Lincoln Electric Welding System IM526 B User Manual

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IM526-B  
December,1999  
INVERTEC V300-PRO  
For use with machines Code 10256 and 10257.  
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 thought-  
ful operation on your part. DO  
NOT INSTALL, OPERATE OR  
REPAIR THIS EQUIPMENT  
WITHOUT READING THIS  
MANUAL AND THE SAFETY  
PRECAUTIONS CONTAINED  
THROUGHOUT. And, most  
importantly, think before you act  
and be careful.  
Date of Purchase:  
Serial Number:  
Code Number:  
Model:  
Where Purchased:  
OPERATOR’S MANUAL  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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4.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 weld-  
ing area.  
7.c.Do not add the fuel near an open flame weld-  
ing arc or when the engine is running. Stop  
the engine and allow it to cool before refuel-  
ing to prevent spilled fuel from vaporizing on  
contact with hot engine parts and igniting.  
Do not spill fuel when filling tank. If fuel is  
spilled, wipe it up and do not start engine  
until fumes have been eliminated.  
4.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.  
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7.d. Keep all equipment safety guards, covers  
and devices in position and in good repair.  
Keep hands, hair, clothing and tools away  
from V-belts, gears, fans and all other mov-  
ing parts when starting, operating or repair-  
ing equipment.  
4.h. Also see item 7c.  
7.e. In some cases it may be necessary to remove safety  
guards to perform required maintenance. Remove  
guards only when necessary and replace them when the  
maintenance requiring their removal is complete.  
Always use the greatest care when working near moving  
parts.  
CYLINDER may explode  
if damaged.  
5.a. Use only compressed gas cylinders contain-  
ing 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.  
7.f. Do not put your hands near the engine fan. Do not  
attempt to override the governor or idler by pushing on  
the throttle control rods while the engine is running.  
5.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
7.g. To prevent accidentally starting gasoline engines while turn-  
ing the engine or welding generator during maintenance  
work, disconnect the spark plug wires, distributor cap or  
magneto wire as appropriate.  
5.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.  
5.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
7.h. To avoid scalding, do not remove the radia-  
tor pressure cap when the engine is hot.  
5.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
5.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
ELECTRIC AND MAGNETIC  
FIELDS  
5.g. Read and follow the instructions on compressed gas cylin-  
ders, 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.  
may be dangerous  
8.a. Electric current flowing through any con-  
ductor causes localized Electric and  
Magnetic Fields (EMF). Welding current  
creates EMF fields around welding cables  
and welding machines.  
FOR ELECTRICALLY  
powered equipment.  
8.b. EMF fields may interfere with some pacemakers, and  
welders having a pacemaker should consult their physician  
before welding.  
6.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
8.c. Exposure to EMF fields in welding may have other health  
effects which are now not known.  
6.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s rec-  
ommendations.  
8d. All welders should use the following procedures in order to  
minimize exposure to EMF fields from the welding circuit:  
6.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
8.d.1. Route the electrode and work cables together - Secure  
them with tape when possible.  
8.d.2. Never coil the electrode lead around your body.  
FOR ENGINE  
8.d.3. Do not place your body between the electrode and  
work cables. If the electrode cable is on your right side,  
the work cable should also be on your right side.  
powered equipment.  
7.a. Turn the engine off before troubleshooting and maintenance  
work unless the maintenance work requires it to be running.  
---------------------------------------------------------------------------------------  
8.d.4. Connect the work cable to the workpiece as close as  
possible to the area being welded.  
8.d.5. Do not work next to welding power source.  
7.b. Operate engines in open, well-ventilated  
areas or vent the engine exhaust fumes out-  
doors.  
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Mar. ‘93  
3 –  
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zones où l’on pique le laitier.  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
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 échauf-  
fement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
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.  
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.  
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.  
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.  
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.  
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:  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
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.  
b. Porter des vêtements convenables afin de protéger la peau  
de soudeur et des aides contre le rayonnement de 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.  
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.  
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.  
3. Avant de faires des travaux à l’interieur de poste, la debrancher  
à l’interrupteur à la boite de fusibles.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
4. Garder tous les couvercles et dispositifs de sûreté à leur place.  
Mar. ‘93  
4 –  
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TABLE OF CONTENTS  
Page  
Safety Precautions .............................................................................................................2-4  
Introductory Information.......................................................................................................6  
Product Description..............................................................................................................7  
Specifications.......................................................................................................................7  
Installation .........................................................................................................................7-10  
Safety Precautions ........................................................................................................7  
Location.........................................................................................................................7  
Electrical Installation......................................................................................................7  
Input Voltage Setup.......................................................................................................8  
Power Cord Connection ................................................................................................8  
Connection of Wire Feeders to Invertec .....................................................................8-10  
Output Cables & Plugs .................................................................................................10  
Operating Instructions ......................................................................................................11-13  
Safety Precautions .......................................................................................................11  
Controls Description and Function.............................................................................11-13  
Maintenance.....................................................................................................................13-14  
Capacitor Discharge Procedure ...................................................................................13  
Routine Maintenance....................................................................................................13  
Periodic Maintenance...................................................................................................14  
Troubleshooting Guide.....................................................................................................14-20  
Matched Parts.....................................................................................................................20  
Switch P.C. Board Replacement Procedure.......................................................................20  
Replacement of Power Modules and Output Diodes .......................................................20-21  
Connection Diagrams.......................................................................................................22-31  
Wiring Diagrams...............................................................................................................32-33  
Parts Lists......................................................................................................................appendix  
5 –  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
Please Examine Carton and Equipment For Damage Immediately  
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims  
for material damaged in shipment must be made by the purchaser against the transportation company at the  
time the shipment is received.  
Please record your equipment identification information below for future reference. This information can be  
found on your machine nameplate.  
Model Name & Number _____________________________________  
Code & Serial Number _____________________________________  
Date of Purchase _____________________________________  
Whenever you request replacement parts for or information on this equipment always supply the information  
you have recorded above.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or  
loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to  
this equipment.  
