Beruflich Dokumente
Kultur Dokumente
SVM101-B
January, 2007
INVERTEC V300-I
For use with machines having Code Number : 9825 THRU 10450
SERVICE MANUAL
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of Safety in Welding & Cutting - ANSI Standard Z49.1 from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding Safety booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE
powered equipment.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from 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.
____________________________________________________
1.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 moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.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.
___________________________________________________
1.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.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.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.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar 95
ii
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.
ii
SAFETY
AUG 06
iii
iii
SAFETY
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.
6.h. Also see item 1.c.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturers
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturers recommendations.
Mar 95
iv
iv
SAFETY
PRCAUTIONS DE SRET
3. Avant de faires des travaux linterieur de poste, la debrancher linterrupteur la boite de fusibles.
Mar. 93
i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P243 Series
V300-I
TABLE OF CONTENTS
- INSTALLATION SECTION -
Section A-1
Installation ..............................................................................................................Section A
Section A-1
V300-I
A-2
A-2
INSTALLATION
SINGLE PHASE
Standard
Input Current
Code
at Rated Output
Voltage
Number
200/230/280-415/440
43/39/259826, 9827,
50/60
25/22
10036, 10037,
10132, 10133
Standard
Input Current
Code
at Rated Output
Number
Voltage
200/230/380-415/440
53/47/329826, 9827,
50/60
32/29
10036, 10037,
10132, 10133
RATED OUTPUT
THREE PHASE
SINGLE PHASE
Volts at
Rated
Amperes
32
30
Amps
300
250
Duty Cycle
60% Duty Cycle
100% Duty Cycle
Duty Cycle
60% Duty Cycle
100% Duty Cycle
Volts at
Rated
Amperes
28
26.5
Amps
200
165
OUTPUT
THREE PHASE
Welding
Current Range
5-300 Amps
Constant Open
Circuit Voltage
60-70 VDC
SINGLE PHASE
Auxiliary
Power
42 VAC, 5.5 Amps
24 VAC, 1 Amp
*115 VAC, 2 Amps
*Not on all codes
Welding
Current Range
5-200 Amps
Constant Open
Circuit Voltage
60-70 VDC
Auxiliary
Power
42 VAC, 5.5 Amps
24 VAC, 1 Amp
*115 VAC, 2 Amps
*Not on all codes
Input
Voltage
Frequency(1)
200/50-60
220/50-60
380/50-60
415/50-60
440/50-60
Fuse
Input
(Superlag) Ampere
or
Rating
Breaker
on
Size
Nameplate
60
60
35
35
35
43
39
25
25
22
Type 75C
Copper
Wire in
Conduit
AWG (IEC)
Sizes
Type 75C
Copper
Ground
Wire in
Conduit
AWG (IEC)
Sizes
6 (16mm2)
8 (10mm2)
10 (6mm2)
10 (6mm2)
10 (6mm2)
10
10
10
10
10
(6mm2)
(6mm2)
(6mm2)
(6mm2)
(6mm2)
Input
Voltage
Frequency(1)
Fuse
Input
(Superlag) Ampere
or
Rating
Breaker
on
Size
Nameplate
200/50-60
220/50-60
380/50-60
415/50-60
440/50-60
80
70
50
50
50
53
47
32
32
29
Type 75C
Copper
Wire in
Conduit
AWG (IEC)
Sizes
Type 75C
Copper
Ground
Wire in
Conduit
AWG (IEC)
Sizes
6 (16mm2)
6 (16mm2)
8 (10mm2)
8 (10mm2)
10 (6mm2)
10
10
10
10
10
PHYSICAL DIMENSIONS
Height
18.7 in.
Width
10.8 in.
Depth
22.2 in.
Weight
64 lbs.
475 mm
274 mm
564 mm
29 Kg
V300-I
(6mm2)
(6mm2)
(6mm2)
(6mm2)
(6mm2)
PRODUCT DESCRIPTION
ELECTRICAL INSTALLATION
WARNING
A-3
INSTALLATION
1. The Invertec should be connected only by a qualified electrician. Installation should be made in
accordance with the U.S. National Electrical Code,
all local codes and the information detailed below.
2. When received from the factory, multiple voltage
(200/220/380-415/440) machines are internally
connected for 440 volt input.
3. Single voltage, 575 VAC machines, can only be
connected to 575 VAC. No internal reconnection
for other input voltages is possible.
4. Initial 208 VAC and 230 VAC operation will require
a voltage panel setup, as will later reconnection
back to 460 VAC:
a.
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 followed in order to assure long life and reliable operation.
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.
Keep machine dry. Shelter from rain and snow. Do
not place on wet ground or in puddles.
b.
c.
440-460V
CAUTION
380-415V
A-3
220-230V
200-208V
VOLTAGE=380-460V
V300-I
VOLTAGE=200-230V
9-11-92
S20324
A-4
INSTALLATION
CONNECTION OF WIRE FEEDERS TO
THE INVERTEC
Connect the supply lines to the upper and lower terminals of the line switch. Torque to 3.0 Nm. Do not use
center terminal of the line switch.
A-4
4. Place the local-remote switch in the remote position 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 operation).
LN-7 Connection Instructions (not applicable to
IEC machines with only 42V Aux.).
1. Turn the Invertec power switch off.
3 phase
50/60 Hz
1 phase
50/60 Hz
(1)
Input Volts(1)
200
220
380-415
440
60
60
35
35
200
220
380-415
440
80
70
50
50
V300-I
A-5
INSTALLATION
4. Place the local-remote switch in the remote position to allow output control at the LN-9 GMA.
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 voltage.
6. K608-1* adapter is required in LN-9 GMA for LN-9
type control. K608-1 is installed in line with P10. See
diagram S20607.
