. Wait for the machine’s output to be automati-
cally turned off and then back on.
RY button.
3. Turn on the V450-PRO.
12. Repeat the above two steps if necessary.
4. Rotate the Output Control knob until the dis-
play reads “cur cAL”.
13. Press and release the Mode SELECT/MEM-
ORY button to save the calibration.
5. Release the Mode SELECT/MEMORY but-
14. The left display will scroll the message IcAL
SAVEd.
ton.
6. The left display will change to “IcAL” to indicate
that current calibration is in progress.
15. The machine will reset to normal operation.
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F-18
F-18
NOTES
INVERTEC® V450-PRO
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F-19
F-19
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD 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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the “power section” of the switch boards are functioning cor-
rectly. This test will NOT indicate if the entire PC board is functional. This resistance test
is preferable to a voltage test with the machine energized because this board can be dam-
aged easily. In addition, it is dangerous to work on this board with the machine energized.
MATERIALS NEEDED
Analog Volt/Ohmmeter
5/16 in. Wrench
7/16 in. Wrench
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F-20
F-20
TROUBLESHOOTING AND REPAIR
MAIN SWITCH BOARD TEST PROCEDURE (continued)
FIGURE F.2 - CAPACITOR TERMINAL LOCATIONS
T
R
I
A
S
C
R
R
I
A
T
S
R
R
S
I
O
RESISTOR
RESISTOR
CAPACITOR
TERMINALS
CAPACITOR
TERMINALS
TEST PROCEDURE
Check 11/12 to -20 and 11/12 to +19
1. Remove input power to the INVERTEC®
V450-PRO.
Check 15/16 to -20 and 15/16 to +19
Check 13/14 to -20 and +19 to 13/14
Check 17/18 to -20 and +19 to 17/18
3. Use a DC voltmeter to check that the voltage is
not present across the terminals on three
capacitors.
6. If any test fails (measures a short) isolate the
PC board and retest, if board still fails, replace
4. Locate label and remove leads 19C and 19D
from the reconnect switches with the 3/8”
wrench. Note lead placement for reassembly.
Clear leads. See Figure F.2.
7. If the switch board tests are OK, check the
molex pin connections and associated wiring
from the switch boards to the control board.
See the Wiring Diagram.
5. Using the Analog ohmmeter, perform the following
resistance tests. See Figure F.2 for the test points.
Any readings below 100 ohms can be considered a
short circuit. However, readings usually are below 30
ohms. A short on any of the following points indicates
a possible failed switch board.
8. Reconnect leads 19C and 19D to the reconnect
switches. Ensure that the leads are installed in
the same location they were removed from.
9. Install the right and left case sides and top
using the 3/8” nut driver.
INVERTEC® V450-PRO
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F-21
F-21
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER 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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the input rectifier has “shorted” or “open” diodes.
MATERIALS NEEDED
Analog Voltmeter/Ohmmeter (Multimeter)
5/16” Nut Driver
Phillips Head Screwdriver
Wiring Diagram
INVERTEC® V450-PRO
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F-22
F-22
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST PROCEDURE (continued)
FIGURE F.3 - INPUT RECTIFIER
C
INPUT
RECTIFIER
B
A
NEG (-)
POS (+)
PROCEDURE
NOTE: Some RTV sealant may have to be
removed from the input rectifier terminals.
The RTV should be replaced when test is
complete.
1. Remove input power to the INVERTEC®
V450-PRO.
2. Using the 3/8” nut driver, remove the case top.
5. With the Phillips head screwdriver remove the
positive and negative leads from the rectifier.
4. Locate the Input Rectifier and lead locations.
Refer to Figure F.3.
INVERTEC® V450-PRO
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F-23
F-23
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER TEST PROCEDURE (continued)
6. Use the analog ohmmeter to perform the tests
detailed in Table F.1.
9. If the input rectifier is good, be sure to recon-
nect the positive and negative leads to the cor-
rect terminals and torque to 31 in.-lbs. See the
Wiring Diagram.
7. If the input rectifier does not meet the accept-
able readings outlined in the table, the compo-
nent may be faulty. Replace.
10. Replace any RTV sealant previously removed.
11. Install the case top.
NOTE: Before replacing the input rectifier, perform
dure.
TABLE F.1 – INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS
ANALOG METER X100
RANGE
TEST POINT TERMINALS
+ Probe
- Probe
Acceptable Meter Readings
A
B
C
NEG
NEG
NEG
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
A
B
C
POS
POS
POS
Approx. 500 ohms
Approx. 500 ohms
Approx. 500 ohms
NEG
NEG
NEG
A
B
C
Approx. 500 ohms
Approx. 500 ohms
Approx. 500 ohms
POS
POS
POS
A
B
C
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
INVERTEC® V450-PRO
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F-24
F-24
NOTES
INVERTEC® V450-PRO
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F-25
F-25
TROUBLESHOOTING AND REPAIR
INPUT CONTACTOR 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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the input contactor is functional and if the contacts are
functioning correctly.
MATERIALS NEEDED
3/8” Nut Driver
Volt-Ohmmeter
External 24 VAC supply
INVERTEC® V450-PRO
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F-26
F-26
TROUBLESHOOTING AND REPAIR
INPUT CONTACTOR TEST PROCEDURE (continued)
FIGURE F.4 – INPUT CONTACTOR COIL
X
C
T
T
R
INPUT
CONTACTOR
601
X4
PROCEDURE
4. Using the external 24 VAC supply, apply 24
VAC to the terminals of the input contactor coil.
If the contactor does NOT activate, the input
contactor is faulty. Replace.
1. Remove input power to the INVERTEC®
V450-PRO.
2. Using the 3/8” nut driver, remove the input
access panel and case top.
3. Locate, mark, and remove the two leads (601,
X4) that are connected to the input contactor
coil. See Figure F.4.
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F-27
F-27
TROUBLESHOOTING AND REPAIR
INPUT CONTACTOR TEST PROCEDURE (continued)
FIGURE F.5 – INPUT CONTACTOR TEST POINTS
L1
L2
T1
T2
L3
T3
L3
T3
L2
L1
T2
T1
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. Replace the input con-
tactor.
7. Reconnect the two leads (601, X4) to the input
contactor coil.
8. Install the input access door and case top using
the 3/8” nut driver.
6. When the contactor is NOT activated, the resis-
tance should be infinite or very high across the
contacts. If the resistance is low, the input con-
tactor is faulty.
INVERTEC® V450-PRO
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F-28
F-28
NOTES
INVERTEC® V450-PRO
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F-29
F-29
TROUBLESHOOTING AND REPAIR
INPUT BOARD 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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the Input Board is sending the correct voltages, as well as
if the Input Board is regulating and producing the correct DC voltages.
MATERIALS NEEDED
3/8” Nut Driver
Volt-Ohmmeter
Wiring Diagram
INVERTEC® V450-PRO
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F-30
F-30
TROUBLESHOOTING AND REPAIR
INPUT BOARD TEST PROCEDURE (continued)
FIGURE F.6 – INPUT CONTACTOR CR1
5
6
7
8
6
7
6
8
9
0
I
N
C
R
6
J60
J61
J60
J61
601
1
2
3 4
1
2
3 4
5
X4
INPUT
CONTACTOR
5
6
7
8
6
7
8
9 10
J60
J61
PROCEDURE
WARNING
1. Remove input power to the INVERTEC®
450-PRO.
ELECTRIC SHOCK can kill.
2. Using the 3/8” nut driver, remove the case top.
High voltage is present when input
power is applied to the machine.
3. Remove lead X4 from the coil terminal of main
input contactor CR1. Insulate lead X4. See
Figure F.6.
5. Turn on the INVERTEC® 450-PRO. Carefully
test for the correct voltages according to Table
4. Carefully apply input power to the INVERTEC®
450-PRO.
INVERTEC® V450-PRO
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F-31
F-31
TROUBLESHOOTING AND REPAIR
INPUT BOARD TEST PROCEDURE (continued)
6. Remove input power to the INVERTEC® V-
9. Turn on the INVERTEC® V-450 PRO.
450 PRO. If any of the voltages are low or
not present, perform the Input Contactor
may by faulty.
Check for the presence of 24 VAC from
voltage is not present, perform the
7. Reconnect lead X4 to the main input contac-
tor CR1 coil terminal.
9. This 24 VAC is the coil voltage for main
input contactor CR1. It will normally be
present approximately 12 seconds after
input line switch (SW1) is activated.
8. Carefully apply the correct input voltage to
the INVERTEC® V-450 PRO.
10. When the test is completed, remove input
power from the INVERTEC® V-450 PRO.
WARNING
11. Install the case top using the 3/8” nut driver.
ELECTRIC SHOCK can kill.
High voltage is present when
input power is applied to the
machine.
INVERTEC® V450-PRO
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F-32
F-32
TROUBLESHOOTING AND REPAIR
INPUT BOARD TEST PROCEDURE (continued)
TABLE F.2 – INPUT BOARD VOLTAGE CHECKS
LEAD
NUMBERS
EXPECTED
VOLTAGE
READINGS
TEST POINTS
COMMENTS
PLUG J61 PIN 8 (H1D)
TO
PLUG J61 PIN 2 (612)
J61
SAME AS
INPUT
VOLTAGE
Present when Input
Switch SW1 is closed.
#612
H1D
PLUG J61 PIN 10 (T3)
TO
PLUG J61 PIN 2 (T1)
J61
A LITTLE LESS
THAN INPUT
VOLTAGE
This is Pre-Charge Voltage and
will normally be present 6 sec-
onds after activating Input Switch
SW1. The Pre-Charge Voltage
should remain for approximately 6
seconds and then be removed.
T1
T3
PLUG J60 PIN 3 (238)
TO
PLUG J60 PIN 4 (604)
J60
13 – 15 VDC
This is the Coil Voltage for the
Pre-Charge Relay. Normally this
DC Voltage will be present 6 sec-
onds after Input Switch SW1 is
activated. This 13 - 15 VDC will
remain for approximately 6 sec-
onds and then be removed. The
Relay is controlled by the Control
Board. See the Wiring Diagram.
#604
#238
PLUG J60 PIN 3 (238)
TO
PLUG J60 PIN 5 (232)
J60
13 – 15 VDC
This is the DC Coil Voltage for the
Control Relay. Normally this DC
Voltage will be present approxi-
mately 12 seconds after Input
Switch SW1 is activated. The
Relay is controlled by the Control
PC Board. See the Wiring
Diagram.
#238
#232
INVERTEC® V450-PRO
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F-33
F-33
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer No. 2, as well as if the correct voltage is being induced on the secondary
winding of the transformer.
MATERIALS NEEDED
Volt-Ohmmeter (Multimeter)
3/8 in. Nut Driver
Wiring Diagram
INVERTEC® V450-PRO
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F-34
F-34
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 2 TEST (continued)
FIGURE F.7 – PLUGS P52 AND P54
P
1
T
A
N
O
M
R
2
P
2
P
3
”
O
N
NG
3/8” MOUNTING
SCREWS (2)
P52
P50
TRANSFORMER #2
P51
PROCEDURE
8. If 115 VAC is not present between pins #1 and
#4, check the associated leads and plugs for
loose or faulty connections.
1. Remove the main input supply power to the
INVERTEC® V-450 PRO.
2. Remove any load that may be connected to the
115 VAC receptacle.
WARNING
High voltage is present at plug P50.
3. Using the 3/8 in. nut driver, remove the left and
right case sides.
9. Carefully test for the correct AC input voltage
applied to the primary windings at H6 and H1.
(P50 Pins 1 and 5) Normal is 550-575 VAC.
See wiring diagram.
5. Locate plugs P50 and P51 at the Auxiliary
Transformer No. 2. See Figure F.7.
10. If the correct AC input voltage is applied to the
primary of the Auxiliary Transformer No. 2 and
the secondary voltage is NOT correct, the
transformer may be faulty. Replace.
6. Carefully apply the correct input power and
check for 115 VAC at plug P51 pins #1 and #4.
7. If 115 VAC is present, the Auxiliary Transformer
No. 2 is good.
11. Install the left and right case sides using the
3/8 in. nut driver.
INVERTEC® V450-PRO
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F-35
F-35
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the correct voltage is being applied to the primary of Auxiliary
Transformer No. 1, as well as if the correct voltage is being induced on the secondary
windings of the transformer.
MATERIALS NEEDED
Volt-Ohmmeter (Multimeter)
3/8 in. Nut Driver
Wiring Diagram
INVERTEC® V450-PRO
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F-36
F-36
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST (continued)
FIGURE F.8 – TEST LEAD LOCATIONS
PLUG
95
T
R
A
N
S
F
O
R
M
E
R
#
3
8
R
E
U
S
T
(
G
3/8” MOUNTING
SCREWS (2)
TRANSFORMER #1
PLUG
P59
PROCEDURE
1. Remove the main input supply power to the
INVERTEC® V450-PRO.
NOTE: The secondary voltages will vary if the
input line volage varies.
2. Using the 3/8 in. nut driver, remove the case
sides and top.
8. If the secondary voltages are present, the T1
auxiliary transformer is functioning properly. If
any of the secondary voltages are missing or
low, check to make certain the primary is con-
figured correctly for the input voltage applied.
See Wiring Diagram.
4. Locate leads X8 and 41B at Power Board
Bridge.
9. If the correct voltage is applied to the primary,
and the secondary voltage(s) are not correct,
the T2 transformer may be faulty.
5. Locate secondary leads X3 and X5 (fan motor
leads).
6. Locate secondary lead X4 (at main
contactor).
10. Install the case sides and top using the 3/8” nut
driver.
7. Carefully apply the correct input voltage to the
INVERTEC®ꢀV450-PRO and check for the cor-
INVERTEC® V450-PRO
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F-37
F-37
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 TEST (continued)
TABLE F.3
NORMAL EXPECTED
VOLTAGE
LEAD IDENTIFICATION
X8 to 41B
28 VAC
X3 to X5
X3 to X4
X6 to X7
X6 to X9
115 VAC
24 VAC
24 VAC
42 VAC
INVERTEC® V450-PRO
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F-38
F-38
NOTES
INVERTEC® V450-PRO
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F-39
F-39
TROUBLESHOOTING AND REPAIR
POWER BOARD TEST
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the power board is receiving the correct voltages as well as
if the power board is regulating and producing the correct DC voltages.
MATERIALS NEEDED
3/8 in. Nut Driver
Volt-Ohmmeter
Wiring Diagram
INVERTEC® V450-PRO
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F-40
F-40
TROUBLESHOOTING AND REPAIR
POWER BOARD TEST (continued)
FIGURE F.9 – POWER BOARD
4
5
6
3
3
4
7
1
8
9
0
2
1
2
1
2
2
3
4
5
6
J
J
J
J42
J41
J43
1
2
4
1
4
2
3
6
1
7
2
8
3 4
5
6
3
5
9 10 11 12
J43
J42
J41
PROCEDURE
6. Turn on the INVERTEC® V-450 PRO. Carefully
test for the correct voltages at the Power Board
1. Remove input power to the INVERTEC® V-450
PRO.
2. Using the 3/8” nut driver, remove the case top.
7. If either of the 40 VDC voltages is low or not
present at plug J41, check capacitor C3 and the
rectifier bridge. See the Wiring Diagram. Also
perform the T1 Auxiliary Transformer Test.
4. Locate the Power Board and plugs J42 and
J43. Do not remove plugs or leads from the
Power Board. See Figure F.9.
8. If any of the DC voltages are low or not present
at plugs J42 and/or 43, the Power Board may
be faulty.
5. Carefully apply input power to the INVERTEC®
V-450 PRO.
9. Install the case top using the 3/8” nut driver.
WARNING
ELECTRIC SHOCK can kill.
High voltage is present when input
power is applied to the machine.
INVERTEC® V450-PRO
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F-41
F-41
TROUBLESHOOTING AND REPAIR
POWER BOARD TEST (continued)
TABLE F.4 – POWER BOARD VOLTAGE CHECKS
CHECK POINT
LOCATION
TEST
DESCRIPTION
CONNECTOR
PLUG PIN NO.