6 –  
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PRODUCT DESCRIPTION  
The Invertec V300-PRO is a 300 amp arc welding  
power source that utilizes single or three phase input  
power to produce either constant voltage or constant  
current outputs. The V300-PRO is designed for 60 Hz  
supply systems. The welding response of the Invertec  
has been optimized for GMAW, SMAW, TIG and  
FCAW processes. It is designed to be used with the  
LN-25 and LN-7 semiautomatic wire feeders.  
SPECIFICATIONS  
Product  
Name  
Ordering  
Information  
Input AC  
Voltage  
Rated DC Output  
Amps/Volts/Duty Cycle  
Input Amps at Rated DC Output  
Output  
Range  
(continuous)  
Weight  
with Gun  
(net)  
Dimensions  
HxWxD  
208  
230  
460  
575  
208/230/460  
3 Phase  
300A / 32V / 60%(1)  
250A / 30V / 100%(1)  
300A / 35/39/41V /60%(2)  
48  
37  
49  
43  
33  
48  
24  
19  
28  
60 Hz  
18.7*x10.8x  
22.2”  
Invertec  
V300-  
PRO  
K1349-3  
K1349-4  
208/230/460  
1 Phase  
250A / 30V / 60%(1)  
160A / 28V / 100%(1)  
250A / 37/41/43V / 60%(2)  
69  
53  
75  
62  
47  
67  
38  
29  
42  
AMPS  
5-350  
64 lbs.  
(29 kg)  
(475x274x  
564 mm)  
60 Hz  
* Includes  
handle  
575  
300A / 32V / 60%(1)  
250A / 30V / 100%(1)  
300A / 36V / 60%(2)  
20  
16  
22  
3 Phase  
60 Hz  
(1 )NEMA Class I Rated Output / Based on a 10 min. Period .  
(2 )Lincoln plus rating.  
* Overall Height Including Handle, (16.4” (417mm without handle).  
INSTALLATION  
WARNING  
ELECTRICAL INSTALLATION  
ELECTRIC SHOCK can kill.  
• Have an electrician install and service  
this equipment.  
1. The Invertec should be connected only by a quali-  
fied electrician. Installation should be made in  
accordance with the U.S. National Electrical Code,  
all local codes and the information detailed below.  
• Turn the input power off at the fuse  
box before working on equipment.  
• Do not touch electrically hot parts.  
---------------------------------------------------------------------  
2. Single voltage, 575 VAC machines, can only be  
connected to 575 VAC. No internal reconnection  
for other input voltages is possible.  
LOCATION  
The Invertec has been designed with many features to  
protect it from harsh environments. Even so, it is  
important that simple preventative measures are fol-  
lowed in order to assure long life and reliable opera-  
tion.  
• The machine must be located where there is free  
circulation of clean air such that air movement into  
the sides and out the bottom and front will not be  
restricted. Dirt and dust that can be drawn into the  
machine should be kept to a minimum. Failure to  
observe these precautions can result in excessive  
operating temperatures and nuisance shutdown of  
the Invertec.  
3. Initial 208 VAC and 230 VAC operation will require  
a voltage panel setup, as will later reconnection  
back to 460 VAC:  
a. Open the access panel on the right side of  
the machine.  
b. For 208 or 230: Position the large switch to  
200-230.  
For 460: Position the large switch to 380-460.  
c. Move the “A” lead to the appropriate terminal.  
• Keep machine dry. Shelter from rain and snow. Do  
not place on wet ground or in puddles.  
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INPUT VOLTAGE SETUP  
Recommended Fuse Sizes Based On The U.S.  
National Electrical Code And Maximum  
Machine Outputs  
CAUTION  
DO NOT ATTEMPT TO POWER THIS UNIT  
FROM THE AUXILIARY POWER SUPPLY  
Fuse Size in Amps  
(1)  
Input Volts  
(Time Delay Fuses)  
OF AN ENGINE WELDER.  
3 phase  
208  
230  
460  
60  
60  
40  
• Special protection circuits may operate, causing  
loss of output.  
50/60 Hz  
• The supply from engine welders often has exces-  
sive voltage peaks because the voltage waveform  
is usually triangular shaped instead of sinusoidal.  
• If voltage peaks from the engine welder exceed  
380V, the input circuits of this machine protecting  
the filter capacitors, FETS and other components  
from damage will not be energized .  
(2)  
1 phase  
208  
85  
80  
50  
(2)  
50/60 Hz  
230  
460  
3 phase  
60 Hz  
575  
30  
(1)  
(2)  
Input voltage must be within 10% of rated value.  
When operating on these inputs, at outputs exceeding 200A/60%  
or 165A/100%, the input line cord should be changed to an input  
conductor of 6 AWG or larger.  
---------------------------------------------------------------------  
RECONNECT PROCEDURE  
.
Disconnect input power before  
1. BE SURE POWER SWITCH IS OFF.  
inspecting or servicing machine.  
.
Do not operate with wraparound  
2. CONNECT LEAD ’A’ TO DESIRED  
INPUT VOLTAGE RANGE.  
CONNECTION OF WIRE FEEDERS TO THE  
INVERTEC  
removed.  
.
Do not touch electrically live parts.  
440-460V  
.
Only qualified persons should install,  
(Note: IEC units do not have 110 VAC auxiliary  
power).  
380-415V  
220-230V  
200-208V  
use or service this equipment.  
’A’  
IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)  
AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;  
REPLACE WITH A 3 AMP SLOW BLOW ONLY.  
LN-25 Connection Instructions  
3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.  
VOLTAGE=380-460V  
1. Turn the Invertec power switch “off”.  
VOLTAGE=200-230V  
2. Connect the electrode cable to the output terminal  
of polarity required by electrode. Connect the work  
lead to the other terminal.  
9-11-92  
THE LINCOLN ELECTRIC CO.  
CLEVELAND, OHIO  
U.S.A.  