7. K442-1* Pulse Power Filter Board is also required
for GMAW,but should beremoved for FCAW.
A-5
PARALLEL OPERATION
The Invertec is 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.
To set machine outputs, start with output control pots
and arc force/pinch pots in identical positions. If running in a CC mode, adjust output and arc force 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.
V300-I
INSTALLATION
A-6
OUTPUT CABLES
A-6
Length Up
61m (200 ft.)
Current
61-76m
(200-250 ft.)
BRASS PLUG
COPPER TUBE
100%
60%
250
300
1/0
1/0
1/0
2/0
WELDING CABLE
25 mm
TRIM
1 in.
V300-I
TABLE OF CONTENTS
- OPERATION SECTION -
Section B-1
Operation ................................................................................................................Section B
Section B-1
V300-I
B-2
B-2
OPERATION
OPERATING INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
Do not touch electrically live parts or
electrode with skin or wet clothing.
Insulate yourself from work and
ground.
Always wear dry insulating gloves.
-----------------------------------------------------------------------FUMES AND GASES can be dangerous.
Keep your head out of fumes.
Use ventilation or exhaust to remove
fumes from breathing zone.
----------------------------------------------------------------------WELDING SPARKS can cause fire or
explosion.
Keep flammable material away.
Do not weld on closed containers.
-----------------------------------------------------------------------ARC RAYS can burn eyes and skin.
Wear eye, ear and body
protection.
REMOTE
OFF
V300-I
OPERATION
B-3
MODE SWITCH
GTAW
CC SOFT
CC Crisp
CV FCAW
Return to Section TOC
B-3
CV GMAW
SMAW
CRISP
FCAW
SMAW
SOFT
GMAW
GTAW
EXX18 thru
EXX28 stick
EXX10 thru
EXX14 stick
3 to 10
None
Innershield or
Outershield
10
None
None
7.5
5 to 10
1 to 10
CC SMAW 1
CC SMAW 2
CV FCAW
ON
Recommended
Adjustment Range
Process
Nominal
Setting
Mode
OUTPUT
TERMINALS
other
predominantly
inert gases
REMOTE
V300-I
B-4
OPERATION
B-4
AUXILIARY POWER
T13086-84
V300-I
TABLE OF CONTENTS
- ACCESSORIES SECTION -
Options/Accessories...............................................................................................C-2
Section C-1
Accessories ............................................................................................................Section C
Section C-1
V300-I
C-2
ACCESSORIES
OPTIONS / ACCESSORIES
C-2
CABLE PLUGS
Cable Plug Kit for 1/0-2/0 cable (K852-70) attaches to
welding cable to provide quick disconnect from
machine.
V300-I
TABLE OF CONTENTS
- MAINTENANCE SECTION -
Section D-1
Maintenance ...........................................................................................................Section D
Section D-1
V300-I
D-2
MAINTENANCE
WARNING
6. Use electrically insulated gloves and insulated pliers. Hold body of the resistor and connect resistor
leads across the two capacitor terminals. Hold
resistor in place for 10 seconds. DO NOT TOUCH
CAPACITOR TERMINALS WITH YOUR BARE
HANDS.
4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This
resistor is not supplied with machine. NEVER
USE A SHORTING STRAP FOR THIS PROCEDURE.
.
D-2
V300-I
D-3
MAINTENANCE
D-3
PREVENTIVE MAINTENANCE
OVERLOAD PROTECTION
2. Remove the machine wrap-around cover and perform the input filter capacitor discharge procedure
(detail at the beginning of this chapter).
THERMAL PROTECTION
3. Clean the inside of the machine with a low pressure airstream. Be sure to clean the following
components thoroughly. See Figure D.2 for location of these components.
Power Switch, Driver, Protection, and Control
printed circuit boards
Power Switch
Main Transformer
PC BOARD REPLACEMENT
Input Rectifier
1. Handle PC Boards by edges only.
Heat Sink Fins
2. Store PC Boards only in the bags that disperse
static charges.
V300-I
3. Inspect PC Board for burned conductors or components. 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
reoccurs. If the problem does not reoccur, check
the wiring harness and plugs for loose connections.
D-4
D-4
MAINTENANCE
FIGURE D.2 LOCATION OF MAINTENANCE COMPONENTS.
3
4
11
6
10
7
COMPONENT
PC BOARDS
CONTROL
DRIVER
PROTECTION
SWITCH
POWER
INPUT RECTIFIER
POWER SWITCH
HEAT SINK FINS
MAIN TRANSFORMER
OUTPUT STUDS
INPUT FILTER CAPACITORS
QTY,
ITEM
NO.