LEAD NO. OR
IDENTITY
NORMAL
ACCEPTABLE
VOLTAGE
READING
POWER BOARD
CONNECTOR
PLUG J41
CHECK 40 VDC
INPUT FROM
DC BUS BOARD
2 (+)
1 (-)
477 (+)
475 (-)
38 – 42 VDC
NEG.
POS.
POWER BOARD
CONNECTOR
PLUG J42
CHECK +15
VDC SUPPLY FROM
POWER BOARD
1 (+)
5 (-)
+15 VDC
225 (+)
222 (-)
225
222
POWER BOARD
CONNECTOR
PLUG J42
CHECK +5 VDC
SUPPLY FROM
POWER BOARD
3 (+)
5 (-)
221 (+)
222 (-)
+5 VDC
-15 VDC
+5 VDC
221
222
POWER BOARD
CONNECTOR
PLUG J42
CHECK -15 VDC
SUPPLY FROM
POWER BOARD
2 (+)
5 (-)
222 (+)
223 (-)
223
222
4 (+)
9 (-)
226 (+)
228 (-)
POWER BOARD
CONNECTOR
PLUG J43
CHECK +5 VDC
“RS-232” SUPPLY
FROMPOWERBOARD
226
228
6 (+)
11 (-)
266 (+)
267 (-)
+15 VDC
POWER BOARD
CONNECTOR
PLUG J43
CHECK +15 VDC
SPI SUPPLY FROM
POWER BOARD
266
267
3 (+)
12 (-)
POWER BOARD
CONNECTOR
PLUG J43
CHECK +5 VDC
SPI SUPPLY FROM
POWER BOARD
+5 VDC
268A(+)
262 (-)
268A
262
7 (+)
1 (-)
POWER BOARD
CONNECTOR
PLUG J43
CHECK +20 VDC STT
SUPPLY FROM
POWER BOARD
345 (+)
346 (-)
+20 VDC
346
345
INVERTEC® V450-PRO
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F-42
F-42
NOTES
INVERTEC® V450-PRO
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F-43
F-43
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the V450-PRO current transducer and associated wiring are
functioning correctly.
MATERIALS NEEDED
3/8” Nut Driver
Volt-Ohmmeter
INVERTEC® V450-PRO
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F-44
F-44
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST (continued)
FIGURE F.10 – CURRENT TRANSDUCER TEST
T
A
C
R
1
3
P
1
D
6
7
2
1
1
3
31
J8
C
N
R
J8
L
CONTROL BOARD
J8
211 212 213
1
2
3 4
J8
5
6
7 8
216
CURRENT
TRANSDUCER
1234
P91
TEST PROCEDURE
WARNING
1. Remove input power to the V-450 PRO.
ELECTRIC SHOCK can kill.
2. Using the 3/8” nut driver, remove the case
top and the control box cover.
High voltage is present when
input power is applied to the
machine.
3. Locate the current transducer leads at
Control Board plug J8. See Figure F.10.
4. Carefully apply input power to the V-450
PRO.
INVERTEC® V450-PRO
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F-45
F-45
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST (continued)
5. Turn on the V-450 PRO. Check for the correct
DC supply voltage to the current transducer at
8. If for any reason the machine cannot be loaded
to 250 amps, Table F.5 shows what feedback
voltage is produced at various current loads.
A. Pin 2 (lead 212+) to pin 6 (lead 216-)
should read +15 VDC.
9. If the correct supply voltages are applied to the
current transducer, and with the machine
loaded, the feedback voltage is missing or not
correct, the current transducer may be faulty.
Also make certain that lead 211 (plug J8 pin 1)
has continuity (zero ohms) between the current
transducer and the control board. See the
Wiring Diagram.
B. Pin 3 (lead 213-) to pin 6 (lead 216+)
should read -15 VDC.
If the DC supply voltages are not present, the
control board may be faulty.
6. If both of the supply voltages are low or missing,
check the associated leads between plug J8
and current transducer plug P91 and the
Control Board.
10. Install the right side case cover using the 3/8”
nut driver.
7. With the V-450 PRO triggered, check the feed-
back voltage from the current transducer. The
current feedback voltage can be read at plug J8
on the Control Board.
A. Pin 1 (lead 211) to pin 6 (lead 216) should
read 2.0 VDC (machine loaded to 250
amps).
TABLE F.5 - CURRENT FEEDBACK AT VARIOUS OUTPUT LOADS
OUTPUT LOAD CURRENT
EXPECTED TRANSDUCER FEEDBACK
VOLTAGE
500
450
400
350
300
250
200
150
100
50
4.0
3.6
3.2
2.8
2.4
2.0
1.6
1.2
0.8
0.4
INVERTEC® V450-PRO
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F-46
F-46
NOTES
INVERTEC® V450-PRO
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F-47
F-47
TROUBLESHOOTING AND REPAIR
THERMOSTAT TEST – THERMAL PROTECTION
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
NOTE: The procedures and tests described in this test are written with the under-
standing that the repair technician fully understands the process of locating and
accessing (within the welding machine) the specific board or device involved in
each procedure or test.
TEST DESCRIPTION
The Thermostats are located in various locations within the welding machine. See Machine
Diagram for specific locations.
This test will determine if a thermostat is intermittently opening or is fully open.
MATERIALS NEEDED
Small, gauge (#18) short jumper wire
(Wire should be approximately 4 inches in length)
INVERTEC® V450-PRO
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F-48
F-48
TROUBLESHOOTING AND REPAIR
THERMOSTAT TEST – THERMAL PROTECTION (continued)
FIGURE F.11 – THERMOSTAT CIRCUIT
0
O
E
S
A
(
C
O
291
4
4
0
2
A
224A
291
224
220
224A
224
OUTPUT RECTIFIER
CHOKE
THERMOSTAT
THERMOSTAT
(BOLTED CONNECTION)
(CONNECTED W/EPOXY)
220
Thermostat
J5
LED 6
SIMPLIFIED TEST PROCEDURE
NOTE: Never run the V-450 PRO under load when
any of the thermostats are bypassed. This is
only a means of isolating the inoperative or
open thermostat.
All thermostats are normally closed so moving the
jumper as indicated and watching the Thermal LED
should help determine which thermostat or
associated wiring is defective.
1. Temporarily bypass thermostat circuits with a
shorting jumper as follows:
Don’t forget to check the incline splice 224 to 224A as
a possible open.
• All thermostats at the Control Board (2J5 to
3J5)
• Choke thermostat only (224A to 291)
• Output Rectifier thermostat only (220 to 291)
Located on the Output Rectifier Heat Sink
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F-49
F-49
TROUBLESHOOTING AND REPAIR
FAN CONTROL AND MOTOR TEST
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This test will help determine if the fan motor, control board, switch board, and associated
leads and connectors are functioning correctly.
MATERIALS NEEDED
Voltmeter
3/8” Nut Driver
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F-50
F-50
TROUBLESHOOTING AND REPAIR
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.
FIGURE F.12
F
e
S
R
A
E
TP4
C
+
3
J
J
F
ONTR
O
V
F
t
s
b
+
X3A
TP4
3R
J7-15
J7-16
FAN CONTROL (+15VDC)
FAN CONTROL (-)
Fan comes on when
output is enable
3W
CR2
444
-
FAN
SOLID STATE
RELAY
Located in Rear of
PowerSource
4. Carefully apply the correct input power to the
machine.
FAN CONTROL TEST PROCEDURE
5. Carefully check for 115VAC at X3A and 444.
See Figure F.12.
1. Locate plug J7 on the control board. Do not
remove the plug from the control board. See
Figure F.12.
WARNING: HIGH VOLTAGE IS PRESENT AT
THE RELAY TERMINALS.
2. Energize the weld output terminals (Select
Weld Terminals ON) and carefully check for
+15VDC at plug J7 pins 15 & 16 on the control
PCꢀboard. If the 15VDC is present and the fan
is not running then the relay or fan may be
faulty. If the 15VDC is not present when the
weld terminals are energized, then the control
board may be faulty.
6. If the 115VAC is low or not present, perform the
breaker CB2 and associated leads for loose or
7. Energize the weld output terminals (Select
Weld Terminals ON) and carefully check for
115VAC at the fan motor leads. If the 115VAC
is present and the fan is not running, the fan
WARNING
HIGH VOLTAGE IS PRESENT
AT THE SWITCH BOARD.
WARNING: HIGH VOLTAGE IS PRESENT AT
THE FAN LEADS.
WARNING
ELECTRIC SHOCK can kill.
High voltage is present when input
power is applied to the machine.
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F-51
F-51
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER 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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if any of the output rectifiers are shorted.
MATERIALS NEEDED
Analog Volt-Ohmmeter
3/8” Nut driver
5/16” Wrench
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F-52
F-52
TROUBLESHOOTING AND REPAIR
OUTPUT RECTIFIER TEST PROCEDURE (continued)
FIGURE F.13 - OUTPUT TERMINAL LOCATION
N
R
I
L
OUTP
R
U
LA
C
A
S
L
AMPS
VOLTS
OUTPUT
CONTROL
REMOTE
LOCAL
SELECT
TOUCH
START
TIG
HI-FREQ
TIG
SOFT
CRIP
NEGATIVE (-)
OUTPUT
POSITIVE (+)
OUTPUT
TERMINAL
TERMINAL
PROCEDURE
Capacitor Discharge procedure.
1. Remove main input supply power to the V450-
PRO.
6. Using the 5/16” wrench, remove and insulate
lead 202A from the negative output terminal.
Repeat step 4 to confirm if it is less than 10
ohms short.
2. Remove any output load that may be connect-
ed to the V450-PRO.
3. With the analog ohmmeter, measure the resis-
tance between the positive and negative output
terminals. Refer to Figure F.13.
7. Reconnect lead 202A to the negative output ter-
minal.
Important: The positive (+) meter probe must be
attached to the positive output terminal and the
negative (-) meter probe must be attached to the
negative output terminal.
8. Replace the shorted modules if necessary.
4. If the reading is approx. 50 ohms, the output
rectifier modules are not shorted. If the reading
is less than 10 ohms, one or more of the rectifi-
er modules may be shorted. Reverse meter
probe and verify low reading.
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F-53
F-53
TROUBLESHOOTING AND REPAIR
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
The Weld Choke is located down and behind the work stud. This test will help determine
whether the Choke is shorted to ground or is open.
MATERIALS NEEDED
Digital Volt/Ohmmeter
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F-54
F-54
TROUBLESHOOTING AND REPAIR
CHOKE TEST PROCEDURE (continued)
FIGURE F.14 – CHOKE ASSEMBLY
C
H
O
K
E
/
R
O
N
CHOKE/IRON
PROCEDURE
1. Using an Ohmmeter, make sure that the
choke windings are not grounded to the
lamination (> 1megohm).
No windings or terminal connections should look
burned or over-heated. AC welding may cause
choke to buzz slightly.
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F-55
F-55
TROUBLESHOOTING AND REPAIR
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. As a result, the troubleshooting chart will typically recommend other areas to be tested before the
Control Board.
If the Control Board does seem to be the most likely solution, perform the checks outlined below, and then try
downloading the latest software into the machine. If a solution is still not evident, use the Diagnostic facility to
take a “snapshot” that can then be sent to the Lincoln Service Department via e-mail for assistance in determin-
ing where the problem. Contact the Lincoln Service Department at 1-888-935-3877.
TEST PROCEDURE
1. Check the LED’s on the Control Board. Compare
the pattern to Page 3 of the Machine Schematic.
3. If LED’s 9 & 10 are flashing an error code and all
other LED’s are correct:
Normal operation will show 8 Green LED’s ON
and both Red LED’s OFF.
Check the Error Code list in this section to deter-
mine where the problem may be.
Green LED’s 1 through 8 indicate the pres-
ence of the various DC supplies to the Board.
If the Error Code is not listed, contact the Lincoln
Service Department for determination.
LED 7 (red) will only be ON in the event of a
Primary Over Current. Cycle the Power
Switch to reset LED 7.
4. Check the DIP switches. In a single machine set-
up, switches 1 through 7 should be OFF. Switch 8
should be ON if a remote sense lead is attached.
LED’s 9 (green) & 10 (red) will mimic the
Status LED on the front panel in the event of
an error. If the Status LED is OFF, these will
still indicate the error code.
NOTE: If any switches need to be changed because
the machine was removed from a multi
machine application be sure to write down
their position before changing them so they
can be properly reset when the machine is
returned to it’s position.
2. If any of the Green LED’s 1 through 8 are not lit or
are dimmer than the others:
Turn the power off and disconnect all of the
Control Board Molex connectors except J4 and
turn the power back on . If the LED(s) in question
stay the same:
Check the DC voltage levels in connector J4.
ings.
If voltages are correct, replace the Control
Board. If not, replace the Power Board.
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F-56
F-56
NOTES
INVERTEC® V450-PRO
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F-57
F-57
TROUBLESHOOTING AND REPAIR
SPI CABLE RESISTANCE AND VOLTAGE 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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if there is a possible “open” in the SPI cable and also if the
correct supply voltages are being applied to the boards in the SPI network.
MATERIALS NEEDED
Volt/Ohmmeter
5/16” Nut Driver
Phillips Head Screwdriver
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F-58
F-58
TROUBLESHOOTING AND REPAIR
SPI CABLE RESISTANCE AND VOLTAGE TEST PROCEDURE (continued)
TEST PROCEDURE
10. Turn on the machine.
1. Remove the input power to the V450-PRO.
11. Carefully check for the presence of +15VDC
from plug J33 pin -1(+) to plug J33 pin -10(-) at
the display board receptacle.
2. Using the #2 Phillips screwdriver, remove the
case front panel.
5. Locate and remove plug J33 from the control
board. See Figure F.15.
12. Carefully check for the presence of +5VDC
from plug J33 pin -2(+) to plug J33 pin -10(-) at
the display board receptacle.
6. Check the resistance and continuity of the SPI
cable by testing with the ohmmeter from each
pin on plug J33 to the corresponding pins on
plug J34. See the Wiring Diagram.
13. If either of these voltages are low or not pre-
sent, the control board may be faulty. Replace.
7. The resistance reading pin to corresponding
pin should be zero ohms or very low resis-
tance. If the resistance reading is high or
“open” check the plug connections to the SPI
network PC boards. If the connections are OK
and the resistance is high or “open” the SPI
cable may be faulty.
14. Remove the input power to the V450-PRO
machine.
15. Replace any cable ties previously removed.
16. Replace the case front.
8. Reconnect the plug into the control board.
9. With plug J33 reinstalled in the control board,
carefully apply the correct input power to
V450-PRO.
FIGURE F.15 - Plug J33
J
3
PLUG J33
1
2
3
4
5
6
7
8
9
10
5
4
10
9
J33
3 8
2
7
1 6
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F-59
F-59
TROUBLESHOOTING AND REPAIR
CONTROL OR POWER BOARD
REMOVAL AND REPLACEMENT 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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of either the power
board or the control board.
MATERIALS NEEDED
3/8 in. Nut Driver
Phillips Head Screwdriver
Anti-Static Wrist Strap
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F-60
F-60
TROUBLESHOOTING AND REPAIR
CONTROL OR POWER BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.16 – BOARD LOCTION
C
C
POWER BOARD
COMPARTMENT
COVER
CONTROL BOARD
REMOVAL PROCEDURE
7. Label and remove the two molex plugs and
white and black wires with quick connects from
the power PC board.
1. Remove input power to the V450-PRO.
2. Remove the case top, sides and front.
8. Using the 3/8 in. nut driver, remove the two
screws holding the rear of the Control Box in
place.
4. Observe all static electricity precautions.
9. Clear the lead harnesses from the left and right
sides, and carefully remove the power and con-
trol PC board assembly.
5. Using the 3/8 in. nut driver, remove the PC
board compartment cover. Refer to Figure
F.16.