S20324  
POWER CORD CONNECTION  
3. LN-25 with remote control options K431 and K432.  
Use K876 adapter with K432 cable or modify K432  
cable with K867 universal adapter plug. See con-  
nection diagram S19899 and S19309 or S19405 at  
the back of this manual.  
A 10 ft. (3.0m) power cord is provided and wired into  
the machine. Follow the power cord connection  
instructions. Incorrect connection may result in equip-  
ment damage.  
4. Place the local-remote switch in the “remote” posi-  
tion if output control is desired at the wire feeder  
rather than the Invertec. (LN-25 must have K431  
and K432 options for remote output control opera-  
tion).  
BLACK  
GREEN  
RED  
WHITE  
LN-7 Connection Instructions  
Single Phase Input  
1. Connect green lead to ground per U.S. National  
Electrical Code.  
1. Turn the Invertec power switch “off”.  
2. Connect black and white leads to power.  
3. Wrap red lead with tape to provide 600V insula-  
tion.  
2. Connect the K480 control cable from the LN-7 to  
the Invertec control cable connector. The control  
cable connector is located at the rear of the  
Invertec.  
Three Phase Input  
3. Connect the electrode cable to the output terminal  
of polarity required by electrode. Connect the work  
lead to the other terminal.  
1. Connect green lead to ground per U.S. National  
Electrical Code.  
2. Connect black, red and white leads to power.  
4. Place the local-remote switch in the “local” posi-  
tion to allow output control at the Invertec. (K864  
Install in accordance with all local and national electric  
codes.  
8 –  
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remote control adapter and K857 remote control  
are required for remote output control).  
Parallel Operation  
The Invertec’s are operable in parallel in both CC and  
CV modes. For best results, the currents of each  
machine should be reasonably well shared. As an  
example, with two machines set up in parallel for a  
400 amp procedure, each machine should be set to  
deliver approximately 200 amps, not 300 amps from  
one and 100 amps from the other. This will minimize  
nuisance shutdown conditions. In general, more than  
two machines in parallel will not be effective due to  
the voltage requirements of procedures in that power  
range.  
5. Set the meter polarity switch on the rear of the  
Invertec to coincide with wire feeder polarity used.  
The wire feeder will now display the welding volt-  
age.  
6. If K480 is not available, see connection diagram  
S19404 for modification of K291 or K404 LN-7  
input cable with K867 universal adapter plug.  
General Instructions for Connection of Wire  
Feeders to Invertec  
To set machine outputs, start with output control pots  
and arc force/pinch pots in identical positions. If run-  
ning in a CC mode, adjust outputs and arc forces to  
maintain current sharing while establishing the proper  
output current. In CV modes, the pots in identical  
positions. Then switch the machine meters to amps  
and adjust one of the output control pots for current  
balance. Check the voltage and if readjustment is  
necessary, repeat the current balancing step. Pinch  
settings should also be kept identical on the  
machines.  
Wire feeders other than LN-7 and LN-25 may be used  
provided that the auxiliary power supply capacity of  
the Invertec is not exceeded. K867 universal adapter  
plug is required. See connection diagram S19406 and  
S19386 at the back of this manual for more informa-  
tion.  
Remote Control of Invertec  
Remote control K857, hand amptrol K963 and foot  
amptrol K870 require K864 remote control adapter.  
See 19309 instruction at the back of this manual for  
connection information.  
K900-1 DC TIG Starter Connection  
This versatile new kit was made to mate with the  
Invertec.  
K954-1 MIG PULSER  
The MIG Pulser is a hand-held “pendant” type GMAW  
Pulsing option for the V300 Power Source. Refer to  
the Mig Pulser’s IM manual (IM555) for connection  
information.  
A control cable assembly is supplied with the kit to  
connect the kit to an Invertec. The cable can be con-  
nected, either end, at the DC TIG Starter kit and at  
the Invertec by attaching to the 14-pin Amphenols on  
the backs of each unit. Refer to diagram S20405 at  
the back of this manual.  
A negative output cable assembly is also supplied  
with the DC TIG Starter kit to connect the kit with the  
Invertec’s negative output terminal.  
All Magnum™ one and two piece water-cooled torch-  
es with 7/8 left-hand threads and gas-cooled torches  
with 7/8 and 5/16 right-hand threads can be connect-  
ed to the starter kit.  
To secure the DC TIG Starter kit to the bottom of the  
Invertec and for more detailed instructions, refer to  
the K900-1 manual.  
MAR97  
9 –  
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LN-9 GMA Connection Instructions  
2. Slide rubber boot onto cable end. The boot end  
may be trimmed to match the cable diameter.  
Soap or other lubricant will help to slide the boot  
over the cable.  
1. Turn the Invertec power switch “off”.  
BOOT  
WELDING CABLE  
2. Connect the K596 control cable assembly from the  
LN-9 GMA to the Invertec control cable connector.  
The control cable connector is located at the rear  
of the Invertec.  
25 mm  
TRIM  
1 in.  
3. Connect the electrode cable to the output terminal  
of polarity required by electrode. Connect the work  
lead to the other terminal.  
3. Slide the copper tube into the brass plug.  
4. Insert cable into copper tube.  
4. Place the local-remote switch in the “remote” posi-  
tion to allow output control at the LN-9 GMA.  
SET SCREW  
5. Set the meter polarity switch on the rear of the  
Invertec to coincide with wire feeder polarity used.  
The wire feeder will now display the welding volt-  
age.  
BRASS PLUG  
COPPER TUBE  
5. Tighten set screw to collapse copper tube. Screw  
must apply pressure against welding cable. The  
top of the set screw will be well below the surface  
of the brass plug after tightening.  
6. K608-1 adapter is required in LN-9 GMA for LN-9  
type control. K608-1 is installed in line with P10  
connection at the LN-9 GMA voltage board. See  
diagram S20607 at the back of this manual.  
6. Slide rubber boot over brass plug. The rubber  
boot must be positioned to completely cover all  
electrical surfaces after the plug is locked into the  
receptacle.  