1
1
1
2
1
1
1
2
1
1
2
1
2
3
7
10
4
5
6
8
9
11
8
9
V300-I
TABLE OF CONTENTS
- THEORY OF OPERATION SECTION -
Section E-1
POWER SWITCH
SECTIONS
20KHZ
LEFT SWITCH BOARD
MAIN
TRANSFORMER
FET MODULES
CHOKE
RECTIFIER
HEATSINK
TOP
CAP
1 DIODE
FET MODULES
CURRENT
TRANSFORMER
1 OR 3 DETETCTION (H5)
PRE-CHARGE
INPUT
RECTIFIER
LINE
SWITCH
DRIVER
BOARD
3A
AC1
AC2
AC3
5 DIODES
CONTROL
BOARD
CR1
1
2
3
PROTECTION
BOARD
PULSE
TRAIN
Y-Y FEEDBACK
BOTTOM
CR2
A-LEAD
24VDC
FAN
PRE-CHARGE
RIGHT SWITCH BOARD
AUXILIARY
TRANSFORMER
24VAC
5 DIODES
FET MODULES
18VAC
CAP
POWERBOARD
<1 VDC
TOP
FET MODULES
1 DIODE
TO
WIREFEEDER
Section E-1
CHOKE
LOCAL
REMOTE
METER MODE
POT
POT
VOLTAGE FEEDBACK
CURRENT FEEDBACK-PROTECTION
V300-I
CHOKE
SHUNT
E-2
THEORY OF OPERATION
E-2
POWER SWITCH
SECTIONS
20KHZ
LEFT SWITCH BOARD
MAIN
TRANSFORMER
FET MODULES
CHOKE
RECTIFIER
HEATSINK
TOP
CAP
1 DIODE
FET MODULES
CURRENT
TRANSFORMER
1 OR 3 DETETCTION (H5)
PRE-CHARGE
INPUT
RECTIFIER
LINE
SWITCH
DRIVER
BOARD
3A
AC1
AC2
AC3
5 DIODES
CONTROL
BOARD
CR1
1
2
3
PROTECTION
BOARD
PULSE
TRAIN
Y-Y FEEDBACK
BOTTOM
CR2
A-LEAD
24VDC
FAN
PRE-CHARGE
RIGHT SWITCH BOARD
AUXILIARY
TRANSFORMER
24VAC
5 DIODES
FET MODULES
18VAC
CAP
POWERBOARD
TOP
FET MODULES
<1 VDC
1 DIODE
TO
WIREFEEDER
CHOKE
LOCAL
REMOTE
METER MODE
POT
POT
VOLTAGE FEEDBACK
CURRENT FEEDBACK-PROTECTION
CHOKE
SHUNT
24VAC-THERMOSTATS-GUN TRIGGERING
NOTE: Unshaded areas of block logic diagram are the subject of discussion
V300-I
E-3
THEORY OF OPERATION
E-3
POWER SWITCH
SECTIONS
20KHZ
MAIN
TRANSFORMER
CHOKE
RECTIFIER
HEATSINK
TOP
CAP
1 DIODE
FET MODULES
CURRENT
TRANSFORMER
1 OR 3 DETETCTION (H5)
PRE-CHARGE
INPUT
RECTIFIER
LINE
SWITCH
DRIVER
BOARD
1
2
3
3A
AC1
AC2
AC3
5 DIODES
CONTROL
BOARD
CR1
PROTECTION
BOARD
PULSE
TRAIN
Y-Y FEEDBACK
BOTTOM
CR2
A-LEAD
24VDC
FAN
PRE-CHARGE
RIGHT SWITCH BOARD
AUXILIARY
TRANSFORMER
24VAC
5 DIODES
FET MODULES
18VAC
CAP
POWERBOARD
<1 VDC
TOP
FET MODULES
1 DIODE
TO
WIREFEEDER
CHOKE
LOCAL
REMOTE
METER MODE
POT
POT
VOLTAGE FEEDBACK
CURRENT FEEDBACK-PROTECTION
CHOKE
SHUNT
24VAC-THERMOSTATS-GUN TRIGGERING
V300-I
THEORY OF OPERATION
E-4
E-4
POWER SWITCH
SECTIONS
20KHZ
LEFT SWITCH BOARD
MAIN
TRANSFORMER
FET MODULES
CHOKE
RECTIFIER
HEATSINK
TOP
CAP
1 DIODE
FET MODULES
CURRENT
TRANSFORMER
1 OR 3 DETETCTION (H5)
PRE-CHARGE
INPUT
RECTIFIER
LINE
SWITCH
DRIVER
BOARD
3A
AC1
AC2
AC3
5 DIODES
CONTROL
BOARD
CR1
1
2
3
PROTECTION
BOARD
PULSE
TRAIN
Y-Y FEEDBACK
BOTTOM
CR2
A-LEAD
24VDC
FAN
PRE-CHARGE
RIGHT SWITCH BOARD
AUXILIARY
TRANSFORMER
24VAC
5 DIODES
FET MODULES
18VAC
CAP
POWERBOARD
<1 VDC
TOP
FET MODULES
1 DIODE
TO
WIREFEEDER
CHOKE
LOCAL
REMOTE
METER MODE
POT
POT
VOLTAGE FEEDBACK
CURRENT FEEDBACK-PROTECTION
CHOKE
SHUNT
24VAC-THERMOSTATS-GUN TRIGGERING
SWITCH BOARDS
The Switch Boards contain the the Field Effect
Transistors (FETs) which, when switched ON, supply
power to the primary windings of the main transformer.
Each Switch Board powers a separate, oppositely
wound primary winding. The opposite direction of current flow in those windings and a slight offset in of the
FET switching produces a square wave AC signal in
the secondary of the transformer.
Along with ease of control, the 20Khz operating frequency allows for a much smaller and lighter transformer
Signals from the Current Transformer insure that one
switch circuit is turned off before the other is gated on.
Field Effect Transistor operation and Pulse Width
Modulation are discussed in more detail later in this
section.
V300-I
E-5
THEORY OF OPERATION
E-5
MAIN
TRANSFORMER
CHOKE
RECTIFIER
HEATSINK
TOP
CAP
1 DIODE
FET MODULES
CURRENT
TRANSFORMER
1 OR 3 DETETCTION (H5)
PRE-CHARGE
INPUT
RECTIFIER
LINE
SWITCH
DRIVER
BOARD
3A
AC1
AC2
AC3
5 DIODES
CONTROL
BOARD
CR1
1
2
3
PROTECTION
BOARD
PULSE
TRAIN
Y-Y FEEDBACK
BOTTOM
CR2
A-LEAD
24VDC
FAN
PRE-CHARGE
RIGHT SWITCH BOARD
AUXILIARY
TRANSFORMER
24VAC
5 DIODES
FET MODULES
18VAC
CAP
POWERBOARD
TOP
FET MODULES
<1 VDC
1 DIODE
TO
WIREFEEDER
CHOKE
LOCAL
REMOTE
METER MODE
POT
POT
VOLTAGE FEEDBACK
CURRENT FEEDBACK-PROTECTION
CHOKE
SHUNT
24VAC-THERMOSTATS-GUN TRIGGERING
The Control Board also monitors signals from the thermostats and the Protection Board and if necessary,
shuts off the weld output. The protection circuit information is discussed in more detail later in this section.