10. Remove either the power or the control board
from the PC board assembly.
6. Remove the molex plugs from the control
board.
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F-61
F-61
TROUBLESHOOTING AND REPAIR
CONTROL OR POWER BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
INSTALLATION PROCEDURE
5. Connect the molex plugs to the control PC
board.
1. Install either the power or control board to the
PC board assembly and secure it in place.
6. Install the PC board compartment cover using
the 3/8 in. nutdriver.
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.
7. Install the case top and sides using the 3/8 in.
nut driver and Phillips screwdriver.
3. Secure the rear of the control box in place.
4. Connect two molex plugs and black and white
wires with quick disconnects to the power PC
board.
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F-62
F-62
NOTES
INVERTEC® V450-PRO
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F-63
F-63
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER REMOVAL AND REPLACEMENT 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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input rectifi-
er module.
MATERIALS NEEDED
3/8” Nut Driver
3/16” Allen Wrench
Phillips Head Screwdriver
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F-64
F-64
TROUBLESHOOTING AND REPAIR
INPUT RECTIFIER
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.17 – INPUT RECTIFIER LOCATION
A
INPUT
RECTIFIER
B
C
NEG (-)
POS (+)
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
1. Remove input power to the V450-PRO.
1. Clean heat sink surfaces.
2. Using the 3/8” nut driver, remove the case top,
input access panel and sides.
2. Apply an even coating of joint compound
(Penetrox A-13) to both the heat sink and mod-
ule mounting surfaces. The joint compound
should be 0.002 - 0.005 in. thick per surface.
4. Locate and remove the RTV sealant from the
input rectifier connection terminals. See Figure
F.17.
3. Mount the module to the heat sink and evenly
torque the mounting screws (with washers) to
44 in/lbs.
5. Label and, using the Phillips head screwdriver,
carefully remove the five leads from the input
4. Assemble the leads to the correct module ter-
minals and torque to 26 in/lbs. See Figure F.17.
rectifier terminals. Note placement for
reassembly. See Figure F.17.
5. Apply RTV sealant to the rectifier connection
terminals.
6. Using the 3/16” allen wrench, remove the two
mounting screws and washers from the rectifier
module.
6. Install the case top, sides, and input access
panel using the 3/8” nut driver.
7. Carefully remove the input rectifier module.
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F-65
F-65
TROUBLESHOOTING AND REPAIR
INPUT CONTACTOR REMOVAL AND REPLACEMENT 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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the input con-
tactor.
MATERIALS NEEDED
3/8” Nut Driver
5/16” Nut Driver
Slot Head Screwdriver
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F-66
F-66
TROUBLESHOOTING AND REPAIR
INPUT CONTACTOR
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.18 – INPUT CONTACTOR LOCATION
I
P
U
A
X
O
R
6
1
601
X4
INPUT
CONTACTOR
REMOVAL PROCEDURE
REPLACEMENT PROCEDURE
1. Remove input power to the V450-PRO.
1. Mount the contactor and tighten the mounting
screws.
2. Using the 3/8” nut driver, remove the case top,
and input access panel.
2. Assemble the previously removed leads to the
correct terminals. See wiring diagram
3. Install the case top, sides, and input access
panel using the 3/8” nut driver.
4. Locate the input contactor. Label leads and,
using the slot head screwdriver, carefully
remove the leads from the input contactor ter-
minals. Note placement for reassembly. See
Figure F.18.
5. With the 5/16” nut driver, remove the three
mounting screws.
6. Carefully remove the input contactor.
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F-67
F-67
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT 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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of auxiliary trans-
former No. 2.
MATERIALS NEEDED
3/8” Nut Driver
Wire Cutters
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F-68
F-68
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT PROCEDURE (continued)
FIGURE F.19 – TRANSFORMER AND PLUG LOCATIONS
P51
T
A
N
S
F
R
M
E
R
#
P
5
P
5
3
8
R
M
E
W
S
T
G
3/8” MOUNTING
SCREWS (2)
P52
P50
TRANSFORMER #2
P51
REMOVAL PROCEDURE
4. Using the 3/8” nut driver, remove the case back.
5. Disconnect plugs P50, P51, and P52 and clean.
1. Remove input power to the V450-PRO.
2. Using the 3/8” nut driver, remove the case top,
input access panel and case sides.
6. Using the 3/8” nut driver, remove the two trans-
former mounting screws. See Figure F19.
7. Label and clean all leads for transformer
removal.
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F-69
F-69
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 2 REMOVAL AND
REPLACEMENT PROCEDURE (continued)
REPLACEMENT PROCEDURE
4. Connect any leads and install cable ties as nec-
essary.
1. Carefully place the transformer into the V450-
PRO.
5. Install the case back using the 3/8” nut driver.
2. Install the two mounting screws that hold the
transformer to the machine base using the 3/8”
nut driver.
6. Install the case top, sides, and input access
panel using the 3/8” nut driver.
3. Connect plugs P50, P51 and P52.
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F-70
F-70
NOTES
INVERTEC® V450-PRO
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F-71
F-71
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT 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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of auxiliary trans-
former No. 1.
MATERIALS NEEDED
3/8” Nut Driver
Wire Cutters
Wire Splicer and Soldering Equipment
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F-72
F-72
TROUBLESHOOTING AND REPAIR
AUXILIARY TRANSFORMER NO. 1 REMOVAL AND
REPLACEMENT PROCEDURE (continued)
FIGURE F.20 – DOOR REMOVAL
P
PLU
95
T
R
A
N
S
F
O
R
M
E
R
#
1
3/
S
RE
W
TING
2)(
3/8” MOUNTING
SCREWS (2)
TRANSFORMER #1
PLUG
P59
REMOVAL PROCEDURE
5. Remove leads 41B and unplug P59. See
Figure F.20.
1. Remove input power to the V450-PRO.
2. Using the 3/8” nut driver, remove the case top,
and input access panel.
6. Label and cut or remove all primary and sec-
ondary leads from transformer #1. See Wiring
Diagram.
4. Using the 3/8” nut driver, remove the case back.
7. Disconnect plug P59. See Figure F.20.
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F-73
F-73
TROUBLESHOOTING AND REPAIR
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. Carefully remove the transformer from the
V450-PRO.
REPLACEMENT PROCEDURE
1. Carefully place the transformer into the V450-
PRO.
2. Install the two mounting screws that hold the
transformer to the fan baffle and the machine
base using the 3/8” nut driver.
3. Reconnect plug P59 and lead 41B.
4. Reconnect all primary and secondary leads.
See Wiring Diagram.
5. Reposition any wire leads and install cable ties
as necessary.
6. Install the case back using the 3/8” nut driver.
7. Install the case top, sides, and input access
panel using the 3/8” nut driver.
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F-74
F-74
NOTES
INVERTEC® V450-PRO
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F-75
F-75
TROUBLESHOOTING AND REPAIR
CONTROL, REMOTE, MODE OR DISPLAY PC BOARD
REMOVAL AND REPLACEMENT
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the
Control Board, Remote Board, Mode Board or Display PC Board.
MATERIALS NEEDED
3/8" Nut Driver
Anti-Static Wrist Strap
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F-76
F-76
TROUBLESHOOTING AND REPAIR
CONTROL, REMOTE, MODE OR DISPLAY PC BOARD
REMOVAL AND REPLACEMENT (continued)
FIGURE F.21 – BOARD LOCATIONS
B
D
B
T
(
3
C
D
DISPLAY BOARD
CONTROL BOARD
3/8” MOUNTING
BOLTS (4)
MODE
BOARD
REMOVAL PROCEDURE
3. Observe all static electricity precautions.
1. Remove input power to the V450-PRO.
4. Remove, replace and add panels as needed
and/or follow advanced process panel kit
instructions.
2. Using the Phillips screwdriver, remove the case
front mounting screws and tilt forward.
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F-77
F-77
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT 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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Current
Transducer.
MATERIALS NEEDED
3/8” Nut driver
5/16” Open-End Wrench
9/16” Wrench
3/4” Wrench
Phillips Head Screwdriver
Wire Cutters
Wiring Diagram
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F-78
F-78
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.22 – CURRENT TRANSDUCER LOCATION
C
S
F
O
T
3
(
C
R
E
T
CURRENT
TRANSDUCER
HEAVY LEAD
BOLTED CONNECTION
(BEHIND CASE FRONT)
3/8” SCREWS AT
BOTTOM OF
CASE FRONT (3)
REMOVAL PROCEDURE
6. Label all leads to all output terminals. Using the
5/16” wrench and the 3/4” wrench, remove all
leads from the two output terminals.
1. Remove input power to the V450-PRO.
2. Using the 3/8” nut driver, remove the case top
and sides and the control box cover.
7. Cut any necessary cable ties. Then carefully
swing the front panel aside.
3. Perform the Capacitor Discharge Procedure.
4. Using the 3/8” socket wrench or nut driver,
remove the three screws along the bottom case
front. See Figure F.22.
8. Remove the insulating tape from the heavy lead
bolted connection. Using the 9/16” wrenches,
remove the bolt, lock washer and nut.
5. Using the 3/8” socket wrench, remove the four
screws that hold the case front to the machine.
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F-79
F-79
TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER
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.
3. Run the heavy lead through transducer and
secure the bolted connection with the 9/16” bolt,
lock washer and nut. Replace the insulating
tape around the connection.
10. Remove the Current Transducer.
4. Replace plug P91 into the new current trans-
ducer.
11. Remove the standoffs from the transducer
and save them for reassembly with the new
transducer. Note placement upon removal.
5. Using the 5/16” wrench and the 3/4” wrench,
attach all leads previously removed to the three
output terminals. See the Wiring Diagram.
12. Remove plug P91. See Wiring Diagram.
6. Replace any cable ties cut during removal.
REPLACEMENT PROCEDURE
7. Install the case top and sides using the 3/8” nut
driver.
1. Attach the stand-offs to the transducer.
2. Position the transducer on the back of the
front panel and attach it with the two phillips
screws and lock washers. Feed the output
leads through the transducer. Note direction
of output lead through current transducer.
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F-80
F-80
NOTES
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F-81
F-81
TROUBLESHOOTING AND REPAIR
SWITCH BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT
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.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the switch
board(s) and/or filter capacitor(s).
MATERIALS NEEDED
3/8” Nut Driver
7/16” Wrench
3/16” Allen Wrench
Slot-Head Screwdriver
Penetrox A13 Thermal Joint Compound
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F-82
F-82
TROUBLESHOOTING AND REPAIR
SWITCH BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT (continued)
FIGURE F.23 – SWITCH BOARD LOCATION
SWIT
CH
OB
R
SWITCH BOARD
REMOVAL PROCEDURE
8. Using the 7/16” wrench, remove leads 11/12 or
NOTE: Observe all static electricity precautions.
Lead and plug references below use a slash (/) to
indicate machine right side/left side wire number
differences.
9. Using the 7/16” wrench, remove leads 19C/D+
and 20C/D- from the switch board capacitor
1. Remove input power to the V450-PRO.
10. With the slot head screwdriver, remove the
two nylon mounting screws at the bottom of
the switch board. Note placement of the
shake-proof washers and fiber spacers.
2. Using the 3/8” nut driver, remove the case top
and sides.
11. Using the 3/16” allen wrench, carefully remove
the four cap screws that mount the switch
board to the heat sink.
4. Using the 3/8” nutdriver, remove the screw
mounting the plastic high voltage protective
shield. Remove the shield and it’s mount from
the machine.
12. Carefully remove the switch board from the
heat sink.
5. Remove molex plug J50 from the top of the
13. If the filter capacitor is to be removed, careful-
ly slide it out of the mounting bracket.
6. Remove the mylar insulating shield covering
leads 13/14 or 17/18 (marked clearly on the
board). Cut any necessary cable ties.
7. Using the 7/16” wrench, remove leads 13/14 or
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F-83
F-83
TROUBLESHOOTING AND REPAIR
SWITCH BOARD AND FILTER CAPACITOR
REMOVAL AND REPLACEMENT (continued)
REPLACEMENT PROCEDURE
6. Make sure the capacitor is positioned correctly.
Connect leads 19C/D+ and 20C/D- to the cor-
rect terminals. Tighten to 55 in/lbs.
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.
7. Position and mount the two nylon screws, fiber
spacers, and washers. Torque from 4 to 8 in-
lbs.
2. All heat sink and IGBT mounting surfaces
must be clean.
8. Connect leads 15/16 to the correct terminal.
9. Connect leads 17/18 to the correct terminal.
3. Apply a thin coat of thermal compound
(Penetrox A13) 0.005 to 0.010 inches thick to
the mating surfaces. Do not apply around
mounting holes.
10. Install the mylar insulating shield covering
leads 15/16. Replace the cable tie.
11. Connect molex plug J40/J50 to the top of the
switch board.
4. Apply a thin coat of Penetrox A13 to the
capacitor terminals. Be careful not to apply
compound to screw threads or threaded area
of terminals.
12. Using the 5/16” nut driver, install the plastic
high voltage protective shield.
5. Mount the new switch board and tighten the
four cap head screws in the following manner.
13. Install the case top and sides using the 3/8”
nut driver.
Tighten all until snug.
Tighten all from 24 to 28 in-lbs.
Tighten all from 40 to 48 in-lbs.
FIGURE F.24 – SWITCH BOARD LEADS
(
d
C
a
d
C
)
(
d
6
5
)
P
PLUG J40/J50
7/16” NUT
(Leads 13/14 or 17/18)
7/16” NUT
(Leads 11/12 or 15/16)
7/16” NUT
(Leads 19C/D+ and 20C/D-)
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F-84
F-84
TROUBLESHOOTING AND REPAIR
RETEST AFTER REPAIR
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.
OR
If you repair or replace any electrical components.
INPUT IDLE AMPS AND WATTS
Input Volts/Hertz
Maximum Idle Amps
Maximum Idle KW
208/60
230/60
400/60
460/60
575/60
4.0
3.3
2.1
2.0
1.8
0.40
0.40
0.40
0.40
0.40
MAXIMUM OUTPUT VOLTAGES
Output Terminals
- No load
115 Volt Receptacles
Input Volts/Hertz
208/60
230/60
400/60
460/60
575/60
OCV
10 Amp Load
111 - 119 VAC
50-70 VDC
115 - 123 VAC
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G-1
G-1
TABLE OF CONTENTS - DIAGRAM SECTION
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram - Complete Machine - (G4923) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Schematic – Complete Machine - (G4875) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3 / G-5
Schematic – Digital Control PC Board (G3789) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6 / G-9
Schematic - Digital Power Supply PC Board (G5631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-10
Schematic – Input PC Board - (M19528) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-11
PC Board Assembly – Input PC Board - (L11396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12
Schematic - Switch PC Board - (L11385) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-13
PC Board Assembly – Switch PC Board - (G3734) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-14
Schematic – SPI / Remote Control PC Board - (G4017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-15
Schematic - Display PC Board - (L11108) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-16
PC Board Assembly – Display PC Board - (L11130) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-17
Schematic - LED Potentiometer PC Board - (S25258) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-18
PC Board Assembly – LEDꢀPotentiometer PC Board - (M19874) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-19
Schematic - LED SelectꢀPC Board - (S25259) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-20
PC Board Assembly – LEDꢀSelect PC Board - (M19875) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-21
* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-lay-
ered and are therefore considered to be unserviceable. Assembly drawings of these boards are
no longer provided.