7. K442-1 Pulse Power Filter Board is also required  
for GMAW, but should be disconnected for FCAW.  
8. If K596 is not available, see connection diagram  
S20608 at the back of this manual for modification  
of K196 LN-9 GMA input cable with K867 universal  
adapter plug.  
Output Cables  
Select the output cable size based upon the following  
chart.  
Cable sizes for Combined Length of Electrode and  
Work Cable (Copper) 75° rated:  
Duty  
Cycle  
Length Up  
61m (200 ft.)  
61-76m  
(200-250 ft.)  
Current  
100%  
60%  
250  
300  
1/0  
1/0  
1/0  
2/0  
Quick Disconnect Plugs  
A quick disconnect system is used for the welding  
cable connections. The welding plug included with the  
machine is designed to accept a welding cable size of  
1/0 to 2/0.  
1. Remote 25mm (1 in.) of welding cable insulation.  
10 –  
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Output Control - This controls the output voltage in  
the CV modes and output current in the CC modes.  
OPERATING INSTRUCTIONS  
Control is provided over the entire output range of the  
power source with 1 turn of the control knob. This con-  
trol may be adjusted while under load to change  
power source output.  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground.  
OUTPUT  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
FUMES AND GASES can be danger-  
ous.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
Local/Remote Switch - Place in the “LOCAL” posi-  
tion to allow output adjustment at the machine. Place  
in the “REMOTE” position to allow output adjustment  
at the wire feeder or with a remote control option  
package.  
------------------------------------------------------------------------  
WELDING SPARKS can cause fire or  
explosion.  
• Keep flammable material away.  
• Do not weld on closed containers.  
REMOTE  
------------------------------------------------------------------------  
ARC RAYS can burn eyes and skin.  
• Wear eye, ear and body  
protection.  
------------------------------------------------------------  
Digital Meter Switch - Select either “A” for amps or  
“V” for volts to display welding current or voltage on  
the meter.  
See additional warning information at  
front of this operator’s manual.  
-----------------------------------------------------------  
When welding current is not present, the meter will  
display the set current for the CC modes or the set  
voltage for the CV modes. This set reading is an indi-  
cation of machine control setting. For a more precise  
process reading, read meter during actual welding.  
DUTY CYCLE  
The Invertec is rated at 300 amps, 60% duty cycle for  
3 phase inputs (based on a 10 minute cycle). It is also  
rated at 250 amps, 100% duty cycle.  
CONTROL FUNCTION / OPERATION  
Power Switch - Place the lever in the “ON” position to  
energize the machine. When the power is on, the digi-  
tal meter will activate and the fan will operate.  
Mode Switch  
GTAW  
Optimized for both scratch start and Hi-  
Freq kit use.  
OFF  
CC SOFT  
CC Crisp  
Best for EXX18 thru EXX28 stick elec-  
trodes.  
Use this mode for stick welding with  
EXX10 thru EXX14 electrodes. Non-  
welding applications such as resistive  
heating or output tests with resistive  
loads should be done in this mode with  
Arc Force Control set to minimum.  
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CV FCAW  
This setting has been optimized for  
Arc Force / Inductance Control  
®
®
Innershield and Outershield flux-cored  
electrodes.  
This control functions in all modes except GTAW. For  
CC modes, this control acts as an Arc Force adjust-  
ment. The arc is soft at the minimum settings and  
more forceful or driving at the maximum settings.  
Higher spatter levels may be present at the maximum  
settings.  
CV GMAW Short circuit, glob and spray transfer  
solid wire and gas welding are done in  
this mode. Low end procedures, less  
than 17V, may operate better in the  
FCAW mode. Voltage in the GMAW  
mode can become erratic when  
welding is attempted using voltages  
equal to or less than 17V DC+.  
For CV modes, this control will set the degree of  
“pinch effect” which predominantly affects short circuit  
transfer. In FCAW, the maximum setting is generally  
preferred. With GMAW, the upper half of the range is  
preferred with CO or high content CO mixed. The  
2
2
SMAW  
CRISP  
lower half is for inert gas mixes.  
FCAW  
GMAW  
SMAW  
SOFT  
GTAW  
Output Terminals Switch  
For processes and equipment that require energized  
machine terminals (stick, TIG, air-carbon arc cutting or  
hot tip LN-25), set the Output Terminals Switch to  
“ON” position.  
Recommended Arc Force / Inductance Settings  
For Selected Applications  
Set to the REMOTE (OFF) position when using LN-25  
with K431 and K432 options or LN-7 which will allow  
the gun trigger to energize the welding terminals.  
Full Range Is 1-10,  
1 Is Very Soft, 10 Is Very Crisp  
ON  
Nominal  
Setting  
Recommended  
Adjustment Range  
Mode  
Process  
OUTPUT  
TERMINALS  
CC SMAW 1  
EXX18 thru  
EXX28 stick  
5
1 (gentle, may stick) to 9  
(forceful, more spatter)  
CC SMAW 2  
CV FCAW  
EXX10 thru  
EXX14 stick  
6
1
3 to 10  
REMOTE  
Air Carbon Arc  
Cutting  
None  
Innershield or  
Outershield  
10  
1
None  
Air Carbon Arc  
Cutting  
None  
CV GMAW* CO or 25% CO  
2
7.5  
5 to 10  
2
or similar  
gas mixes  
98% Ar-2% O Ar,  
2
5
1 to 10  
90% He-7.5% Ar  
2.5% CO and  
2
other  
predominantly  
inert gases  
* 1 = Lowest pinch, highest inductance and least spatter.  
10 = Highest pinch, lowest inductance and most spatter.  
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Meter Polarity Switch  
MAINTENANCE  
WARNING  
The wire feeder polarity switch is located at the rear of  
the machine. The switch provides a work connection  
for wire feeder voltmeters. Place the switch in the  
position of the electrode polarity indicated by the  
decal. The switch does not change the welding  
polarity.  
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.  
---------------------------------------------------------------------  
EXPLODING PARTS can cause  
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.  