V300-I
E-6
GATE
TERMINAL
(0 VOLTS)
SOURCE
TERMINAL
DRAIN
TERMINAL
DRAIN (N)
SOURCE (N)
SUBSTRATE (P)
E-6
THEORY OF OPERATION
N CHANNEL
A. PASSIVE
GATE
TERMINAL
(+ 6 VOLTS)
SOURCE (N)
DRAIN (N)
ELECTRONS
B. ACTIVE
An FET is a type of transistor. FETs are semiconductors well suited for high-frequency switching because
they are capable of going from full off to full on much
more quicklfy than other types of semi-conductors.
Drawing A above shows an FET in a passive mode.
There is no gate signal, zero volts relative to the source
and, therefore, no current flow. The drain terminal of
the FET may be connected to a voltage supply; but
since there is no conduction, the circuit will not supply
current to downstream components connected to the
source. The circuit is turned off like a light switch in the
OFF position.
V300-I
E-7
THEORY OF OPERATION
PULSE WIDTH MODULATION
E-7
sec
48
50
sec
sec
sec
MINIMUM OUTPUT
24 sec
24 sec
2 sec
50 sec
MAXIMUM OUTPUT
MINIMUM OUTPUT
By controlling the duration of the gate signal, the FET
is turned on and off for different durations during a
cycle. The top drawing above shows the minimum
output signal possible over a 50-microsecond time
period.
MAXIMUM OUTPUT
By holding the gate signals on for 24 microseconds
each and allowing only 2 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 under the curve, the
more power is present.
V300-I
E-8
THEORY OF OPERATION
PROTECTIVE CIRCUITS
THERMAL PROTECTION
OVERLOAD PROTECTION
The machine is electronically protected from producing excessive output current. Should the output current exceed 340 to 360 amps, an electronic protection circuit will reduce the current to approximately
150 amps. Lincoln Electric refers to this current
reduction as Fold Back. The machine will continue
to produce this low current until the protection circuit
is reset by removing the load.
Another protection circuit is included to monitor the
voltage across input filter capacitors. In the event
that the capacitor voltage is too high, the protection
circuit will signal the Control Board to prevent output.
The protection circuit may prevent output, if any of
these circumstances occur:
E-8
V300-I
Section F-1
TABLE OF CONTENTS
- TROUBLESHOOTING & REPAIR SECTION -
Section F-1
Test Procedures
Input Filter Capacitor Discharge Procedure .........................................................F-11
Output Pilot Circuit Test .......................................................................................F-13
Protection Board Output Test...............................................................................F-17
Capacitor Balance Test ........................................................................................F-21
Switch Board Test.................................................................................................F-25
Snubber Resistor Test ..........................................................................................F-29
Output Diode Test.................................................................................................F-31
Input Rectifier Test................................................................................................F-33
OverCurrent Protection Current Trigger Test........................................................F-35
Overvoltage Protection DC Trigger Circuit Test ...................................................F-38
Thermal Protection AC Trigger Circuit..................................................................F-43
Replacement Procedures
Capacitor Replacement ........................................................................................F-51
Switch Board Replacement ..................................................................................F-55
Test After Switch Board or Capacitor Replacement .............................................F-57
Output Diode Replacement ..................................................................................F-59
V300-I
F-2
F-2
CAUTION
Service and repair should be performed by only 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.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
V300-I
F-3
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.
CAUTION
F-3
V300-I
F-4
Do not use oscilloscopes and other pieces of test equipment that are powered by 115 VAC. This
equipment should not be used with inverter-type machines, such as Invertec V300-I. There are
high voltages present, which are floating off case ground (floating ground). Connecting the
ground lead of a test probe (which may be connected to the case of the test equipment) to a
high voltage potential presents a shock hazard as well as the possibility of damage to the equipment in question.
MATCHED PARTS
The following parts must be replaced in matched sets:
Capacitors: C1 & C2
The machine should now work normally. If not,continue with the Troubleshooting Section of this manual.
Return to Section TOC
F-4
V300-I
F-5
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FEEDING PROBLEMS
F-5
RECOMMENDED
COURSE OF ACTION
7. Look for broken or loose connections on high current-carrying parts of machine (i.e.,
choke, output bridges, output
studs, main transformer.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
V300-I
F-6
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FEEDING PROBLEMS
No output or reduced output the first
time power is applied to machine.
F-6
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
V300-I
F-7
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
F-7
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FEEDING PROBLEMS
No ouput. Main fuses open, indicating excessive current draw.
Inspect interior of machine for physical signs of electrical and heat damage. Replace any damaged components after conducting the tests
below:
1. See Input Rectifier test.
Normal operation.
Nothing is wrong.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
V300-I
F-8
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
F-8
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FEEDING PROBLEMS
Meter reads low voltage (1-2 VDC),
and output is extremely low or no
output.
3. Check for loose or faulty connections in heavy current-carrying leads (i.e., choke, shunt,
output bridge, and output
studs). See wiring diagram in
Section G.
4. See Overcurrent Protection
Current Trigger Circuit tests.