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G-2
G-2
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - COMPLETE MACHINE - (G4923)
INVERTEC V450-PROTM WIRING DIAGRAM
LEF
T
SIDE OF MACHINE
CON
T
RO
L
BOARD
CB
3
TO
J7
SOLID 3R
3W
DIGITA POWER
L
3.5A
CIRCUIT
BREAKER
STATE
41B
SUPPLY BOARD
RELAY +
1
4
-
3
2
TO
TO
AUX #2
AU
X
ILIARY
T
H6
RANSFORMER #1
276
2
3
4
P59
H1A
1
2
3
225
223
221
227
222
TO
J4
SPI EXTENSION CIRCUIT
SPI FLEX CIRCUIT
TO TP6
TO
5
4
10
9
16
8
7
6
5
4
3
3316
3315
3314
3313
(0
V
)
275
277
41A
51
1
2
3
4
X6
H1B
J
9
H6A
(550-575)
H5
I
NPUT
SWITCH
15
14
13
12
11
10
9
202
J4
2
1
H6
H5
5
6
7
8
(24
(28
(42
V
V
V
)
)
)
612B
J3
J2
4
5
6
X7
X8
X9
J37
42
3
8
(440-460)
H4
TO TP3
24
3305
3304
3303
10A
1
TO
J
61
W
ORK
H4
H4B
2
1
7
TO
R
1
612
H1
(380-415)
FUSE
202A
1
TO
NEGA
POSA
9
TO
6
TO
P
OWE
R
B
D. RECTIFIE
R
A
UX
#2
3312
2
3
4
10
_
J4
C3
N.J.
X3
DI
S
PLAY
444
X3A
UX
CB3
TP4
202C
TO
A
UX
#
1
W
H3
H3
H2
H1
X3
X4
X5
(220-230)
RECONNECT PANEL
1
2
3
4
251
J33
(24V)
TO FAN TO
A
#
1
N
R
224A
H2
1
2
3
4
5
2
1
346
(200-208)
CH KE
THERM
O
3301
253
254
J60A
(115V)
J60B
H1
J333
3313
TO
R
EC
HERM
T
268
226
5
T
2
3316
3314
3305
TO
J4
TO
S
OLID
S
TATE RELAY
TO FAN
291
WELD
M
AIN CHOKE
4
3
2
1
C1
.05/600V
1
2
444
3304
3312
3315
3303
3
4
TO
CR
J60
267
266
268
TP1
16
3216
3215
R5
8
7
6
5
4
3
1
266
345
TERMINALS
6
3207
3206
J4
3
10K/2W
1
3
4
5
6
FAN
7
O
UT
PUT
P91
4
3
2
1
CONTROL 5
228
267
X3A
TO SOLID STATE RELAY
15
14
13
12
11
10
9
TO
J8
8
9
10
11
12
CURRENT
216
211
213
212
228
226
227
221
X5
T
RANSDUCER
3205
3204
3203
TO
A
UX#1
+
J4
J5
3213
3212
3211
7
8
TO
J42
J43
277
275
LE
D
SELECT
LE
D
S
EL
ECT
276
THIS AREA VIEWED FROM
REAR OF MACHINE
9
T
O
J5
220
10
222
223
225
224
MAIN
3202
11
N.B.,
WI
N
.G., N.H
.
TO
J6,J10A
2
1
TRANSFORMER
12
OU
T
PU
T
3201
4A
224A
J332
J331
L
EFT SIDE
1
2
3
4
REC
T
TO
TO
RECONNEC
T
S
T
CH
R
CHOKE
THERM
S3
RS232
224
220
RECT
TO
T
HERM
E
M
O
T
220
291
16
SWITC
H
B
D
#2
TO
SWITC
6
5
4
3
2
1
12
11
10
9
291
RECONNECT
PANEL
CONNECTOR
13
14
H
B
D
#1
4
RECT
THERM
POS
1
231
232
2
19C
1
2
TO SW1
N.C.
75
77
76
2
3
4
SEC
PR
I
TO
253
254
TO
N.J.
(TOP
SWITCH
(TOP
3
19
J40
J50
J60
LEFT)
LEFT)
B
D
#2
76A
4
504
503
TO
TO
A
UX
#1
200-208V
220-230V
440-460V
550-575V
TO
J2
5
6
7
8
554
5
H2
H3
H5
H6
E
D4
HARMONI
C
8
553
AD
J34
PROCESS
VANCED
6
406
TO
SWITCH BD
NEG
FILTER
'A
'
F4
F4
7
7
251
405
MODE
P
ANEL
OR
18
#1
J6
J40
238
505
9
20
554
553
10
20D
11
12
13
14
15
16
SWI
T
CH BOARD
#1
TO
SWITC
J61
604
H
B
D
#2
12
TO
20
506
403
404
HARMONI
C
+
2.7 10W
3500
F
F
ILTER
500V
C4
PR
I
TO
N.G.
SEC
(BOTTOM SWITCH
NOTE: IF ADVANC
E
D
P
ROCES
S
PANEL I
PI CABL
ROCESS
PANEL
PI
S
1
WIRE FEEDER R
EMOT
E
(BOTTOM
LEFT)
LEFT)
B
D
#1
.022
2
3
4
SPI FLEX CIRCUIT
INSTALL
E
D TH
E
REMOT
ADVANC
ROCES
CONNECTS TO TH
XTENSION C BLE.
E
S
E
(REAR VIEW)
800
V
20C 19C
D3
PLUGS INTO TH
PANEL. ADVANC
PI CABL
E
E
D
P
TO
TRANSFORMER
MAI
N
F3
E
D
P
S
6
PI
N
5
6
7
8
14
32A
ND
31A
S
E
E
S
11 12
41
REMOT
E
TO
F3
G
42
E
A
RECONNECT
SWITCH
41A
0A
J7
HARMONIC
A
L
J
9
N.G.
TO RECONNECT
SWITCH
10
19
C
B1
1
20 FIL
TER
4
2
K
41B
21
24
B
D
I
2A
D
41B
2A
11
12
13
14
15
16
2.7
10
15
H
C
N
F
(REAR VIEW )
E
A
51
POS
NEG
W
.022
800
M
G
G
ND
F
C
75A
75
4A
V
PR
I
TO
TO
3R
3W
E
SWITCH
B
(BOTTOM
RIGHT)
SSR
SEC
(BOTTOM
RIGHT)
INPU
REC
T
B
D
#2
75A
77A
76A
1
211
PO
W
ER BD
77A
77
T
IFIER
206D
D2
2
3
4
5
6
212
19D
20C
76
REC
T
IFIER
213
POS
F2
TO
17
P91
J8
J9
TO
J
6
,
J10B
TO
C3
POS
NEG
AC
AC
41B
216
F2
21
AUX. #1
SW2
7
AC
3
AC
2
AC
1
8
11
INPUT BOARD
NEG
X8
206
202
1
2.7
1
TP7
601
X3
238
604
232
202C
2
3
4
10
W
17
18
C
2
B
A
PR
I
SEC
(TOP
TO
SWITCH
B #1
TO
3
.022
N.F
.
(TOP
4
CR1
J6
NEG
5
6
1
2
800
V
RIGHT)
RIGHT)
D
J6
0
5
6
7
8
LOAD
LIN
INPUT
IN
FILTER
NEG
A
414
418
D1
A
UX
#1
TO
J10A
J10B
L
E
J4
J5
0
0
1
2
514
F1
F1
POSA
POS
231
13
518
E
J5
0
1
2
2400
F
C3
SWI
T
CH BOARD
#2
T1
T2
100V
TO
J4
TO
WORK
3
TO
3
RIGH
T
SIDE
4
5
6
7
8
9
CR1
SW1
TP3
+
TO
J61
J6
1
3500
F
612
H1D
T3
N.K.
500V
C5
TO ELECTRODE
T3
L3
T2
T1
TO 60
J
601
202A
15 16
10
20D 19D
R1
50
C
R1
X4
TO
TO
A
UX
#
1
L2
L1
206A
TO MAIN
TRANSFORME
RECONNEC
SWITCH
T
R
P50
5
H6
N.E.
H6A
H1A
(550-575)
P52
1
W
P51
1
TO
CB3
UX
31
34
352A
(115V) R
L3B
L1B
4
2
A
#
1
1
4
6
(230V)
SW1
L3A
W
V
U
H1
C6
F
TO
L3
TO
R
ECONNECT
P
ANEL (TOP)
AU
X
ILIARY
T
RANSFORMER #2
TO
S
UPPLY
L
INES
S4
A
CB2
.0047
440
LOA
D
LIN
E
TO
TO
C
ONTACTOR
L3A
TO J61
H1D
C7
N.F
.
L1A
TO SW
1
G
S4
TO
C
B4
C
ONTACTOR
L1A
N.G.
SWITC LEAD
H
115V
612B
TO
A
S
YSTEM GROUN
D
PER
ODE.
FILTER
RECEPTACLE
NATIONAL
E
LECTRICAL
C
31A
32A
32
31
TO
J
9
206
NOTES
:
ELECTROD
E
TO
R1
N.A. PIN NEARES
T
THE FLA
T
EDGE OF LED
L
ENS (CATHODE)
206A
CB2
CIRCUIT
A
LIGN
S
W
ITH BLAC
K
LEAD OF LED SOCKET.
15
A
BREAKER
TO TP3
34
206D
N.B. PLAC
E
SWITCH IN APPROPRIA
T
E
POSITION FOR INPU
IS FOR 440-575V
T
VOLTAGE. CONNECTION SHOWN
FRONT
REAR
FAN
RECONNECT RECONNECT
BRACKET
OPERATION.
HORIZONTAL HORIZONTAL SHROUD SHELL
C2
.05/600V
TP2
BAFFLE
BAFFL
E
OR
N.C.
N.D.
P
L
AC
INPU
OPER
E
"A
VOLTAGE. CONNECTION SHOWN
TION.
"
LEAD ON APPROPRIA
T
E CONNECTION FOR
T
I
S FOR 550-575V
A
P
IN NEARES
T
THE FLA
T
EDGE OF LED
L
ENS (ANODE)
AUX.
1
AUX.
2
REAR
UPPER
BASE
FRONT
CASE
FRONT
N.F.
A
LIGN ITH WHIT
S
W
E
LEAD OF
L
ED SOCK
ET.
UPPER
BASE
S4
352A
220V
RECEPTACLE
N.E. LEAD 34 IS PRESENT IN MODELS WITH 115V RECEPTACLE
ON THE CASE FRONT. LEAD 352A IS PRESENT ONLY IN
MODELS WITH 220V RECEPTACLE ON THE CASE FRONT.
PROTECTIVE BONDING CIRCUI
T
31
5
A
CIRCUIT
CB2
BREAKER
N.F
.
COMPON
CAPACITOR: MFD/
RESISTOR: OHMS/ ATT
E
NT
VAL
U
E
UNITS:
LEGEND
PHANTOM
"
"
=
OPTION
N.F. ONLY PRESENT ON CE MODELS
V
OLT
S
351
W
S
LEA
D
COLO
R
CODING
N.G. ONLY PRESENT ON NON-CE MODELS. (EARLIE
10A CIR UIT BREAKE ).
R
MODELS USE
D
B=BLACK
G=GREEN
N=BROWN
R=RED
U=BLUE
W=WHITE
C
R
CONNECTOR PIN NUMBERS:
EX. 12 PIN CONNECTOR
N.H. "CE" MODELS DO NOT HAVE A RECO
CO NECTS DIRECTLY O ( ) OF C4. LEAD C CO
(-) OF C4 TO 5 AN NEG LEAD CO NECTS
N
NECT SWITCH. POS LEAD
NECTS
O (-) OF C5.
N
T
D
+
N
1
2
6
(+)
C
N
T
COMPONENT VALUES:
CAPACITORS=MFD/VOLTS
RESISTORS=OHMS/WATTS
7
12
N.J. THE "CE" MODELS DO NOT HAVE A RECONNECT PANEL. INSTEAD
LATCH
LEAD 4B CO NECTS H4 TO SW1.
H
N
RIGHT SIDE OF MACHINE
ELECTRICAL SYMBOLS PE
R
E1537
VIEW OF CONNECTOR ON PC BOARD
N.K. ON CE MODELS LEADS T1, T2 AND T3 ARE REPLACED BY LEADS
A, B AN C. LEADS A, B AND C ARE CO NECTED TO THE INPUT
RECTIFIER TERMINALS RATHER THAN CR1.
D
N
C
G4923PRINT
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.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-3
G-3
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - (G4875 SHEET 1)
7 5 4 8 G
E
NGINEERING CONTROLLED
CHANGE
DETAIL:
C
B2 AND F
USE, REVISED AMPS
R
EVISED NOTE N.B.
MANUFACTURER: No
Heatsink isolated from
Switch Boards
MAIN
SWITCH BOARD
#1
T1
LoTcaRt ANSFORMER
of Machine)
(
ed
Front Cent
er
Schematic
:
L11385
Under
Over
voltage = 200V
oltage = 467V
v
(Locat n left sid of Machine)
ed
o
e
S
13
OUTPUT DIODES
D1-D4
C6
+
3500uF
A
Top Rear
(Locat
ed
above Main tr
a
nsf
ormer)
500V
2.7
.022u
C4
RECONNECT
SWITCH
RECTIFIER
10W
11
800V
T
O
14-PI
N
AMPHENOL
206D
206D
N.B.
Conductive Heatsink
INPU
T
F
S
R2
See Pag
e
2
41
4
J40-1
J40-2
RED(-)
8
Hertz per Volt
206
380-575V
208-230V
14
41
8
CT
frequency =
2.7
N.C.
325 Volts = 260 Hertz
0
ELECTRODE
+
WHI
T
E(+)
.022u
800V
C5
C6
10W
(Locat
ed
bottom
20 kHz
AC3
HARMONIC
right side)
PO
S
B
R3
POS
404
405
403
J40-4V/F (+)
J40-5
J40-3 IGBT DRIVE (+)
J40-6
+1
5
FIL
T
ER
}
V/F (-)
12
2.7
.022u
800V
206A
C2
TP2
0
10W
F
.05uF
600V
320V
160J
19
19C
AC2
AC1
}
NEG
NEG
R4
R5
(Locat
ed Middle
IGBT DRIVE (-)
406
-15
Front side)
R1
50
TP
150V
0J
3
CURRENT
TRANSDUCER
125:1
2.7
S
15
10W
.022u
800V
C7
2
0C
SWITCH BOARD
#
2
8
(Locate
d
right of Work stud)
TO
14-PI
N
AMPHENOL
202C
202C
202
Schematic:L11385
ocat ri ht si
C
20
See Pag
e
2
NEG
L
ed
on
g
de
of machine
+
202A
N.B.
17
20D
L
ocat
e
d
o
n
rear
affl
F
WORK
L
ocat
e
d
behind
horiz
o
ntal
b
e
-
(Locat
ed
bottom
r
econnect panel
left side)
MAI
HOKE
oc L1
N
S
16
C
C6
+
TP
1
C1
(L at
e
d B
ehind
3500uF
D
320V
160J
.05uF
600V
Work Stud)
500V
P91
F
18
N.A.
51
4
J50-1
J50-2
RED(-)
8
INPU
T
LINE
ER
CT
51
8
Hertz per Volt
WHI
T
E(+)
FIL
T
325 Volts = 260 Hertz
0
frequency =
+1
20 kHz
J50-5
505
504
503
506
V/F (-)
5
}
J50-4
V/F (+)
0
J50-3
J50-6
IGBT DRIVE (+)
IGBT DRIVE (-)
}
-15
216 212
213 211
Toroid from
L
ocat
e
d
o
n
rear
main harness
horiz
o
ntal panel
N.A.
224
224A
INPUT BOARD
L
ocat
e
d
behind
G
Schematic: M19528
r
econnect panel
CR1
N
ot recommended for
L
ocat
e
d i
n
reconnect
cavity in rea
r
of machine
N.C.
single phase operation.
220
L1
T1
J60-3
J60-8
224A
291
+13V
238
231
224
U
SINGLE PHASE DETECT
CHOK
THERM
E
OUTPUT RECTIFIE
R
(
L
OW 1 P ASE
=
H
)
THERM
(Connected with
epoxy)
206
(Bol
t
c
ed
tion
L1B
J61-2
T1
T2
220
202
C
onne
)
L2
T2
J61-4
V
PRECHARGE
RELA
frequency = 20 kHz
+15
J61-10
Y
T3
T3
L3
CURRENT FEEDBACK
+13V
4V=500AMPS
W
0
+15V
-15V
+ELECTRODE
VOLTAGE SENSE
- ELECTRODE
VOLTAGE SENSE
L3B
-
15
SWITCH
LEA
FILTE
CR1
CONTROL BOARD COMMON
D
R
24Vac
}
(Locat
e
d
ri
g
ht
L3
THERMOSTA
T
T
J61-8
J61-6
H1D
612
(NORMALLY CLOSED)
of Contactor)
N.B.