----------------------------------------------------------------------------------  
Capacitor Discharge Procedure  
Auxiliary Power  
1. Obtain a power resistor (25 ohms, 25 watts).  
A 24 VAC @ 1 amp supply is included for use with the  
LN-25 wire feeder (24 volts needed for K431 and  
K432 options). This supply is protected by a self-  
resetting current limiter.  
2. Hold resistor body with electrically insulated glove.  
DO NOT TOUCH TERMINALS. Connect the resis-  
tor terminals across the two hex head cap screws  
in the position shown. Hold in each position for 1  
second. For 575 VAC only, repeat for second  
capacitor. Repeat for the capacitor(s) on the other  
side of the machine  
A 42 VAC @ 5.5 amp supply is included for use with  
other wire feeders. This supply is protected by a 6  
amp breaker located on the rear of the machine.  
A 110/115 VAC @ 2 amp supply is included for use  
with the LN-7 or LN-9 GMA wire feeders. This supply  
is protected by a 2.5 amp breaker located on the rear  
of the machine. It is NOT available on IEC units.  
RESISTOR  
All three supplies are not to be loaded simultaneously.  
CAPACITOR  
TERMINALS  
3. Use a DC voltmeter to check that voltage is not  
present across either capacitor.  
Routine Maintenance  
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:  
• Power, switch, driver, protection and control printed  
circuit boards.  
• Power switch  
• Main transformer  
• Input rectifier (located in front of fan blade)  
• Heat sink fins  
2. Examine the sheet metal case for dents or breakage.  
Repair the case as required. Keep the case in good con-  
dition 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.  
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PERIODIC MAINTENANCE  
TROUBLESHOOTING  
WARNING  
Overload Protection  
ELECTRIC SHOCK can kill.  
• Have an electrician install and service  
this equipment.  
The machine is electrically protected from producing  
high output currents. Should the output current  
exceed 340-360A, an electronic protection circuit will  
reduce the current to approximately 150A. The  
machine will continue to produce this low current until  
the protection circuit is reset. Reset occurs when the  
output load is removed.  
• Turn the input power off at the fuse  
box before working on equipment.  
• Do not touch electrically hot parts.  
---------------------------------------------------------------------  
EXPLODING PARTS can cause  
injury.  
Thermal Protection  
Failed parts can explode or cause other  
parts to explode when power is applied.  
Thermostats protect the machine from excessive  
operating 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.  
Always wear a face shield and long sleeves when servicing.  
----------------------------------------------------------------------------------  
Visual Inspection  
Clean interior of machine with a low pressure  
airstream. 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.  
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 were obstructed,  
then the power must be switched off for 15 minutes in  
order to reset. The fan problem or air obstruction must  
also be corrected.  
Open Circuit Voltage  
The open circuit voltage of the Invertec V300-PRO is  
60 to 75 VDC and cannot be adjusted by the output  
control.  
Test Conditions  
Filter Capacitor Conditioning  
Perform all testing at the lowest input voltage avail-  
able, except where a higher voltage is required by a  
test step. Make ohmmeter checks only after power  
has been disconnected from machine and after  
capacitors have been discharged.  
A protection circuit is included to monitor the voltage  
across filter capacitors C1 and C2 (also C14 and C15  
on 575 VAC units). In the event that the capacitor volt-  
age is too high, the protection circuit will prevent out-  
put. The protection circuit may prevent output provid-  
ing all these circumstances are met:  
Certain high voltage connections have been insulated  
with RTV sealant. It is necessary to break through the  
sealant with a sharp probe in order to make voltage or  
resistance checks.  
1. Machine is internally connected for 380 VAC, or  
higher input voltage.  
2. Machine did not have power applied for many  
months.  
Disconnect any control cables from remote control  
receptacle.  
3. Machine did not produce output when power was  
first switched on.  
If these circumstances apply, the proper action is to  
switch the machine on and let it idle for up to 30 min-  
utes. This is required to condition the filter capacitors  
after an extended storage time. The protection circuit  
will automatically reset once the capacitor conditioning  
and resultant voltage levels are acceptable. It may be  
necessary to turn the power switch off and back on  
again after this period.  
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TROUBLESHOOTING GUIDE  
Trouble  
What To Do  
Not output but fan operates and meter is on.  
Perform test steps 1A and 1B.  
Poor welding, weld settings drift, or output power is  
low.  
1. Check front panel wiring and controls.  
2. Replace Control PC Board.  
Main fuses open or Switch PC boards overheated.  
Perform test steps 4 and 5 for both Switch PC Boards  
and 7.  
Output turns on momentarily then switches off and  
repeats. Machine is connected for 380 VAC or higher  
input voltage.  
Perform test steps 3B, 4 and 5.  
OCV is normal (approx. 65-75V) but output power is  
low (less than 20V and 100A). Machine makes  
squealing noise while under load. Machine is connect-  
ed for 230 VAC, or lower, input voltage.  
Perform test steps 4 and 5 for both Switch PC Boards.  
Open circuit voltage is 1-2 volts.  
Perform test step 6.  
Output control not functioning on remote control. Local  
control OK.  
1. Check remote control assembly.  
2. Check S3, Local/Remote switch.  
Machine does not produce more than 250A output  
when connected to 3 phase supply.  
1. Replace main fuse if blown.  
2. Replace Protection PC Board.  
3. Replace Control PC Board.  
4. Perform test step 7.  
Machine does not produce more than 200 A output  
while connected to 1 phase supply.  
Normal operation.  
Machine operates OK at 230 VAC or lower. No output  
at 380 VAC or higher.  
Perform test step 2.  
Poor EXX10 stick electrode (5P) performance. Arc  
“pops out”.  
Check D6 and D12, L1 and L2.  
Check reconnect panel - connections and fuse.  