5. See Control Board test
Welding too hot. Actual weld current is considerably higher than display indicates.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
V300-I
F-9
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FEEDING PROBLEMS
Poor stick electrode performance.
Arc pops out.
F-9
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-888-935-3877.
V300-I
F-10
NOTES
V300-I
F-10
F-11
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will drain off any charge stored in the capacitors that are part of the
Switch Board Assemblies. This procedure MUST be performed as a safety precaution
before conducting any test or repair that requires you to touch internal components of
the machine
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Insulated Gloves
Insulated Pliers
High Wattage Resistor (25-1000 ohms/25watt)
V300-I
F-11
F-12
F-12
6. Use electrically insulated gloves and insulated pliers. Hold body of the resistor and connect resistor
leads across the two capacitor terminals. Hold
resistor in place for 10 seconds. DO NOT TOUCH
CAPACITOR TERMINALS WITH YOUR BARE
HANDS.
7. Repeat discharge procedure for capacitor on other
side of machine. If you are working on a 575 VAC
machine, repeat discharge procedure for second
capacitor on each side of machine.
8. Check voltage across terminals of all capacitors
with a DC voltmeter. Polarity of capacitor terminals
is marked on PC board above terminals. Voltage
should be zero. If any voltage remains, repeat this
capacitor discharge procedure.
V300-I
F-13
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the Thermostats, the Auxiliary Transformer (T1) and the
Output Terminal Switch (S4) are functioning properly.
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
V300-I
F-13
F-14
TEST PROCEDURE
1. Turn Input Power Switch OFF
F-14
V300-I
F-15
F-15
223A
210
302
J5
G2527
CONTROL J1
J2
J4
J3
275D
V300-I
F-16
NOTES
V300-I
F-16
F-17
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the Protection PC Board is defective , or responding to
external signals causing it to prevent the Input Filter Capacitors from charging.
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Misc Hand Tools
V300-I
F-17
F-18
TEST PROCEDURE
1. TURN POWER SWITCH OFF
2. Remove sheetmetal wraparound.
F-18
INPUT RECTIFIER
PROTECTION BOARD/
INPUT RECTIFIER
MOUNTING SCREW
V300-I
F-19
11. Test for less than 1 VDC between leads 313 (-) and
311 (+).
NOTE: During voltage test, be cautious when positioning loose components to avoid shorts and damage to equipment.
PROTECTION
L7915
F-19
313
306
J15
J8
275F
311
V300-I
F-20
L7915
PROTECTION
313
306
J15
J8
275F
311
TEST PROCEDURE
12. Open S4 and Turn Power OFF
F-20
V300-I
F-21
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine the condition of the capacitors,bleeder resistors and
Switch Boards.
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
Wiring Diagram (Section G)
V300-I
F-21
F-22
VDC at Switch
Board Terminals
should be
approximately:
TEST PROCEDURE:
1. Move Output Terminal Switch S4 to ON position.
Adjust the output control to the minimum setting.
Place the mode control at the SMAW (soft) position.
2. Test VDC across terminals 9 and 12 of one Switch
Board (see Fig. F.7). Repeat the test for the other
Switch Board. See Table F.1 for expected voltages
575VAC
407 VDC
460 VAC
325 VDC
440 VAC
311 VDC
415 VAC
293 VDC
380 VAC
269 VDC
a. If less than 25 VDC difference is measured between
the Switch Boards, then capacior balance is OK.
F-22
V300-I
a.
b.
F-23
W R
401/
403
1/
8
9
12
L
L8604-1
8604-1
SWITCH
V300-I
4/
5
402/
404
F-23
12
R W
F-24
NOTES
V300-I
F-24
F-25
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the Switch Boards are working properly. This resistance test is preferable to a voltage test with the machine energized because these
boards are easily damaged. Also, it is more dangerous to work on these boards when
power is applied.
MATERIALS NEEDED
ANALOG Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
Wiring Diagram (Section G)
NOTE: Most digital meters will not supply enough current in the
ohms mode to do this test effectively.
V300-I
F-25
F-26
TEST PROCEDURE
1. Disconnect power to the machine and perform
Input Filter Capacitor Discharge Procedure as
described in Section F.
2. Disconnect all wiring harness leads (401/403, 1/8,
9, 12, 4/5, 402/404) from the Switch Boards.
F-26
V300-I
F-27
12
4/5
1/8
12
4/5
F-27
Apply Negative
Test Probe to
Terminal
Test Result Conclusion Repair Action
12
Greater than OK
None
1K ohm
1/8
4/5
1/8
4/5
12
Less than
100 ohms
Shorted
Replace both
Switch Boards
Snubber Test
Less than
100 ohms
OK
None
Continue
Replace both
Switch Boards
Snubber Test
Greater than OK
1K ohm
None
Continue
Less than
100 ohms
Shorted
Replace both
Switch Boards
Snubber Test
Less than
100 ohms
OK
None
Continue
Replace both
Switch Boards
Snubber Test
Less than
100 ohms
None
Continue
Replace both
Switch Boards
Snubber Test
Greater than OK
1K ohm
None
Continue
Less than
100 ohms
Shorted
Replace both
Switch Boards
Snubber Test
Less than
100 ohms
OK
None
Continue
Replace both
Switch Boards
Snubber Test
Greater than OK
1K ohm
None
Continue
Less than
100 ohms
Replace both
Switch Boards
Snubber Test
OK
Shorted
V300-I
F-28
401/403
402/404
Apply Negative
Test Probe to
Terminal
Test Result Conclusion Repair Action
401/403
Greater than OK
None
1K ohm
12
402/404
Less than
100 ohms
Shorted
Replace both
Switch Boards
Snubber Test
Less than
100 ohms
OK
None
Continue
Replace both
Switch Boards
Snubber Test
Less than
100 ohms
None
Continue
Replace both
Switch Boards
Snubber Test
Greater than OK
1K ohm
None
Continue
Less than
100 ohms
Replace both
Switch Boards
Snubber Test
OK
Shorted
V300-I
F-28
F-29
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the Snubber Resistors are defective.