J60-4
604
THERMOSTA
J4-12
J4-10
225
222
504
505
405
404
+15V
CONTROL BOARD COMMON
601
X4
MAIN CONTACTOR CONTRO
L
J6-5
V/F (+)
Switch Board
Switch Board
2
N.A.
L
3A
L
1A
J6-10
V/F (-)
V/F (-)
V/F (+)
8 Hertz per Volt
325 Volts = 2600
C8
C9
CONTROL BOARD
J60-5
J60-2
232
+13V
H
ertz
J6-8
}
LEDS - 10 TOTA
DIP S itch -1, Bank of 8
(See page 3 for detail)
L
Schematic: G3789
n left sid of cont
Additional input / outputsare
illustratedonschematicpage2.
1
J6-16
Locate
d
o
e
rol box
w
.0047uF
440
601
J60-1
+13V
Single phase is
limited o 325amps
570A Max Output
J6-9
J6-1
238
231
604
232
Fold Back = 100A
t
X3
SINGLE PHASE DETECT (LOW=1 PHASE)
(Ma Output = 325A)
R
emove Load to reset
x
PRECHARGE CONTROL
J6-12
J6-2
AU
X. RECONNECT
ON
H1D
N.B.
MAIN CONTACTOR CONTRO
L
L
ocat
e
d
behi
n
d c
o
nt
r
ol board
S1
POWER
n top
ht of case fr
(left side)
H2
200-2
220-230V behni
440-4 0V
550-5
08V
L
ocat
e
d
o
Locat
e
d in
rea
r
of machine
+
J7-15
J7-16
FAN CONTROL (+15 VDC)
Fan comes on when
output is enable
H3
H5
X3A
TP4
3R
OFF
ont
ri
g
d
r
econnect panel.
A
}
6
3W
FAN CONTROL (-)
CR2
H6
7
5V
LEGEND
AUXILIARY
D
ASHED
= "
" OPTION
" P BOARDS
444
-
Toroid from
Toroid from
P
HANTOM = "
C
TRANSF
(left, rea ORME
R
T3
main harness
main harness
SOLID STAT
E
r, on base)
FAN
RELA
Y
LEAD
COLO
R
CODE:
115V
612B
Locat
e
d i
n
Rea
r
of
H6
H5
H4
X5
POdWo Ee R bBD.rigREofCliftTb .e
J41-2
PowerSourc
e
4
1B
B-BLACK
(550-5
(440-4
(380-4
75)
60)
15)
H6A
L
ocat
e
n c nt
e
r
affl
e
ht
al
G-GREEN
NTC
J41-4
POWER BOARD
2
4V
O-ORANGE
R-RED
POS
POS
6
X4
Schematic: G3631
rea of cont ol box (left)
5VDC
+
C3
Located
on
r
r
X3
L
ocat
e
d
near Auxili
ary
612
24000uF/100V
NEG
U-BLUE
X8
Transf
o
rme
r
0V
X3
W-WHITE
H3
H2
H1
NEG
J41-1
3J41
Y-
LABELS:
OMMON
FRAM GROUND
EART GROUND
YELLOW
(220-2
(200-2
3
0)
N.A.
4
2VAC
8VAC
4VAC
J59-3
42
X9
X8
2
0
8)
C
TO
14-PI
N
2
CAN
LEDS - 2 TOTA
L
SPI
locat
e
d
on lower
X7
J59-4
J59-2
24
51
TROL
CON
RS232
AMPHENOL
CB1
H1
cent
e
r case front
(See page 3 for detail)
E
H
0V
X6
1
0 A
Located on the right side of
Harmonic Filter
4
1B J59-1
4
1A
51
41
41
{
42
41A
24
2A
TO
14-PI
N
AMPHENOL
352A
J51-6
H6
(550-5
C
OMPONENT
VAL
U
E
U
NITS:
H6A
5
See Pag
e
2
3
230V
FU
S
E 10
A
L
ocat
ed
on
7
5)
J52-2
J52-4
J52-1
31A
352
r
econnect area
CAPACIT R: MFD/
O
V
OLT
S
3
3A
Not used
CB2
34
opposit
e
of contactor
RESIST R: HMS/
O
O
W
ATTS
350
115V
CB2
locat
e
d
on lower
cent
e
r case fr
o
nt
351
352A
N.A.
CONNECT
O
R
PIN
NUMBERS:
AUXILIARY
5A
1
5A
J51-4
34
TRA(NrigSht,Fr ORMbaEseR) T2
EX. 12 PIN CONNECTO
R
N.B.
N.B.
Schematic numbers are given
f
or reference only.
H1B
0V
NOTES:
ear, on
J51-1
31
2
1
7
6
N.A CE MACHINE ONLY.
.
located
on
32
31
J51-1
THIS DOCUMENT CONTAINS PROPRIETAR
TO OTHER PARTIES OR USED FOR AN
Y
INFORMATION OWNED B
Y
LINCOLN GLOBAL, INC. AND MA NOT BE DUPLICATED, COMMUNICATED
Y
CB3
3.5 A
r
econnect panel
PROP
R
IETA
R
Y & CONFIDENTIAL:
N
.B. NON-C
E
MACHIN
MODEL LEADS T1, T2 AND T3 AR
AND C EAD A, AND C CONNECTED TO T
TE MINAL RATHER HAN CR1.
E
ONLY. (EARLIER
M
ODEL
S
USED
REPLACED BY LEADS
E INPUT
1
0
A
CIRCUIT BREAKERS).
31
J54
RECEPTACLE
Y
PURPOSE WITHOU
T
THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
M
ANUFACTURING TO
L
ERANC
E
P
ER E2056
N.C
.
O
N C
E
S
E
220V
CONTROL: CLEVELAND
SCA
L
E:
UNLESS OTHERWISE SPECIFIED TOLERANCE:
12
EQUIP
M
ENT TYPE:
3
3
2A
1
3
DOCUMEN
H1
INVERTEC V450-PRO
MACHI E SCHEMATIC
REFERENCE:
J54
PAGE ___ OF ___
T
A,
B
.
L
S
B
A
R
E
H
ON
ON
ON
2
3
PLAC
PLACE
LL ANGL
TO
E
D
ECIMAL
CIMALS IS
.5 OF
ERANC ("
S
I
S
.02 in.
(
0.5 mm)
1
H1A
NONE
LATCH
DRAWN BY:
ENGINEER:
APPROVED:
Dsnell
D
E
.
00
A
2
i
n.
GREE
GREE
(
0.
0
5
mm)
T
DOCUMEN
NUMBER:
IF PRIN
T
ED
RECTIFIE
R
R
S
T
115V
A
E
S
I
S
DE
SUBJECT:
REVISION:
Located on the left side of
Harmonic Filter
N
NUMBER:
Located on the right side of
Harmonic Filter
@
A
1
SIZE
VIEW OF CONNECTOR ON PC BOARD
MATERI
A
L
L
E
"
)
TO
A
J.O'Connor
t
3
1A
locat
ed
on case front
T
UNIINSC: H
WITH PU
DO NO
B
LISHED STANDARDS.
RELoCcatEPTaAseCfrLE
MATERIAL
APPROVA
DA E:
L
PROJEC
T
G4875
1A
UF
DISPOSITION:
7-13-2007
C
CRM36847
.
e
d
on c
ont
T
T
SCAL HIS DR
E
T
AWING
G4421
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - (G4875 SHEET 2)
7 5 4 8 G
E
NGI
NEERING CONTROLLED
CHANGE
DETAIL:
C
B2 AND F
USE, REVISED AMPS
R
EVISED NOTE N.B.
MANUFACTURER: No
NOTES:
N.E. THE REMOTE UI PCB ALWAYS RESPONDS AS A REMOTE
SPI BOARD. CONNECTING PINS 1 & 2 OF J333
OR
TOGETHER WILL ENABLE THE REMOTE UI PCB
TO RESPOND AS A STATUS SPI. CONNECTING
PINS 11 & 14 OF J332 TOGETHER WILL ENABLE
THE REMOTE UI PCB TO RESPOND AS A MODE PCB.
LEDS - 10 TOTAL
DIP SWITCH - 1 BA
NK OF 8
SEE PAGE 3 FO
R DETAILS
CONTROL BOARD
Schematic: G3789
Located on left side of control bo
x
Addi
ut uts are
illust ated on
schematic # 1.
t
iona
l
input
/
o
p
r
SPI CIRCUIT
P
ositiv
e
}
}
2
2
0
6D
2C
O
ut
p
ut St
uds
Factory Install
S
e
e
pag
e
1
OR
0
Field Install
P
olarity Switch for wire feeder
meter
Ne
g
ative
S2
L
ocat next to pi amphenol
e
d
1
4
n
+15
V
V
LED 1
CC-Stick soft
J61-3
J61-4
3212
3206
+10
N.D.
25
13
3207
CC-Stick crisp
3202
J61-14
J61-12
13
25
14
+15
+15
+15
+15
V
V
V
V
LED 2
3204
J61-2
HOT
+10
V
+10
V
ARC
+15
V
LED 3
START
25
1
CONTROL
Tig Gtaw
J61-1
251
J61-5
J61-13
J61-15
3201
3213
MODE
LED 4
25
4
3
SWITCH
CV - wire
J61-6
25
4
3216
321C5V - Innershiel
25
3205
14
3203
25
3
LED 5
ADVANCE
D
PROCESS PANEL
1
MODE PANEL
1
d
(OPTIONAL)
Schematic: S25258-1B0
J61-7
Schematic: G3872-1B1
SPI CIRCUIT
24
41
42
S
e
e
pag
e
1
4
76
77
A
76
24
75
2
77
4A 75
+15V
+15V
A
+15V
+15V
41
21
76A
+15V
J60A-1
J60B-1
3303
3313
3316
3314
N.D.
+15V
42
R
EMOTE
ON
J60A-2
J60A-3
J60B-2
J60B-3
3315
F
H
REM
O
TE
+15V
LOCAL
+15V
G
J
333-16
3316
3315
3314
3313
3312
4
F
E
A
B
I
76
J
333-15
N
M
J60A-4
}
J60B-4
3304
J
333-14
333-13
3305
T
o
115v Case Fr
o
nt Rec
e
pticle
nly)
J
31
A
E
77
A
(For Do estic use
d
Not onmC
E
Modelos
K
J
L
2
D
D
WELD TERMINALS
Led select pc board
OUTLedUseTlecCt pOc bNoaTrdROL
P
A
J
333-12
32
A
3312
B
C
Schematic: S25259-1
Schematic: S25259-1
J
333-
333-
333-
8
R6
75
A
27
6
C
10K/2W
co
+10V
m
J
7
27
5
4A
J
6
27
7
6 PIN REMOT
E
3305
J
333-
5
2B 2A
EEDER REMOT
AMPHENOLS ARE VIEWED
75
J
333-
4
3304
3303
276
277
275
com
J
333-
3
+10V
J
333-2
WIRE
F
E
J
333-1
SPI CIRCUIT
+
10 Volts
J
332-16
3216
3215
F
ROM FRONT OF MACHINE
N.E.
J
J
J
J
332-15
N.D.
332-14
332-13
332-12
3213
3212
3211
3207
3206
3205
J
332-11
graphi
c
al representation
J
332-
7
J
332-
6
of po
t
entiometer
conne tion
c
Open
view of Control Panel
J
332-
5
J
332-
4
AMPS
3204
3203
3202
3201
VOLTS
REMOTE BOARD
Average actual current
_
Average actual voltage
+_
Schematic: G4017-1D0
J
332-
3
+
3%
.5V
J
332-
2
DISPLAY PANEL
J332-
1
Schematic: L11108-3
LEAD COLOR CODE:
LAST No.
USED
COMPONENT VALUE UNITS
CAPACITOR: MFD/VOLT
RESISTOR: OHMS/WATTS
:
R-
6
B-BLAC
K
S
C
S
- 9
G-GREEN
O-ORANG
R-RED
-
2
E
TP - 4
Located in
t
he middle o
f
J-Numbers
CONNECTOR PIN NUMBERS:
X. 12 PIN CONNECTOR
U-BLUE
Control Panel
J2,J3,J4,J5,J6,J7,J8
J9,J10A,J10B,J11,
,
E
W-WHITE
LEGEND
Y-YELLOW
D
ASHE
D
= "
" OPTION
" P BOARDS
2
1
6
J40,J50,J42,J43,J51
,
Schematic numbers are
g
iven for reference only.
LABELS:
P
HANTOM = "
C
J52,J54,J59
J60 andJ61(Inpu
J61(Mode PCB)
,
t
PCB),
COMMON
,
7
12
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROP
RIETA
R
Y & CONFIDENTIAL:
LATCH
J60A,J60B
FRAME GROUND
EARTH GROUN
TO OTHER PARTIES OR USED FOR AN
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
T
J91,J331,
J332,J333
MANUFACTURING TO
L
ERANC
E
P
ER E2056
VIE
W
OF CONNECTOR ON PC BOARD
CONTROL: CLEVELAND
D
SCA
L
E:
UNLESS OTHERWISE SPECIFIED TOLERANCE:
EQUIP
M
ENT TYPE:
2
3
DOCUMEN
INVERTEC V450-PRO
MACHI E SCHEMATIC
REFERENCE:
PAGE ___ OF ___
ON
ON
ON
2
3
PLAC
PLACE
LL ANGL
TO
E
D
ECIMAL
CIMALS IS
.5 OF
ERANC ("
S
I
S
.02 in.
(
0.5 mm)
NONE
DRAWN BY:
ENGINEER:
APPROVED:
Dsnell
D
E
.
00
A
2
i
n.
GREE
GREE
(
0.
0
5
mm)
T
DOCUMEN
NUMBER:
T
IF PRIN
T
ED
A
E
S
I
S
DE
SUBJECT:
REVISION:
N
NUMBER:
@
A
1
SIZE
MATERI
A
L
L
E
"
)
TO
A
J.O'Connor
t
UNIINSC: H
T
WITH PU
DO NO
B
LISHED STANDARDS.
MATERIAL
APPROVA
DATE:
L
PROJEC
T
G4875
UF
DISPOSITION:
7-13-2007
C
CRM36847
.
T
SCAL HIS DR
E
T
A
WING
G4421
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-5
G-5
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - (G4875 SHEET 3)
7 5 4 8 G
E
NGINEERING CONTROLLED
CHANGE
DETAIL:
C
B2 AND FUSE, REVISED AMPS
R
EVISED NOTE N.B.
MANUFACTURER: No
CONTROL BOARD
J7
Error codes for the Invertec V450
The following is a list of possible error codes that the Power Wave can output via the status light
-PRO
1. STD DISPLAY PC BOARD ASSEMBLY
2. SPI ASSEMBLY
J6
J5
J8
J9
3. REMOTE PC BOARD ASSEMBLY
4. LED SELECT PC BOARD ASSEMBLY
5. FACTORY MODE PANEL ASSEMBLY
Error Code #
Indication
Contact the Service Department for instructions on
reloading the Welding Software.
21 Unprogrammed Weld Mode.
22 Empty Weld Table.
LE
D
1
LE
D
9
Contact the Service Department for instructions on
reloading the Welding Software.
LE 10
D
J4
Contact the Service Department for instructions on
reloading the Welding Software.
23 Weld Table checksum error.
LE
D
2
4
Excessive Primary current present. May be related to a
switch board or output rectifier failure.