No output or reduced output the first time power is  
applied to the machine.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-  
tact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
15 –  
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TEST PROCEDURES  
Next  
Test  
Step  
Test  
Step  
Test  
Check  
223A to 210  
Result  
Conclusion  
Repair Action  
1A  
1B  
2
Output pilot circuit  
(set S4 on)  
24 VAC  
Fan thermostat, choke  
thermostat, T1 trans-  
former and S4 all OK.  
1B  
0 VAC  
15 VDC  
0 VDC  
Check above compo-  
nents.  
302 (pos) to 275D (neg)  
313 (neg) to 311 (pos)  
T1 and 15V power sup-  
ply OK.  
2
Check T1 and Power PC  
Board.  
Protection PC  
board output (set  
S4 on)  
<1 VDC  
>5 VDC  
Protection PC Board OK  
Replace Power  
and Control PC  
Boards  
3A  
3A  
Static capacitor  
balance (set S4  
off)  
Compare voltage across  
terminals 9 & 12 of each  
Switch PC Board.  
<25 VDC  
difference  
between  
readings  
C1, C2, R1, R9 - OK  
(575 VAC machine C14,  
C15 - OK)  
575 VAC -- 407 VDC  
460 VAC -- 325 VDC  
440 VAC -- 311 VDC  
415 VAC -- 293 VDC  
380 VAC -- 269 VDC  
575 VAC only - compare  
voltage across 9A & 13  
and 13 & 12A; then, 9B &  
15 and 15 & 12B  
380 VAC input  
and higher test  
Replace  
Protection PC  
Board  
3B  
>25 VDC  
difference  
Check above compo-  
nents.  
3B  
Dynamic capaci-  
tor balance (set  
S4 on)  
Connect as in step 3A.  
Same voltages as above.  
<25 VDC  
>25 VDC  
OK  
380 VAC input  
and higher test  
Power PC Board or  
Switch PC Boards are  
damaged.  
4
and  
5
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-  
tact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
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Next  
Test  
Step  
Test  
Step  
Test  
Conclusion  
OK  
Repair Action  
Check  
Result  
4
Switch PC Board  
resistance test.  
cont  
Terminals on Switch  
PC Board:  
1/8 (pos) to  
12 (neg)  
>1K ohms  
<100 ohms  
Short  
5
Replace Switch PC Board  
No dynamic test  
is possible.  
OK  
cont  
5
1/8 (neg) to  
12 (pos)  
<100 ohms  
>1K ohms  
>1K ohms  
<100 ohms  
<100 ohms  
>1K ohms  
<100 ohms  
>1K ohms  
>1K ohms  
<100 ohms  
<100 ohms  
>1K ohms  
>1K ohms  
<100 ohms  
>1K ohms  
<100 ohms  
<100 ohms  
>1K ohms  
<100 ohms  
>1K ohms  
>1K ohms  
<100 ohms  
Open  
OK  
Replace Switch PC Board  
Replace Switch PC Board  
Replace Switch PC Board  
Replace Switch PC Board  
Replace Switch PC Board  
Replace Switch PC Board  
Replace Switch PC Board  
Replace Switch PC Board  
Replace Switch PC Board  
Replace Switch PC Board  
Replace Switch PC Board  
Remove leads  
401/403, 1/8, 9,  
12, 4/5 and  
cont  
5
9 (pos) to  
4/5 (neg)  
Short  
OK  
402/404.  
cont  
5
9 (neg) to  
4/5 (pos)  
Open  
OK  
cont  
5
1/8 (pos) to  
9 (neg)  
Open  
OK  
cont  
5
1/8 (neg) to  
9 (pos)  
Short  
OK  
cont  
5
12 (pos) to  
4/5 (neg)  
Open  
OK  
cont  
5
12 (neg) to  
4/5 (pos)  
Short  
OK  
cont  
5
12 (pos) to  
401/403 (neg)  
Short  
OK  
cont  
5
12 (neg) to  
401/403 (pos)  
Open  
OK  
cont  
5
9 (pos) to  
402/404 (neg)  
Open  
OK  
cont  
5
9 (neg) to  
402/404 (pos)  
Short  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-  
tact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
17 –  
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Next  
Test  
Step  
Test  
Step  
Test  
Conclusion  
OK  
Repair Action  
Check  
Result  
5
Snubber  
Resistors  
cont  
cont  
cont  
cont  
Lead 401 to terminal  
12  
25 ohms  
R4 open  
R4 shorted  
Replace R4  
>30 ohms  
<20 ohms  
Disconnect leads  
401, 402, 403 and  
404 from Switch  
PC Board  
OK  
25 ohms  
Lead 402 to terminal  
9
R5 open  
R5 shorted  
Replace R5  
>30 ohms  
<20 ohms  
OK  
25 ohms  
R6 open  
R6 shorted  
Lead 403 to terminal  
12  
>30 ohms  
<20 ohms  
Replace R6  
OK  
25 ohms  
R7 open  
R7 shorted  
Replace R7  
>30 ohms  
<20 ohms  
Lead 404 to terminal  
9
Shorted output  
diode D1 thru  
D12  
Test individually  
<100 ohms  
>200 ohms  
6
Output diodes  
+ output plug (pos)  
to  
- output plug (neg)  
Output diodes OK  
Remove output  
load  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-  
tact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
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Next  
Test  
Step  
Test  
Step  
Test  
Conclusion  
OK  
Repair Action  
Check  
Result  
7
D13 Input  
Rectifier  
cont  
4-5  
9 (pos) to H1 (neg)  
>1K ohms  
<100 ohms  
Shorted  
Replace D13, inspect S1,  
test C1 and C2  
OK  
cont  
4-5  
9 (pos) to A (neg)  
9 (pos) to H5 (neg)  
12 (neg) to H1 (pos)  
12 (neg) to A (pos)  
12 (neg) to H5 (pos)  
9 (neg) to H1 (pos)  
9 (neg) to A (pos)  
9 (neg) to H5 (pos)  
12 (pos) to H1 (neg)  
12 (pos) to A (neg)  
12 ( pos) to H5 (neg)  