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
Wiring Diagram (Section G)
V300-I
F-29
F-30
401/
403
1/
8
L8604-1
12
4/
5
402/
404
R W
SWITCH
5. Test for 25 ohms resistance from lead 401 to terminal 12 on Switch Board.
F-30
Test Result
Conclusion
Lead 401 to
Terminal 12
25 ohms
>30 ohms
<20 ohms
OK
R4 open
R4 faulty
Continue
Lead 402 to
Terminal 9
25 ohms
>30 ohms
<20 ohms
OK
R5 open
R5 faulty
Continue
Lead 403 to
Terminal 12
25 ohms
>30 ohms
<20 ohms
OK
R6 open
R6 faulty
Continue
Lead 404 to
Terminal 9
25 ohms
>30 ohms
<20 ohms
OK
R7 open
R7 faulty
Continue
Repair Action
Replace R4
Replace R5
Replace R6
Replace R7
V300-I
F-31
WARNING
Service and repair should be performed by only 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the Output Diodes are defective.
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
V300-I
F-31
F-32
TEST PROCEDURE
b. If reading is less than 100 ohms, one or more
Output Diode is shorted. Test all Output Diodes
(D-1 thru D-12) or diode modules individually.
LINCOLN
+
+ PROBE
- PROBE
F-32
V300-I
F-33
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the Input Rectifier is defective.
MATERIALS NEEDED
ANALOG Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
V300-I
F-33
F-34
TEST PROCEDURE
1. Perform Input Filter Capacitor Discharge
Procedure as detailed in this section.
TABLE F.5
Steps
F-34
A
B
C
D
E
F
G
H
I
J
K
L
Test Points
+ Probe
Probe
9
9
9
H1
A
H5
12
12
12
H1
A
H5
H1
A
H5
9
9
9
H1
A
H5
12
12
12
V300-I
F-35
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the overcurrent trigger circuit is working correctly and
also if the current limiting portion of the Control Board is working correctly.
MATERIALS NEEDED
Digital Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
V300-I
F-35
F-36
TEST PROCEDURE
4. Turn main power ON.
1. Perform Input Filter Capacitor
Procedure detailed in this section.
Discharge
5. Test for 15 VDC between leads 302 and 275D.
F-36
302
J5
G2527
CONTROL J1
J2
J4
275D
V300-I
J3
F-37
2J3 (White)
J5
CONTROL J1
G2527
J3
J4
1J3 (Black)
Discharge
J2
F-37
275D
6J1
1J1
CONTROL
BOARD
1J3
2J3
BLACK
WHITE
L3
CHOKE
400 AMP
SHUNT
V300-I
(-) OUTPUT
TERMINAL
F-38
If for any reason you do not understand the test procedures or are unable to perform the test / repairs safely, contact the Lincoln Electric Service Department for
electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the overvoltage protection and related portions of the
Protection Board and Power Board are functioning properly.
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
Wiring Diagram (Section G)
V300-I
F-38
F-39
TEST PROCEDURE
F-39
4. Arrange the PC boards and wiring so you can easily perform the tests.
Control Board
Protection Board
Power Board
V300-I
F-40
L7915
PROTECTION
313
306
J15
J8
275F
311
7. Test for 0 VDC between leads 311 and 313 on
Protection Board.
a. If 0-1 VDC is present, the Protection Board is
OK. Go to step 8.
F-40
V300-I
212A
309 310
J14
313
311
305
275D
a.
b.
10. Test for 0-1 VDC between leads 301 and 275D on
Power Board.
J6
211A
504
501
301 302
POWER BOARD
L8033
J7
F-41
F-41
a.
b.
V300-I
F-42
THESE LEADS
ARE USED FOR
MONITORING
CAPACITOR
VOLTAGES
52
1J8
14
3J8
#311
1J14
6J6
#313
2J14
1J6
53
SEE TABLE 1
BELOW
NORMAL
325 VDC
325 VDC
14-15 VDC
IF AC TRIGGER
CIRCUIT IS GOOD,
#301 LEAD
IS TAKEN TO
CIRCUIT COMMON
#275D
315 VDC
11. If 15 VDC is present at step 7, test Capacitor voltages using leads shown in Figure F.19.
If voltage does not match table, check reconnect
switches for proper operation and proper position
for voltage applied. Perform Capacitor Balance
Tests.
#301
#275D
(-)
#305
52-53
51-53
14-53
14-52
(+)
PROTECTION
BOARD
OPTOCOUPLER
DEPENDENT ON
PROTECTION BOARD
LEADS
#302
POWER
BOARD
51
F-42
V300-I
5J1
4J1
+15 VDC
CONTROL
BOARD
F-43
WARNING
Service and repair should be performed by only 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will check the two thermostats and associated circuity through the
Auxiliary Transformer, Power Board and Control Board.
MATERIALS NEEDED
Volt/Ohm Meter (multi-meter)
Misc. Hand Tools
V300-I
F-43
F-44
TEST PROCEDURE
1. Turn main power OFF.
2. Perform Input Filter Capacitor Discharge procedure detailed in this section.
3. Detach the following PC boards so you can gain
access to and have ample room to perform the
tests. (Do not disconnect from wiring harness.)