31 Primary overcurrent error.
LE
D
5
LE
D
3
32 Capacitor “ A” under voltage
(Left side facing machine)
Low voltage on the main capacitors. May be caused by
improper input configuration, or an open/short circuit
in the primary side of the machine.
J3
J2
J1
33 Capacitor “ B” under voltage
(Right side facing machine)
34 Capacitor “ A” over voltage
(Left side facing machine)
LE
D
J10B
J10A
(S1 is not used)
LED6
S1
Excess voltage on the main capacitors. May be caused
by improper input configuration, or an open/short
circuit in the primary side of the machine.
35 Capacitor “ B” over voltage
(Right side facing machine)
Indicates over temperature. Usually accompanied by
Thermal LED. Check fan operation. Be sure process
does not exceed duty cycle limit of the machine.
Capacitor precharge failed. Usually accompanied by
36 Thermal error
37 Softstart error
codes 32-35.
J11
The secondary (weld) current limit has been exceeded.
When this occurs the machine output will phase back
to 100 amps, typically resulting in a condition refered
to as “ noodle welding”
4
LED7
2
41 Secondary overcurrent error
43 Capacitor delta error
4
5
3
LE
D
8
1
The maximum voltage difference between the main
capacitors has been exceeded. May be accompanied by
errors 32-35.
Control Panel
Indicates machine is running on single phase input
49 Single phase error
Other
power. Usually caused by the loss of the middle leg
(L2).
Use Snap Shot to interpret other errors or Diagnostic
Sofware
Description of LED functions on the Invertec V450-PRO
For reference only
Factory Mode Panel
R
S232
L11088 Digital Control PC Board
LED #
COLOR
FUNCTION
WEL
C-C Stick Sof
C-C Stick crisp
D
MODE
Hot
Star t
1
2
Green
Green
Green
Green
Green
Green
Red
Indicates +15VDC from power supply board is present
Arc Control
0
Indicates –15VDC from power supply board is present
t
5
3
Indicates +5VDC for +5SPI from power supply board is present
Indicates +15VDC for +15SPI from power supply board is present
Indicates +5VDC for +5V from power supply board is present
Indicates +5VDC for +5VRS232 from power supply board is present
FAULT Signal (See software group for coding)
4
5
Tig Gta
w
6
C
C
V
V
W
ir
e
7
10
Hi-Freq
1
Touc
Start
TI
+10
-1
Soft
0
Select
8
Green
Green
Red
Indicates +5VDC for +5CAN from power supply board is present
h
Innershield
Crisp
TI
G
9
ArcLink Status Indicators (Main System Master ArcLink Connection) Solid
G
Green only when functional (See software for error codes)
10
15
9
13
A
lpha Numeric
Display
1
Advance Process Panel
(Optional)
10
RS232
1. Power Switch
2. 24V-42V 10 Amp Wire Feeder
Circuit Breaker
3. 115V Auxiliary Power
&
Select
Select
Wire Feeder Circuit Breaker
4. 6 pin Remote
Adjus
t
Memory
5. Work Stud
POWER BOARDS
6. Electrode Stud
7. 14 Pin Wire feeder Remote
8. Auxiliary Output (110V or 220V)
9. STD Display Board
11
14
Description of LED functions on the Invertec V450-PRO
For reference only
10. Weld Terminal /Remote ON
11. Output Control /Remote Local
12. Wire Feeder Polarity Switch
13. Control Knob
Adjust Hot Start
Arc control
&
8 Memory
Select Hot Start
or Arc Weld
Select weld process
(encoder)
G3632 Digital Power Supply Board
LED # COLOR FUNCTION
(encoder)
14. Mode Panel or (optional) Advance
1
2
Red
Red
Indicates +5VDC SPI supply is present
Indicates +5VDC control supply is present
Process Panel found underneath
Front Panel Door.
15. Thermal Light
Case front Detail
Invertec V450 PRO
-
4
5
8
3
2
6
12
LINCOLN GLOBAL, INC. AND MA NOT BE DUPLICATED, COMMUNICATED
7
THIS DOCUMENT CONTAINS PROPRIETAR
TO OTHER PARTIES OR USED FOR AN
Y
INFORMATION OWNED B
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
Y
Y
PROP
R
IETA
R
Y & CONFIDENTIAL:
Y
T
M
ANUFACTURING TO
L
ERANC
E
P
ER E2056
CONTROL: CLEVELAND
SCA
L
E:
UNLESS OTHERWISE SPECIFIED TOLERANCE:
EQUIP
M
ENT TYPE:
3
3
DOCUMEN
INVERTEC V450-PRO
MACHI E SCHEMATIC
REFERENCE:
PAGE ___ OF ___
ON
ON
ON
2
3
PLAC
PLACE
LL ANGL
TO
E
D
ECIMAL
CIMALS IS
.5 OF
ERANC ("
S
I
S
.02 in.
(
0.5 mm)
NONE
DRAWN BY:
ENGINEER:
APPROVED:
Dsnell
D
E
.
00
A
2
i
n.
GREE
GREE
(
0.
0
5
mm)
T
DOCUMEN
NUMBER:
T
IF PRIN
A
T
ED
A
E
S
I
S
DE
SUBJECT:
REVISION:
N
@
1
SIZE
MATERI
A
L
L
E
"
)
TO
A
J.O'Connor
t
T
UNIINSC: H
WITH PU
DO NO
B
LISHED STANDARDS.
MATERIAL
APPROVA
DATE:
L
PROJEC
NUMBER:
T
G4875
UF
DISPOSITION:
7-13-2007
C
CRM36847
.
T
SCAL HIS DR
E
T
AWING
G4421
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
G-6
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITAL CONTROL PC BOARD - (G3789 SHEET 1)
O 2 F 9 - 7 3 8 G
CHANG
E
D
ETAIL: PAGE 3, R65, REVISE
D
VALUE
E
NGI
N
EERING CO
LLED
MANUFACTURER:NYTResO
23
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBAL, INC. AND MA NOT BE DUPLICATED, COMMUNICATED
Y
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
T
UNLESS OTHERWISE SPECIFIED TOLERANCE
DESIG
RAWN BY:
ENG NEER:
APPROVED
N
I
NFORMATION
REFERENCE:
M
ANUFACTURING TO
L
ERANC
E
P
ER E2056
EQUIP
M
ENT TYPE:
PAGE _1__ OF _4__
DOCUMENT
INVERTER WELDER
O
N
2
3
P
LAC
LACE DECIMALS IS .002
NGLE DEGREE
OLERANC AGREE
PUBLISHE STAND RDS.
E
DECIMAL
S
I
S
.02
D
FEI
.
G3789-1E2
ON
P
DOCUMENT
O
N
ALL
A
S
I
S
.
5
O
F
A
SUBJECT:
SCHEMATIC DIGITAL CONTROL
N
UM
REVISION:
GB3ER7: 89-
2FO
MATERIAL
T
E
(" ")
T
O
I
SCAL
E:
t
WI
T
H
D
A
MATERIAL
APPROVAL
DATE:
PROJECT
NUMBER:
C
RM22115-G
A
B
UF
:
NONE
10/26/2006
DO NO SCAL HIS DR WING
T
E
T
A
DISPOSITION:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITAL CONTROL PC BOARD - (G3789 SHEET 2)
O 2 F 9 - 7 3 8 G
CHANG
E
D
ETAIL: PAGE 3, R65, REVISE
D
VALUE
E
NGI
N
EERING CO
LLED
MANUFACTURER:NYTResO
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
T
UNLESS OTHERWISE SPECIFIED TOLERANCE
DESIG
RAWN BY:
ENG NEER:
APPROVED
N
I
NFORMATION
REFERENCE:
M
ANUFACTURING TO
L
ERANC
E
P
ER E2056
EQUIP
M
ENT TYPE:
2
PAGE _1__ OF _4__
INVERTER WELDER
O
N
2
3
P
LAC
LACE DECIMALS IS .002
NGLE DEGREE
OLERANC AGREE
PUBLISHE STAND RDS.
E
DECIMAL
S
I
S
.02
D
FEI
.
G3789-1E2
ON
P
DOCUMENT
DOCUMENT
O
N
ALL
A
S
I
S
.
5
O
F
A
SUBJECT:
SCHEMATIC DIGITAL CONTROL
N
UM
REVISION:
GB3ER7: 89-
2
FO
MATERIAL
T
E
(" ")
T
O
I
SCA
L
E:
t
WI
T
H
D
A
MATERIAL
APPROVAL
DATE:
PROJECT
NUMBER:
C
RM22115-G
A
B
UF
:
NONE
10/26/2006
DO NO SCAL HIS DR WING
T
E
T
A
DISPOSITION:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-8
G-8
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITAL CONTROL PC BOARD - (G3789 SHEET 3)
O 2 F 9 - 7 3 8 G
CHANG
E
D
ETAIL: PAGE 3, R65, REVISE
D
VALUE
E
NGI
N
EERING CO
LLED
MANUFACTURER:NYTResO
47.5K
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBAL, INC. AND MA
Y
NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
T
UNLESS OTHERWISE SPECIFIED TOLERANCE
DESIG
RAWN BY:
ENG NEER:
APPROVED
N
I
NFORMATION
REFERENCE:
M
ANUFACTURING TO
L
ERANC
E
P
ER E2056
EQUIP
M
ENT TYPE:
3
PAGE _1__ OF _4__
INVERTER WELDER
O
N
2
3
P
LAC
LACE DECIMALS IS .002
NGLE DEGREE
OLERANC AGREE
PUBLISHE STAND RDS.
E
DECIMAL
S
I
S
.02
D
FEI
.
G3789-1E2
ON
P
DOCUMENT
DOCUMENT
O
N
ALL
A
S
I
S
.
5
O
F
A
SUBJECT:
SCHEMATIC DIGITAL CONTROL
N
UM
REVISION:
GB3ER7: 89-
2FO
MATERIAL
T
E
(" ")
T
O
I
SCAL
E:
t
WI
T
H
D
A
MATERIAL
APPROVAL
DATE:
PROJECT
NUMBER:
C
RM22115-G
A
B
UF
:
NONE
10/26/2006
DO NO SCAL HIS DR WING
T
E
T
A
DISPOSITION:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-9
G-9
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITAL CONTROL PC BOARD - (G3789 SHEET 4)
O 2 F 9 - 7 3 8 G
CHANG
E
D
ETAIL: PAGE 3, R65, REVISE
D
VALUE
E
NGI
N
EERING CO
LLED
MANUFACTURER:NYTResO
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
T
UNLESS OTHERWISE SPECIFIED TOLERANCE
DESIG
RAWN BY:
ENG NEER:
APPROVED
N
I
NFORMATION
REFERENCE:
M
ANUFACTURING TO
L
ERANC
E
P
ER E2056
EQUIP
M
ENT TYPE:
4
PAGE _1__ OF _4__
INVERTER WELDER
O
N
2
3
P
LAC
LACE DECIMALS IS .002
NGLE DEGREE
OLERANC AGREE
PUBLISHE STAND RDS.
E
DECIMAL
S
I
S
.02
D
FEI
.
G3789-1E2
ON
P
DOCUMENT
REVISION:
DOCUMENT
O
N
ALL
A
S
I
S
.
5
O
F
A
SUBJECT:
SCHEMATIC DIGITAL CONTROL
GB3ER7: 89-
2
FO
N
UM
MATERIAL
T
E
(" ")
T
O
I
SCAL
E:
t
WI
T
H
D
A
MATERIAL
APPROVAL
DATE:
PROJECT
NUMBER:
C
RM22115-G
A
B
UF
:
NONE
10/26/2006
DO NO SCAL HIS DR WING
T
E
T
A
DISPOSITION:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-10
G-10
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITAL POWER SUPPLY PC BOARD - (G5631)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-11
G-11
ELECTRICAL DIAGRAMS
SCHEMATIC - INPUT PC BOARD - (M19528)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-12
G-12
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - INPUT PC BOARD - (L11396)
2
3 9 1 6 1 - L
CHANGE DETAIL: REVISED NOTE N.B
.
ENGINEERING CONTROL
MANUFACTURER: No
LED
REFERENCES
C1
CR1, CR2
D1, D3
D2
QTY PART NO.
DESCRIPTION
.022/50
DPST RELAY
1N4004
DIODE,1.0A,1500V
HEADER,VERTICAL
HEADER,VERTICAL
OPTO ISOLATOR
100/1OW
1
2
2
1
1
1
1
8
S16668-5
S14293-18
T12199-1
T12705-58
S24020-8
S24020-10
S15000-22
S24376-3
N.C. J60
N.C. J61
OCI1
R1, R2, R3, R6, R7, R8, R9, R10
R4
R5
1
1
S19400-2673
S19400-4750
267K 1/4W
475 1/4W
P.
C
.
BOARD BLA
N
K
INFORMATION
R11, R12, R13, R14, R15, R16,
R17, R18, R19, R20, R21, R22,
R23, R24, R25
15 S19400-3011
3.01K 1/4W
BUY COMPLETE AS L11396-B
(
2 LAYER BOARD PER E3281)
TP1, TP2, TP3, TP4
4
T13640-23
MOV,250J,660V
(MAKES 8 BOARDS PER PANEL, SEE ELECTRONIC FILE
FOR
A
DDITIONAL IN
FORMATION)
3
N.D.
N.D.
N.A.
4.50 .04
ITEM
REQ'D PART NO.
SEE BLANK INFO. P.C. BD. BLANK
1.0 OZ. E2861 SEALANT
S14020-7 PLASTIC EXPANSION NUT
IDENTIFICATION
INPUT
XXXXXXX
XXXXXXXX
1
2
3
1
J61
J60
2
D1
D2
R22
T
P4
T
P3
P2
R24
R25
R23
R21
R20
R19
R18
OCI1
R11
R12
R13
R14
R15
R16
R17
T
CAPACITORS = MFD / VOLTS
RESISTORS = OHMS/WATTS
1
T
X
X
X
X
X
X
X
X
X
X
P1
XXX
X
CR1
R7
X
X
X
X
X
X
X
X
X
CR2
NOTES:
R6
N.A.
THIS AREA TO BE COVERED ON BOTH SIDES OF BOARD WITH ITEM 2 PRIOR TO
ENCAPSULATION. MATERIAL MUST BE APPLIED THRU SLOTS FROM BOTTOM
SIDE TO COMPLETELY FILL TO UNDERSIDE OF DEVICE ON COMPONENT SIDE.
R9
R8
R3
N.B.
P.C. BOARD HOLES TO BE FREE OF ENCAPSULATION MATERIAL AND RTV FOR
A DIAMETER OF .40 ON COMPONENT AND NON-COMPONENT SIDES OF BOARD
X
X
R1
R2
(6 PLACES)
.
X
X
X
X
X
X
XXX
N.B.
N.C.
N.D.
DO NOT COAT WITH ENCAPSULATION MATERIAL.
R10
APPLY ITEM 2 AS SHOWN, ALL EXPOSED LEADS MUST BE COVERED. MATERIAL
MUST BE APPLIED PRIOR TO ENCAPSULATION.
L11396-2
0
N.E.
APPLY ITEM 2 ON NON-COMPONENT SIDE OF BOARD PRIOR TO
ENCAPSULATION. ALL EXPOSED PINS MUST BE COVERED.
N.D.
N.D.
0
6.00 .04
MAKE PER E1911-ROHS
ENCAPSULATE WITH E1844
TEST PER E3647-I
MANUFACTURED AS:
SCHEMATIC REFERENCE: M19528-2B0
L11396-2B0
IDENTIFICATION CODE
ALL
C
OMPON
E
NTS AND MATERIALS
U
SED IN THIS
ASSEMBLY ARE TO
BE
R
oH OMPLIANT PER
S
C
E4253.
HIS DOCUME
N
T CONTAINS P
R
OPRIETARY INFORMATIO
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
N
D MAY NOT BE
D
UPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:TTO OT
HER PA
SCALE:
1:1
R
TIES O USE
R
D
FOR ANY P RPOSE WITHOUT THE E
U
X
PRESS
W
RITTEN PERMISSIO
N
OF LIN
C
OLN GLOBAL, INC.