>1K ohms  
<100 ohms  
Shorted  
Replace D13, inspect S1,  
test C1 and C2  
OK  
cont  
4-5  
>1K ohms  
<100 ohms  
Shorted  
Replace D13, inspect S1,  
test C1 and C2  
OK  
cont  
4-5  
>1K ohms  
<100 ohms  
Shorted  
Replace D13, inspect S1,  
test C1 and C2  
OK  
cont  
4-5  
>1K ohms  
<100 ohms  
Shorted  
Replace D13, inspect S1,  
test C1 and C2  
OK  
cont  
4-5  
>1K ohms  
<100 ohms  
Shorted  
Replace D13, inspect S1,  
test C1 and C2  
OK  
cont  
4-5  
<100 ohms  
>1K ohms  
Open  
Replace D13, inspect S1,  
test C1 and C2  
OK  
cont  
4-5  
<100 ohms  
>1K ohms  
Open  
Replace D13, inspect S1,  
test C1 and C2  
OK  
cont  
4-5  
<100 ohms  
>1K ohms  
Open  
Replace D13, inspect S1,  
test C1 and C2  
OK  
cont  
4-5  
<100 ohms  
>1K ohms  
Open  
Replace D13, inspect S1,  
test C1 and C2  
OK  
cont  
4-5  
<100 ohms  
>1K ohms  
Open  
Replace D13, inspect S1,  
test C1 and C2  
OK  
cont  
4-5  
<100 ohms  
>1K ohms  
Open  
Replace D13, inspect S1,  
test C1 and C2  
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Matched Parts  
5. Thoroughly clean the heat sink surface.  
Certain parts must be replaced in matched sets.  
Matched sets are required in the following areas:  
6. Apply a thin layer (ideally .005-.010”) of Dow 340  
Heat Sink Compound to the module mounting sur-  
faces of the new Switch PC Board and a thinner  
layer (.002”) to the capacitor terminals. Keep the  
heat sink compound away from the screw threads  
since this compound will affect the torque specifi-  
cations.  
Output diodes: D1, D2, D3, D4 and D5  
Output diodes: D7, D8, D9, D10 and D11  
Capacitor bleeder resistors: R1 and D9  
Capacitors: C1 and C2  
Capacitors: C1, C2, C14 and C15 (575 VAC only)  
7. Carefully place the Switch PC Board onto the heat  
sink. Be sure the mounting holes are lined up  
before making full contact with the heat sink.  
Switch PC Board Repairs  
If a test indicates that a Switch PC Board is defective,  
both Switch PC Boards must be replaced.  
8. Caution: The heat sink and the capacitor terminals  
are relatively soft material and it is very easy to  
cross-thread the mounting screws. Holding the  
Switch PC Board, install the 4 socket head cap  
screws, finger tight only. Then install the hex head  
cap screws into the capacitor, finger tight only.  
Replacement boards must have completely identical  
part numbers. A defective module is likely to damage  
other devices in the power circuitry. The defect may  
be subtle and not detectable by an ohmmeter mea-  
surement. Unknown defective parts may cause newly  
replaced parts to fail.  
9. Torque the 4 socket head cap screws to 44 inch-  
lbs force (5 N - m). Then torque the capacitor hex  
head cap screws to 55 inch-lbs force (6 N - m).  
In addition to replacing the Switch PC Boards, replace  
C1 and C2 (also C14 and C15 of the 575 VAC V300-  
PRO) if the following conditions are met:  
10. Reconnect all the leads to the board.  
1. Machine was operating from 380 VAC or higher  
supply when failure occurred.  
2. Switch PC Boards have burned areas.  
Before applying input power to the machine, check all  
electrical connections. An incorrect connection will result  
in machine damage when the power is switched on.  
Switch PC Board Replacement Procedure  
Test After Repair  
WARNING  
1. Short terminals 14 and 53 of the Protection PC  
Board. Connect an ohmmeter, set for X1000  
range, to terminals 9 (+) and 12 (-) of the Switch  
PC Board. The meter will show the capacitors  
charging up. The meter may take a minute or so to  
stabilize. The value must not exceed 8600 ohms.  
Test both boards. For 575V only units - measure  
across each power capacitor, 2 per switch board;  
All four readings should be approximately 5,000  
ohms.  
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.  
---------------------------------------------------------------------  
EXPLODING PARTS can cause  
injury.  
Failed parts can explode or cause other  
parts to explode when power is applied.  
2. If OK, remove the short and proceed with the  
power test.  
Always wear a face shield and long sleeves when servicing.  
----------------------------------------------------------------------------------  
3. Fuse input supply with 5 amp fuses.  
1. Carefully disconnect the leads at the top of the  
Switch PC Board.  
4. Check output open circuit voltages. Do not apply  
output load.  
2. Remove the four socket head cap screws with a  
3/16” hex key wrench.  
5. Connect machine for 460 (V300-PRO), or 575  
(V300-PRO, 575V), or 380, 415 or 440 (V300-I)  
VAC input.  
3. While holding the Switch PC Board, remove the  
hex head cap screws from the center area of the  
board.  
6. Check output open circuit voltages. Do not apply  
output load.  
4. Remove the board.  
7. Fuse for 20 amps and test under load.  
20 –  
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Replacement of Power Modules and Output  
Diodes  
The compound should be applied to the heat sink in a  
very thin layer, less than 0.001 in. DO NOT apply on  
diode stud and mounting nut threads.  
Input rectifier, D13, is a power module. When mount-  
ing power modules, the heat sink and module mount-  
ing surface should be clean and free of burrs and for-  
eign material. Apply heatsink compound (Dow 340) as  
a uniform layer ideally .010” thick, to eliminate all air  
pockets. This may be verified by mounting and then  
removing the module. When removed, the compound  
on both surfaces will appear textured as if a vacuum  
had created veinlike ridges when the parts were sepa-  
rated. If the compound does not have this appear-  
ance, apply more heatsink compound and recheck.  
Components must have proper torque applied to  
mounting screws and to electrical terminals. Torque  
the modules according to the following:  
Replacement of output diodes D1 thru D12 is similar.  