Power Board
Control Board
V300-I
F-44
CHOKE
THERMOSTAT
#503
T1
F-45
F-45
#212B
#212C
#212A
#223B
#224
24
VOLTS
AC
#212D
EXTERNAL
TRIGGER
#503A
FAN
THERMOSTAT
NORMALLY CLOSED
NOTE:
WHEN THERMOSTATS
TRIP, THE CIRCUIT
WILL BE OPENED
10J6
POWER
BOARD
9J6
S4 OUTPUT
TERMINAL
SWITCH
#223A
11J4
CONTROL
BOARD
4J2
#210
PART OF 14 PIN
AMPHENOL
V300-I
F-46
NOTES
V300-I
F-46
F-47
WARNING
Service and repair should be performed by only 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will help to determine if the Power Board or associated circuitry is
defective.
MATERIALS NEEDED
Volt/ohm Meter (multimeter)
V300-I
F-47
F-48
TEST PROCEDURE
NOTE: Perform Test A before disassembling the unit
Test A
b. If audible click of control relay contacts closing
is not heard, Power Board could be faulty. Go
to Test B.
Test B
F-48
4. Detach Control Panel by removing the four mounting screws. Move the panel to the left to gain
access to the Power Board.
V300-I
212A
309 310
J7
J14
313
501
211A
305
275D
10. Test for 24VDC from lead 309(+) to lead 310(-) (J7
pin 2 to J7 pin 4).
J6
311
504
301 302
POWER BOARD
L8033
F-49
F-49
V300-I
F-50
F-50
POWER BOARD
7J6
2J6
3J4
P
W
M
REMOTE
PROTECTION
BOARD (STT ONLY)
14 AMPHENOL
#379
6J22
#503A
#224
TO
POWER
BOARD
3.5 ohms
#210
6J4
9J4
#223
8J33
13J36
#413
5J4
3.5 ohms
2J31
#305
STT II Only
3J31
11J4
PWM
OUTPUTS
TO POWER
BOARD
2
4
V
A
C
#301
FROM PROTECTION
BOARD OVERVOLTAGE
T1 AUXILIARY
TRANSFORMER
CONTROL BOARD
#212
6J34
12J4
#212C
V300-I
5J36
#405
F-51
WARNING
Service and repair should be performed by only 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid in the relpacement of the Input Filter Capacitors.
MATERIALS NEEDED
MIsc. Hand Tools
Torque Wrench (60 in./lb.)
Return to Section TOC
V300-I
F-51
F-52
PROCEDURE
NOTE: When replacing capacitors, remove the
entire FET Heat Sink Assembly as a unit.
Remove and reassemble one side at a
time, using the other side as a model to
insure that all parts are reinstalled prop
erly
V300-I
F-52
F-53
F-53
V300-I
F-54
V300-I
F-54
F-55
WARNING
Service and repair should be performed by only 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid in the relpacement of the Switch Boards.
MATERIALS NEEDED
Misc. Hand Tools
Torque Wrench (60 in./lb.)
V300-I
F-55
F-56
NOTE: If a test indicates that a Switch Board is defective, unless their part number is L10958-[ ] both Switch
Boards must be replaced at the same time. In addition
to replacing the Switch Boards, Capacitors C1 and C2
(plus C14 and C15 on 575 VAC models) must also be
replaced if the following conditions exist:
b. The machine was operating from 380 VAC or higher when the failure occurred.
F-56
c.
PROCEDURE
11. Torque both sets of screws in 10 inch-pound increments using a diagonal tightening sequence.
Torque the four socket head screws to 44 inchpounds (5 Nm). Torque the two hex head capacitor screws to 55 inch-pounds (6 Nm).
V300-I
F-57
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This test MUST be performed after replacement of either the Switch Boards or Input
Filter Capacitors.
MATERIALS NEEDED
Misc. Hand Tools
Return to Section TOC
V300-I
F-57
F-58
F-58
B300-I
F-59
WARNING
Service and repair should be performed by only 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 troubleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid in the relpacement of the Output Diodes.
MATERIALS NEEDED
Misc. Hand Tools
Torque Wrench (60 in./lb.)
Return to Section TOC
NOTE: Most Output Rectifier Assemblies are made with two sets of five individual diodes
connected in parallel. If one or more diodes in a set fails, all five must be replaced.
Some Output Rectifier Assemblies are made with Diode Modules. It is only necessary to
replace the Defective part on these units
V300-I
F-59
F-60
F-60
V300-I
F-61
F-61
V300-I
F-62
Input
Volts/Hertz
F-62
Single Phase
Max. Amps
Max. Watts
Three Phase
Max. Amps
Max. Watts
220/50 or 60
2.75
425
2.75
425
230/60
3.00
450
3.00
450
440/50 or 60
1.38
425
460/60
1.50
450
380/50 or 60
1.67
425
575/60
60-75V
12A @ 10V.
CV modes
20A @ 19V.
(FCAW, GMAW)
V300-I
V300-PRO
1 phase @ 200A
380V
220/440V
38V
208V
230/460V
38V
575V
36V
3 phase @ 300A
32V
36V
34V
38V
36V
AUXILIARY TRANSFORMER 50 Hz or 60 Hz
TEST POINTS
RANGE
17-20 VAC
22-25 VAC
39-44 VAC
109-120 VAC
V300-I
Section G-1
TABLE OF CONTENTS
- ELECTRICAL DIAGRAMS SECTION -
Section G-1
* NOTE: Many PC Board Assemblies are now totally encapsulated and are therefore considered to be unserviceable. The Assembly drawings are provided for reference only.
V300-I
311
275F
313
306
52
14
53
51
H5
1
2
3
4
5
6
J8
PROTECTION
BOARD
J15
52
14
53
51
H5
314
N.F.