MANUFACTURIN
NLESS OTHERWISE SPE
N 2 PLACE DECIMALS IS .02 in. ( 0.5 mm)
G
TOLERANCE PER E2056
CONTROL:
CLEVELAND
U
C
IFIE TOLERA CE:
D
N
EQUIPMENT TYPE
SUBJECT:
MATERIAL
DISPOSITION:
:
_1__
1
INVERTER WELDERS
PAGE
OF ___
O
DR
NGINEER:
APPROVED:
A
WN BY:
fivory
ON
3
PLA
CE
DECIMALS IS .002
in.
(
0.05 mm)
IF PRINTED
DOCUMENT
DOCUMENT
REVIS ON:
O
N ALL ANGLES IS .5 OF A DEGREE
@
A2
S
IZE
NUMBER:
I
INPUT
DATE:
P.C
.
BOARD ASSEMBLY
E
MATERIAL TOLERANCE ( ") TO A REE
"
G
t
U
NIITNSC: H
WITH PUBLISHED STANDARDS.
REFERENCE:
APPROVAL
PROJECT
L11396-2
UF
2-8-2008
C
-
CRM39233
NUMBER:
L11396-1
DO NOT SCALE THIS
DRAWING
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. 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. Improper PC board repairs could result in damage to the
machine.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-13
G-13
ELECTRICAL DIAGRAMS
SCHEMATIC - SWITCH PC BOARD - (L11385)
1 D 2 3 8 1 5 1 - L ENGINE
CHANGE DETAIL: NE
W.
ERING CONTROL
MANUFACTURER: No
LED
HIS DOCUME
N
T CONTAINS P
R
OPRIETARY INFORMATIO
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
N
D MAY NOT BE
D
UPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:TTO OT
HER PA
R
TIES O USE
R
D
FOR ANY P RPOSE WITHOUT THE E
U
X
PRESS
W
RITTEN PERMISSIO
N
OF LIN
C
OLN GLOBAL, INC.
MANUFACTURIN
NLESS OTHERWISE SPE
N 2 PLACE DECIMALS IS .02 in. ( 0.5 mm)
G
TOLERANCE PER E2056
SCALE:
CONTROL:
CLEVELAN
D
U
C
IFIE TOLERA CE:
D
N
EQUIPMENT TYPE
SUBJECT:
MATERIAL
DISPOSITION:
:
_1__
1
PW-455
PAGE
OF ___
O
NONE
DR
NGINEER:
APPROVED:
A
WN BY:
fivory
ON
3
PLA
CE
DECIMALS IS .002
in.
(
0.05 mm)
IF PRINTED
DOCUMENT
UMBER:
DOCUMENT
REVIS ON:
O
N ALL ANGLES IS .5 OF A DEGREE
@
A2
S
IZE
N
I
SCHEMATI
C
,
SWITCH PCB
E
-
MATERIAL TOLERANCE ( ") TO A REE
"
G
t
U
NIITNSC:
H
WITH PUBLISHED STANDARDS.
REFERE CE:
N
APPROVAL
DATE:
PROJECT
NUMBER:
L11385-2D1
NA
1
1-6-2009
A
D
RS
CRM41517
-
DO NOT SCALE THIS
DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-14
G-14
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - SWITCH PC BOARD - (G3734)
3 - 3 4 3 7 G
CHANGE
D
ETAIL: ADDED ITEM 6 AN
D
NOTE N.Y.
E
NGI
NEERING CONTROLLED
ITEM (USED WITH)*
1
N.D. 2 (B11, B19, B20)*
3
4
5
6
QTY PART NUMBER DESCRIPTION
R
EVISED MANUFACTURED AS, IDENTIFI
C
ATION CO
D
E AND SCHEMATIC REFERENCE PART NUMBERS
MANUFACTURER: No
1
3
1
G3734-E
T9147-11
S24869-2
PC BOARD BLANK
CONNECTOR,EYELET,POWER,FEMALE
PC BOARD SHIELD
EPOXY ENCAPSULATING RESIN
PC BOARD SHIELD
P.C. BOARD BLANK REFERENCE INFORMATION
N.X.
NOTES
:
280 g. E2527
1
BUY COMPLETE AS G3734-E (4 LAYER BOARD PER E3281)
S24869-1
N.A. CAUTION:
T
HI
S
DEVI
C
E IS SUBJECT
T
O
DAMAG
E
B
Y
STATI
C
1 oz. E2861
SEALANT
ELECTRICI
EMAL EYELET T
EYELET MUS OT SPI
TH
EYELE
PERMITTED.
AN ARE AROUN
APPROPRIAT MANUF
TO BE ASSEMBLED,
T
Y. SE
E
E
2454 BEFO
RE
HANDLI G.
N
(SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION)
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
N.D.
N.E.
F
E
O
BE
AGAINST T
H
E
COPPE SI
LINCHI G.
COVER
SI ONLY.
SMOOT
KI TA
RI WOR
OLDERED,
R
D
E
AS
SHOWN.
N.D.
T
N
N
A
FT
E
R
C
N
REFERENCES
A1, A2
B11, B19, B20
QTY PART NUMBER DESCRIPTION
2
2
3
1
1
1
1
1
3
1
M21214-2
T9147-15
S24866
ELECTRONIC MODULE,5-T12704-84 IGBT'S
CONNECTOR,EYELET,POWER,MALE
BRACKET,POWER-HOLDER
CONNECTOR,TERMINAL,POWER
CAPACITOR,PPMF,.022,100V,BOX,5%
CAPACITOR,CEMO,0.1, 50V,10%
CAPACITOR,CEMO,.022,50V,20%
CAPACITOR,CEMO,4700pF,50V,10%
CAPACITOR,TAEL,27,35V,10%
N.A.,N.J.,N.R.
SOLDE
R
EYELE
LL AROUN
OLDE LO
T
SO
A
T
S
OLDE
COPPE
US
R
S
E
NTIR
E
EYELE
T
AND
OR
A
S
D
T
O
N
R
D
E
N
O ICICLE
S
N.Q. B13
N.Q. B14
C1
R
B
B
S
M
T
B
E
H
AN
D
EVEN
W
ITHIN .020" OVE
R
SURFACE.
S23006
.275
.285
S20500-14
S16668-11
S16668-5
S16668-6
S13490-93
N.H.
M
OLE
X
CAVITI
PE
E
S
D
A
D
LO
C
N
G
B
TO BE FR
E
E
OF
E
NCAPSULATI MATERIAL.
ON
R .045
C2
C3
C4, C6, C7
C5
C8, C9, C10, C11, C12,
C13, C14, C15, C16, C17
D1, D2
D3, D4, D5, D6, D7, D8,
D9, D10, D11, D12
DZ1
DZ2, DZ3, DZ5, DZ6
DZ4, DZ7
MAS
K
R
E
A
CT
U
N
G
K
IN TR CTIO
S
U
N
S.
N.J. ELECTRONIC MODULE
S
S
AND
SEALE
D
TO
P
C
BOAR
ATERI
D
PE
L (1
R
E
3875.
TERMINAL).
.1
1
6MAX. CRIMP
HEIGHT
N.M. OT OAT T TO
D
O
N
C
H
E
P
SURFACE
S
O
R
TH
E
THREAD
S
W
IT
H
ENCAPSULANT
M
A
10
2
S20500-1
T12705-44
T12705-32
CAPACITOR,PPMF,0.1,1000V,10%,BOX
DIODE,AXLDS,1A,1000V,FR, 818
COPPER SIDE
MAS
K
PE APPROPRIAT
R
E
MANUF RI
A
CT
U
N
G
WOR IN
K
S
TR
U
CTIO S.
N
N.Q. BRACKET MUS HAV
T
E
FULL MATI CONT
NG
A
CT IT
W
H
POWE TERMINA
R
L
AND
HAVE
HOL
ES
ALIGNED.
10
DIODE,TO220,15A,600V,FR,MUR1560
EYELET DETAIL
N.R.
E
LECTRONIC MODULE
S
O
N
A
COMMO P.C.
N
BOAR
D
ASSEMBL TO
Y
1
4
2
1
T12702-4
T12702-29
T12702-40
S24020-6
ZENER DIODE,1W,20V,5%,1N4747A
ZENER DIODE,1W,15V,5%,1N4744A
ZENER DIODE,1W,6.2V,5%,1N4735A
CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN
HAV TH SAM VENDO
E
E
E
R
CODE.
e.g. M21214-2 X XX XXX......
VENDO CODE
VCE( AT)
VGE(TH)
J40
L1, L2, L3, L4, L5, L6, L7,
L8, L9, L10
OCI1
R1
R2
R3, R8
R4, R13, R14, R17, R18,
R19, R20, R21, R23, R24,
R25, R26, R27
R5, R9
R6
R7
R10, R12, R15
R11
R16, R22
R
10
T12218-15
CHOKE,RF,FERRITE BEAD,180 OHM
S
1
1
1
2
S15000-22
S16296-5
S19400-6811
S19400-1002
OPTOCOUPLER,PHOTO-Q,70V,CNY17-3/VDE
TRIMMER,MT,1/2W,10K, 10%,LINEAR
RESISTOR,MF,1/4W,6.81K,1%
N.S. AFTER
S
OLDERI
N
G, INSPECT
T
ERMINA
L
CONNECTIO
N
A
S
T
PER
E
1880.
S
RESISTOR,MF,1/4W,10.0K,1%
N.T. ENCAPSULAT
N.U. NCAPSULAT
N.V. ENCAPSULATI
N. ENCAPSULAT
N.X. BOT P.C.
OF .C
E
COMPONENT
SID
E
OF
P
.C BOAR TO
.
D
HICKNES OF .30 +.12/-.00 I AREA SHOWN.
N
13
S19400-10R0
RESISTOR,MF,1/4W,10.0,1%
E
E
NO COMPONENT
MATERI MUS
OPPOSI COMPONENT
OAR
BOARD.
N.Y. APPLY A BEA OF IT
N
SIDE
OF .C BOAR
BEYON EDGE
ID OF .C BOARD IN
SAM MOUNTIN
P
.
D
TO HICKNES OF .25 +.12/-.00
OF .C BOAR .12 +.12/-.00
REA SHOW TO
OL S. IT
A
T
S
.
2
1
1
3
1
2
5
S19400-2001
S19400-2213
S19400-1000
S19400-1003
S19400-6191
S19400-1001
T14648-9
RESISTOR,MF,1/4W,2.00K,1%
RESISTOR,MF,1/4W,221K,1%
RESISTOR,MF,1/4W,100,1%
RESISTOR,MF,1/4W,100K,1%
RESISTOR,MF,1/4W,6.19K,1%
RESISTOR,MF,1/4W,1.00K,1%
RESISTOR,WW,5W,2.5K,5%,SQ
ON
AL
T
EXTEN
D
D
S
P
.
D
.
W.
E
TE
S
E
P
.
A
S
N
A
M
AXIMUM THICKNES
S
OF .20.
H
P
B
D
S
HIELD
S
S
OLDER INTO
T
HE
E
G
H
E
E
M
3
IS
MOUNT NON-COMPONENT SIDE
ED
ON
N.X.
.
N.W.
N.Y. R28, R29, R30, R31, R32
3
5
D
EM
6
T
O
COVER
R28,
R29,
R30,
R
31 AND
R32.
T1
T2
X1
X2
1
1
1
1
T12737-7
M19612
M13552-3
S15128-10
TRANSFORMER,PULSE,3-WINDING
CURRENT-TRANSDUCER,125-TURN
IC,CONVERTER,V/F,654
6.00 .04
+.12
.30
VOLTAGE REF,ADJ, PRECISION,431I
-.00
C
5
C
1
X2
9
X1
R
R
C
2
3
R
10
R
11
A1
R
5
OCI1
DZ3
DZ2
C
6
DZ4
R
16
R
13
L5
21
L4
L3
19
L2
18
L1
17
N.H.
R
R
20
R
R
R
DZ5
R
1.62
C
7
DZ6
3.00
R
30
R
29
R28
R
14
N.E.
DZ7
N.M., N.S.,N.Q.
(3 PLACES)
J
40
R
27
R
26
L9
R
25
L8
R
24
L7
R
23
L6
L1
0
A2
N.Q.
+.12
.30
-.00
0
N.W.
+.12
N.W.
6
.00
1.20
1.38
-.00
N.T.,N.U.,N.V.
2.00 .12
11.15 .04
MAKE PER E1911-ROHS
POT PER E1911-E-ROHS
TES
T
PER E3901-S
W
NO
N
C
OMPONENT
SCHEMA
T
IC REFERENCE: L11385-3E1
SI
D
E
ENCAPSULATION
MANUFACTURED AS:
ALL
C
OMPONENT
S
AND MAT
oH
E
RIAL
S
U
SED IN THIS
ASSEMBLY ARE TO
B
E
R
S
C
OMPLIANT PER
E4253.
G3734-3E1
IDENTIFICATION CODE
FOR
INCLUD
ONE S25254PRIN
P
ARTS ORDER
ON 3010PRIN
AND ONE T12837-1.
S
OR SUBSIDIAR
Y
ORDERS
N.W.
E
E
G
T,
ONE M19661PRINT,
P.C. BOARD
C
OMPONENT SIDE
T
ENCAPSULATION
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
T
MANUFACTURING TO
L
ERANCE
P
ER E2056
CONTROL: CLEVELAND
SCA
L
E:
UNLESS OTHERWISE SPECIFIED TOLERANCE:
EQUIP
M
ENT TYPE:
1
1
DOCUMEN
INVERTE
R
WELDERS
PAGE ___ OF ___
ON
ON
ON
2
3
PLAC
PLACE
LL ANGL
TO
E
D
ECIMAL
CIMALS IS
.5 OF
ERANC ("
S
I
S
.02 in.
(
0.5 mm)
1:1
DRAWN BY:
ENGINEER:
APPROVED:
fivory
D
E
.
00
A
2
i
n.
GREE
GREE
(
0.
0
5
mm)
T
DOCUMEN
T
IF PRIN
T
ED
A
E
S
I
S
DE
SUBJECT:
REVISION:
NUMGBER3: 734-
3
SWITCH P.C. BD ASSE
MBLY
@
A
1
SIZE
MATERI
A
L
L
E
"
)
TO
A
t
T
UNIINSC: H
WITH PU
DO NO
B
LISHED STANDARDS.
REFERENCE:
G3734-2
MATERIAL
APPROVA
DA E:
L
PROJEC
T
UF
DISPOSITION:
11-6-2009
E
CRM41517
DRS
T
NUMBER:
T
SCAL HIS DR
E
T
A
WING
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. 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. Improper PC board repairs could result in damage to the
machine.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-15
G-15
ELECTRICAL DIAGRAMS
SCHEMATIC - SPI / REMOTE CONTROL PC BOARD - (G4017)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-16
G-16
ELECTRICAL DIAGRAMS
SCHEMATIC - DISPLAY PC BOARD - (L11108)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-17
G-17
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - DISPLAY PC BOARD - (L11130)
5
1 3 1 0 1 - L
CHANGE DE
T
AIL: REVISED NOTE N.D.