Clean and brighten mounting surface with fine steel  
wool. Compound should be used on surface between  
diode and heat sink when mounting individual diodes.  
Component to Heat Sink  
Torque 10%  
Terminal  
Component  
Switch Board  
Module  
Torque 10%  
(1)  
44 Inch - Lbs.  
(5N - m)  
N.A.  
Capacitor  
N.A.  
55 Inch - Lbs.  
(6.3 N - m)  
(2)  
Input Rectifier  
(M15454-1)  
6 Inch - Lbs.  
(0.7 N - m)  
26 Inch - Lbs.  
3 (N - m)  
Output Diode  
(M15482-2)  
25 Inch - Lbs.  
(3 N - m)  
N.A.  
(1)  
Retorque after 3 hours to allow for spread of compound.  
Tighten in staggered fashion one quarter turn at a time.  
(2)  
Environment Protection  
Printed Circuit Board Replacement  
High voltage connections are covered with an RTV  
sealant to prevent malfunction in severe environ-  
ments. Sealant must be applied to connections which  
have been opened or otherwise lost their protection. A  
noncorrosive electronic grade sealant such as Dow  
Corning 3140, 3145, 738, Columbus Adhesives 0172  
or GE RTV-162 is recommended. Sealant may also  
be purchased from Lincoln Electric (order E2519  
Silicone Rubber RTV Coating). Apply sealant after  
machine is repaired and tested.  
1. Handle PC Boards by edges only.  
2. Store PC Boards only in the bags that disperse  
static charges.  
3. Inspect PC Board for burned conductors or com-  
ponents. If damage is visible, inspect the machine  
wiring for grounds or shorts to avoid damaging a  
new PC Board.  
4. If there is no visible damage to the PC Board,  
install a new PC Board and see if the problem is  
fixed. If the problem is fixed by the new board,  
reinstall the old board and see if the problem reoc-  
curs. If the problem does not reoccur, check the  
wiring harness and plugs for loose connections.  
High voltage areas which require sealant are as listed:  
- Input rectifier D13, all 5 terminals.  
21 –  
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R 1 1  
R 1 2  
R 8  
R 1  
R 9  
MAR97  
32 –  
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R 1 1  
R 1 2  
R 8  
R 9  
R 1  
MAR97  
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NOTES  
INVERTEC V300-PRO & V300-I  
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NOTES  
INVERTEC V300-PRO & V300-I  
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NOTES  
INVERTEC V300-PRO & V300-I  
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Now Available...12th Edition  
New Lessons in Arc Welding  
The Procedure Handbook of Arc Welding  
Lessons, simply written, cover manipulatory techniques;  
machine and electrode characteristics; related subjects,  
such as distortion; and supplemental information on arc  
welding applications, speeds and costs. Practice materials,  
exercises, questions and answers are suggested for each  
lesson.  
With over 500,000 copies of previous editions published  
since 1933, the Procedure Handbook is considered by many to  
be the “Bible” of the arc welding industry.  
This printing will go fast so don’t delay. Place your  
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528 pages, well illustrated, 6” x 9” size, bound in simulated,  
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The hardbound book contains over 750 pages of welding  
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$5.00 postage paid U.S.A. Mainland  
A must for all welders, supervisors, engineers and  
designers. Many welding instructors will want to use the book  
as a reference for all students by taking advantage of the low  
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$15.00 postage paid U.S.A. Mainland  
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How To Read Shop Drawings  
The book contains the latest information and application  
data on the American Welding Society Standard Welding  
Symbols. Detailed discussion tells how engineers and  
draftsmen use the “short-cut” language of symbols to pass  
on assembly and welding information to shop personnel.  
For details write:  
Lincoln Welding School  
22801 St. Clair Ave.  
Cleveland, Ohio 44117-1199.  
Practical exercises and examples develop the reader’s ability  
to visualize mechanically drawn objects as they will appear  
in their assembled form.  
and ask for bulletin ED-80 or call 216-383-2259 and ask for the  
Welding School Registrar.  
187 pages with more than 100 illustrations. Size 8-1/2” x 11”  
Durable, cloth-covered board binding.  
Lincoln Welding School  
BASIC COURSE  
$700.00  
$4.50 postage paid U.S.A. Mainland  
5 weeks of fundamentals  
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.  
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.  
Prices include shipment by 4thClass Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.  
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:  
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For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.  
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.  
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders)  
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USE THIS FORM TO ORDER:  
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Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199  
Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.  
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(ED-93)  
A New Approach to Industrial Economics $5.00  
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Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground.  
Keep flammable materials away.  
Wear eye, ear and body protection.  
WARNING  
Spanish  
No toque las partes o los electrodos Mantenga el material combustible  
Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa moja-  
da.  
Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
Gardez à lécart de tout matériel  
inflammable.  
Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
Isolez-vous du travail et de la terre.  
German  
Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
Isolieren Sie sich von den  
Entfernen Sie brennbarres Material! Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
Mantenha inflamáveis bem guarda- Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURERS INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE  
USED AND FOLLOW YOUR EMPLOYERS SAFETY PRACTICES.  
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS  
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A  
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-  
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
38 –  
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Keep your head out of fumes.  
Use ventilation or exhaust to  
remove fumes from breathing zone.  
Turn power off before servicing.  
Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
Los humos fuera de la zona de res-  
piración.  
Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
Débranchez le courant avant lentre- Nopérez pas avec les panneaux  
tien.  
Gardez la tête à l’écart des fumées.  
Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ouverts ou avec les dispositifs de  
protection enlevés.  
ATTENTION  
German  
Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
Vermeiden Sie das Einatmen von  
Schweibrauch!  
Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
Não opere com as tampas removidas.  
Desligue a corrente antes de fazer  
serviço.  
Mantenha-se afastado das partes  
moventes.  
Não opere com os paineis abertos  
ou guardas removidas.  
Mantenha seu rosto da fumaça.  
Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
39 –  
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• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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