ENGINEERING CONTROL
MANUFACTURER: No
LED
ITEM / REFERENCE DESIGNATORS QTY
PART NUMBER
L11757-F
T15176-2
DESCRIPTION
1
2
3
4
5
1
4
P.C. BOARD BLANK
LED, SPACER, 0.140 HIGH
ELECTRICAL INSULATING COMPOUND
FLEX CIRCUIT
.01 OZ. E3539
1
1
L11166-2
T15067-2
LABEL
FOR ITEMS BELOW REFER TO ELECTRONIC COMPONENTS DATABASE FOR COMPONET SPECIFICATIONS
C1
1
8
2
1
4
3
2
6
1
5
2
1
1
1
1
1
1
3
S25024-7SMT
S25020-3SMT
S17395-9
S18248-10
T13657-6
CAPACITOR,SMD,TANTALUM,47MF,20V,10%,S7343
CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X7R,S0805
LED,DISPLAY,7-SEGMENT,CC,4-DIGIT
CONNECTOR,MOLEX,MINI,PCB,10-PIN
LED,T-1,RED,HLMP-K101
C2, C3, C4, C5, C11, C12, C19, C20
N.A., N.D. DISP1, DISP2
J37
N.A. LED1, LED2, LED3, LED4
N.A. LED5, LED6, LED7
T13657-14
LED,T-1,3/4,AMBER,HIGH-INTENSITY
R6, R16
R9, R10, R11, R12, R13, R14
R20
R21, R25, R26, R28, R29
R22, R23
R24
S25000-1501SMT
S25000-1212SMT
S25000-2670SMT
S25000-1001SMT
S25000-10R0SMT
S25000-4751SMT
S25000-4752SMT
S17900-8SMT
S17900-26SMT
S17900-28SMT
S17900-10SMT
S20496-1SMT
RESISTOR,SMD,METAL FILM,1/10W,1.50K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,12.1K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,267OHMS,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,1.00K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,10.0OHMS,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,4.75K,1%,S0805
RESISTOR,SMD,METAL FILM,1/10W,47.5K,1%,S0805
IC,SMD,CMOS,INVERTER,SCHMITT,HEX,HC14A(SS)
IC,CMOS,SMD,MUX,DAT,8-INPUT,HC151(SS)
IC,SMD,CMOS,HEX INVERTING BUFFER,3-ST (SS)
IC,SMDCMOS,REGISTER,SHFT,S-PI/SO,8-BIT(SS)
IC,SMD,CMOS,DRIVER,DISPLAY,LED,CC,MCU
R27
N.B. X1
N.B. X2
N.B. X3
N.B. X4
N.G.
N.B. X5, X6, X7
1
5
N.A.
N.E.
.15
2.95
NOTES:
N.A DO NO
1.75
1.60
1.45
R6
SPI DISPLAY L11130-5
DISP1
.
T
COA
T
W
ITH ENCAPSULATION MATERIAL.
S SUBJEC TO DAMAGE BY STATI
SEE E2454 BEFORE HANDLING.
C20
R21
LED5
N.B. CAUTION: THIS DEVICE
I
T
C
X6
1
R25
X2
ELECTRICIT
Y.
N.A.
LED
X5
LED6
LED7
N.A.
X4
C12
DISP2
LED1
LED2
LED3
C3
N.C
.
USE
I
TEM 2 TO STAND LED1
,
LED2,LED3 AND LED4 FROM
THE P.C
.
BOARD. THERE
C1
X7
R16
2
LED4
R26
R11
.50
0
R13
MUS
T
NO BE MORE HAN 020 GAP BETWEEN SPACER AND P.C
BETWEEN SPACER AND LED ENCAPSULATE P.C.BOARD SPACER AND LOWER HALF
LED TOP 1/4 O LED BODY MUS BE REE O ENCAPSULATION.
T
T
.
.
BOARD OR
X1
R24
3
5
4
.
,
R28
R9
R27
N.C.
C2
J37
C5
.15
R14
R10
OF
.
F
T
F
F
5.65
5.90
5.75
2
N.D. DISP 1 AND DISP 2 MUS ALWAYS BE MATCHED BY VENDOR NAME AND EACH MUST
T
,
HAVE HE SAME NTENSITY LETTER CODE ETC.). DO NOT MIX DIFFERENT
VENDORS ON HE SAME BOARD ASSEMBLY ENCAPSULATE LEADS AND SOLDER
CONNECTIONS O DISPLAYS FACE O DISPLAYS MUS BE KEP FREE OF
ENCAPSULATION ENCAPSULATION AROUND UPPER HAL DISPLAYS MUS
EXCEED 006 PER SIDE.
T
I
(G,
H,
J,
0
.25
T
.
GROUND
SIDE
F
.
F
T
T
.
F
OF
T
NOT
.
UNLESS OTHERWISE SPECIFIED:
CAPACITORS = MFD/VOLTS
N.E
.
CONNECTOR MUS
T
BE GREASED WIT
H
I
TEM 3 PRIOR
T
O PLACING IN STOCK. MOUNT
4
FLEX CABLE BETWEEN CONNECTOR AND BOARD ON SOLDER SIDE.
I
NDUCTANCE = HENRIES
RESISTANCE = OHMS
N.F. IDENTIFY INISHED ASSEMBLY WITH SERIAL NUMBER AND MANUFACTURING CODE.
F
PLACE LABEL ON NON-COMPONEN SIDE.
T
N.G
.
PRIN "L11130-5 ON ITEM 5 AND PLACE OVER EXISTING PAR NUMBER.
T
"
T
MAKE AS:
L11757-2 MUST B
E
R
EVIEWED
WHEN
M
ODIF IN THI
Y
G
S
B
OARD.
FRONT
S
ID
E
OF
CONNECTOR
MANUFACTURE
ENCAPSUL TE
E1844 ITH
BY LINCOLN ELECTRIC COMPANY
P
ER E1911-ROH
ITH HUMISEA
QUIVALEN
S
A
W
L
1A27LU
P
ER
L11130-5F0
OR
W
E
T
AS APPROVED
.
(2
COATS)
SCH MATIC REFERENCE: L11108-5F0
E
IDENTIFICATION CODE
PART NO.
A
LL
C
OMPON
E
NTS AND MATERIALS
USED IN THIS ASSEMBLY ARE
TO
B
E
R
oH
S
C
OMPLIANT PE E4253.
R
TEST PER E3856-D
HIS DOCUME
N
T CONTAINS P
R
OPRIETARY INFORMATIO
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
N
D MAY NOT BE
D
UPLICATED,
COMMUNICATED
PROPRIETARY & CONFIDENTIAL:TTO OT
HER PA
SCALE:
1:1
R
TIES O USE
R
D
FOR ANY P RPOSE WITHOUT THE E
U
X
PRESS
W
RITTEN PERMISSIO
N
OF LINCOLN GLOBAL, INC.
MANUFACTURIN
NLESS OTHERWISE SPE
N 2 PLACE DECIMALS IS .02 in. ( 0.5 mm)
G
TOLERANCE PER E2056
CONTROL:
CLEVELAND
U
C
IFIE TOLERA CE:
D
N
EQUIPMENT TYPE
SUBJECT:
MATERIAL
DISPOSITION:
:
_1__
1
MISCELLANEOUS
PAGE
OF ___
O
DR
NGINEER:
APPROVED:
A
WN BY:
ddietz
ON
3
PLA
CE
DECIMALS IS .002
in.
(
0.05 mm)
IF PRINTED
DOCUMENT
DOCUMENT
REVIS ON:
O
N ALL ANGLES IS .5 OF A DEGREE
@
A2
S
IZE
N
UMBER:
I
SP
I
D
ISPLA
Y
P
C
B
OARD
A
SSE
MBL
Y
E
MATERIAL TOLERANCE ( ") TO A REE
"
G
t
U
NIITNSC: H
WITH PUBLISHED STANDARDS.
REFERENCE:
APPROVAL
DATE:
PROJECT
NUMBER:
L11130-5
UF
10/
31/2008
D
-
CRM39937
L11130-4
DO NOT SCALE THIS
DRAWING
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. 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. Improper PC board repairs could result in damage to the
machine.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-18
G-18
ELECTRICAL DIAGRAMS
SCHEMATIC - LED POTENTIOMETER PC BOARD - (S25258)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-19
G-19
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - LED POTENTIOMETER PC BOARD - (M19874)
2
1 9 M 8 7 4 -
REVISED NOTE N.B. AND ADDED NOTE N.E.
HANGE DETAIL:
C
ENGINEERIN
G
CONTR
LED
NoOL
REVISED DETAIL GRAPHICS
M
ANUFACTURER:
ITEM (USED WITH)*
QTY PART NUMBER
DESCRIPTION
SEE BLANK INFO PC BOARD BLANK
T15176 LED,SPACER,0.220 HIGH
1
1
5
2 (LED1, LED2, LED3, LED4, LED5)*
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
REFERENCES
J61
LED1, LED2, LED3, LED4, LED5
R1, R2
R3, R4, R5, R6, R7
S1
QTY PART NUMBER
DESCRIPTION
P.C. BOARD BLANK INFORMATION
1
5
2
5
1
S19365-15
T13657-13
S19366-1
S19400-2211
T13381-17
CONNECTOR,PCB,WW,MALE,RT-L,15-PIN
LED,T-1,3/4,RED,HIGH-INTENSITY,OVAL
POT,SINGLE-TURN,0.5W,10K,10%,LINEAR
RESISTOR,MF,1/4W,2.21K,1%
BUY COMPLETE AS M19874-C (2 LAYER BOARD PER E3281).
(MAKES 18 BOARDS PER PANEL. SEE ELECTRONIC FILE
FOR ADDITIONAL INFORMATION).
SWITCH,PUSHBUTTON,SPST,GREEN,W/BLACK EXTENDER
N.C.
N.D.
N.C.
RESISTANCE
=
OHMS
N.B.
1.90
MANUFACTURE AS:
M19874-2C0
LED1
LED2
LED3
LED4
LED5
R3
R4
R5
L
ED/POT
J6
1
M19874-2
R2
R1
S1
.88
0
R6
R7
IDENTIFICATION CODE
2
PART NO.
ENCAPSULATE WITH E1844. (2 COATS)
BRUSH COAT ACCEPTABLE
0
1.80
5.35
MAKE PER E1911-ROHS
N.C.
TEST PER E3964-MS
N.A.
NOTES:
N.A. DO NOT COAT WITH ENCAPSULATION MATERIAL.
N.B. THERE MUST NOT BE MORE THAN A .010 GAP
BETWEEN SPACER & LED, OR BETWEEN SPACER
& P.C. BOARD. LEDS MUST BE PERPENDICULAR
WITH P.C. BOARD AFTER ALL OPERATIONS ARE
N.E.
COMPLETE.
N.C. ENCAPSULATE AROUND BASE OF COMPONENT
N.D. COAT EXTERNAL PINS WITH ENCAPSULATION MATERIAL.
N.E. ENCAPSULATE P.C. BOARD, SPACER AND LOWER HALF
OF LED.
ALL COMPONENTS AND
MATERIALS USED IN THIS
SCHEMATIC REFERENCE: S25258-2C0
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
ENLARGED DETAIL
(LED ORIENTATION)
THIS DOCUMENT CONTAINS PROPRIETARY INFO
R
MATION O
W
NED BY
L
INCOLN GLO
B
AL
,
INC. AN
D
MAY NOT BE
D
UPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO
O
THER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN
P
ERMISSION OF LINCOLN GLO
B
AL INC.
,
U
NLESS OTHERWISE SPE
C
IFIED
CE PER E2056
MALS IS .0
PLACE DECIMALS IS .002
TOLERANCE
DESIGN INFO
RAW BY:
ENGINEER
APP OVED:
RMAT
IO
N
REFERENCE:
MANUFACTURING TOLERA
N
EQUIPMENT TYPE:
1_
PAGE _1_ OF __
INVERTER WELDERS
_
ON
ON
2
3
PLACE DEC
I
2
FEI
D
N
M19874-1
DOCUMENT
DOCUM
ENT
ON ALL ANGLES IS .5 OF A DEGREE
SUBJECT:
LED POT P.C. BOARD ASSEMBLY
N
UMBER:
REVISION:
:
MATERIAL TOLERANCE (" ") TO AGREE
t
SCALE
:
WITH PUBLISHED STANDARDS.
MATERIAL
APPROVAL
DATE:
PROJECT
NUMBER:
C
CRM38610
M19874-2
UF
R
-
1:1
4/5/2007
DISPOSITION:
DO NOT
S
CA
L
E THIS
DRAWING
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. 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. Improper PC board repairs could result in damage to the
machine.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-20
G-20
ELECTRICAL DIAGRAMS
SCHEMATIC - LED SELECT PC BOARD - (S25259)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
G-21
G-21
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - LED SELECT PC BOARD - (M19875)
2
1 9 M 8 7 5 -
ITEM
1
2
QTY PART NUMBER
1
1
DESCRIPTION
SEE BLANK INFO. PC BOARD BLANK
CI001498 E3165-.25-.75-.20
ADDED MAKE PER E1911-ROHS
CHANGE DETAIL:
ENGINEERIN
G
CONTR
LED
NoOL
M
ANUFACTURER:
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
REFERENCES
QTY PART NUMBER
DESCRIPTION
J60
1
6
2
1
S19365-5
CONNECTOR,PCB,WW,MALE,RT-L,5-PIN
LED,T-1,3/4,RED,HIGH-INTENSITY,OVAL
RESISTOR,MF,1/4W,750,1%
LED1, LED2, LED3, LED4, LED5, LED6
R1, R2
S1
T13657-13
S19400-7500
T13381-16
P.C. BOARD BLANK INFORMATION
SWITCH,PUSHBUTTON,SPST
BUY COMPLETE AS M19875-C (2 LAYER BOARD PER E3281).
(MAKES 63 BOARDS PER PANEL. SEE ELECTRONIC FILE
FOR ADDITIONAL INFORMATION).
RESISTANCE
=
OHMS
MANUFACTURE AS:
M19875-2C0
1
N.D.
N.A.
.20
1.33
1.15
M19875-2
LED SELECT
N.E.
IDENTIFICATION CODE
LED6 LED5 LED4
LED3 LED2 LED1
J60
PART NO.
N.B.
2
.18
MAKE PER E1911-ROHS
0
ENCAPSULATE WITH E1844. (2 COATS)
BRUSH COAT ACCEPTABLE
TEST PER E3964-ST
N.A.
0
2.02
2.55
NOTES:
N.C.
N.A. DO NOT COAT WITH ENCAPSULATION MATERIAL.
N.B. INSERT ITEM 2 BETWEEN ROWS OF LED'S. ITEM 2
MUST BE FLUSH WITH LED BULB.
CATHODE
N.C. ENCAPSULATE PC BOARD AND LOWER HALF OF LED.
(SQUARE)
N.D. ENCAPSULATE AROUND BASE OF COMPONENT
N.E. COAT EXTERNAL PINS WITH ENCAPSULATION MATERIAL.
ANODE
(ROUND)
SCHEMATIC REFERENCE: S25259-2C0
ALL COMPONENTS AND
MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
ENLARGED DETAIL
(LED ORIENTATION)
THIS DOCUMENT CONTAINS PROPRIETARY INFO
R
MATION O
W
NED BY
L
INCOLN GLO
B
AL
,
INC. AN
D
MAY NOT BE
D
UPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO
O
THER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN
P
ERMISSION OF LINCOLN GLO
B
AL INC.
,
U
NLESS OTHERWISE SPE
C
IFIED
CE PER E2056
MALS IS .0
PLACE DECIMALS IS .002
TOLERANCE
DESIGN INFO
RAW BY:
ENGINEER
APP OVED:
RMAT
IO
N
REFERENCE:
MANUFACTURING TOLERA
N
EQUIPMENT TYPE:
1_
PAGE _1_ OF __
INVERTER WELDERS
_
ON
ON
2
3
PLACE DEC
I
2
FEI
D
N
M19875-1
DOCUMENT
REVISION:
DOCUM
ENT
ON ALL ANGLES IS .5 OF A DEGREE
SUBJECT:
LED SELECT PC BOARD ASSEMBLY
N
UMBER:
:
MATERIAL TOLERANCE (" ") TO AGREE
t
SCALE
:
WITH PUBLISHED STANDARDS.
MATERIAL
APPROVAL
PROJECT
NUMBER:
B
CRM34409
M19875-2
UF
R
-
1:1
3/16/2007
DISPOSITION:
DATE:
DO NOT
S
CA
L
E THIS
DRAWING
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. 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. Improper PC board repairs could result in damage to the
machine.
INVERTEC® V450-PRO
Download from Www.Somanuals.com. All Manuals Search And Download.
|