52
7500
25W
14
316
315
53
317
9A
9A
R7
25
25W
L2
T2
RIGHT
MAIN
TRANSFORMER S
F
4, 5
402, 404
C2
25 2200 F
25W 450V
R6
12A
12A
SWITCH
BOARD
(LEFT)
401, 403
R W
12
W 1, 8
F
BOTTOM
AUX
S
F
TOP
OUTSIDE
S
S
BOTTOM
INSIDE
F
12C 12D
3 AMP
SLOW
BLOW
REMOTE
OUTPUT
CONTROL
MIN
75
75
76
77
31
F
E
J
76
77B
212
32
41
42
2
A
I
K
C
81
82
21
GND
SPARE
M
L
H
B
N
TRIGGER
N.C.
WIRE
FEEDER
NOTES:
N.A.
H1
32
212
42
221122
212C
223B
21
GND
211B
REMOTE
CONTROL
RECEPTACLE
CB2
2AMP
+
-
N.D.
J13
380415V
440460V
R3
F
BOTTOM
C4
C5
TP6
285
B W
C6
TP4
1 3 2 4
503A
224
204C
220
214
275B
225
226
227
275C
CHOKE
THERMOSTAT
J11
- ARC
286
CHOKE
D11
D10
D9
D8
D7
J10
62 54
L3
.001/400
.001/400
N.E.
J9
10
2W
C7
H1
H2
H3
H4
H6
S6
WIRE FEEDER
285 WELDING
POLARITY
229
SWITCH
W R
402, 404
401, 403
H1
H3
4, 5
Y I
SWITCH
BOARD
(RIGHT)
J12
504
4
6
501
32A
F
BOTTOM
OUTSIDE
S
D1
D2
D3
D4
D5
TOP
F
S
TOP
AUX
F
C3
10
2W
R2
10
2W
R10
.001/400
.001/400
C8
D6
L1
LEFT
220
204A
76
203
206
211A
223A
227
213
214
225
226
1
J3
10
5
3
4
12
J4
11
2
9
6
8 J5
7
275F
2
3
1
5
6
4
7
8
18V
110V
42V
24V
0V
42A
503
212D
T1
AUXILIARY
TRANSFORMER
FAN
THERMOSTAT
224
S5
METER
FUNCTION
SWITCH
V
A
+5
GND
DPC
D P 1M E T E R
IN(+)
IN(-)
2
4
5
6
1
3
311
313
POWER
BOARD
J7
J6
1
2 J14
3
4
2
7
6
3
8
1
4
5
9
10
305
301
302
303
304
275D
211A
211B
212B
212D
275D
301
302
305
303
304
J1
J2
2
1
1
2
8
13
12
7
3
6
14
4
11
10
5
9
1
3
4
2
CONTROL
BOARD
W
B
502
229
228
207
208
276
218
75
77A
215
306
Y
Y
210
275A
212A
150 5W
218
77B
77A
276
275C
275B
275A
CC GTAW
CC SOFT
CC CRISP
CV FCAW
CV GMAW
CW (MAX)
10K
2W
S3
LOCAL/REMOTE
SWITCH
REMOTE
207
CW (MAX)
208
10K
2W
212A
212B
R12
ARC FORCE
/INDUCTANCE
CONTROL
ON
223B
223A
REMOTE
502
503
503A
S2
MODE
SWITCH
R11
OUTPUT
CONTROL
LOCAL
228
204B
204C
210
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
Y = YELLOW
1
2
3
4
5
204A
204B
213
212C
N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "I".
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
N.E. D1 THRU D5 OUTPUT DIODES ARE A MATCHED SET.
D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET.
N.F. R1, R9 BLEEDER RESISTORS ARE A MATCHED SET.
N.G. C1, C2 CAPACITORS ARE A MATCHED SET.
N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 380-460V OPERATION.
7
8
307
308
309
310
501
504
H4
H5
215
206
N.E.
S
TOP
INSIDE
1, 8
12
H2
T3
CURRENT
TRANSFORMER
330077 3 0 9
308 310
C1 +
25 2200 F
25W 450V
R4
12B
12B
H3
220230V
32A
CB1
6AMP
42A
9B
9B
H3
FAN
MOTOR
DRIVER
BOARD
J16
12 3 4 5 6
R13
203
R5
25
25W
200208V
32 51
400A
SHUNT
D12
10
2W
229
229
21R
51
7500
25W
CR1(N0)
CR2(N0)
CR3(N0)
CR4(N0)
314 315
317 316
N.G.
N.F.
A
42
VAC
N.H.
9D
9A
12B
12D
229
TP5
250
25W
11R
110/115
VAC
S7
RECONNECT
9B
9C
9B
12A
12C
12A
9B
12A
9R
INPUT
S1
RECTIFIER 9 C 9 D
D13
POWER
OFF ON
AC1
+
W
H1
TP1
U
H1
AC2
R
V
H5
TP3
TP2
B
AC3
W
A
INPUT
PER
N.A.
+ ARC
N.G.
8R
G-2
ELECTRICAL DIAGRAMS
1R
G-2
S4
OUTPUT
TERMINAL
SWITCH
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
S2
MODE SWITCH
S4
OUTPUT TERMINAL SWITCH
J3
J6
J2, J8
J11, J14
J4
S5
METER FUNCTION SWITCH
S3
LOCAL/REMOTE SWITCH
J1, J7
J5
R11
OUTPUT CONTROL
R12
ARC FORCE/INDUCTANCE CONTROL
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
CONTROL PANEL
LAYOUT
9-11-92
L8657
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
V300-I
J8
J15
N.F.
52
7500
25W
14
316
315
53
317
9A
9A
R7
25
25W
402, 404
C2
25 2200 F
25W 450V
R6
12A
12A
L2
T2
RIGHT
MAIN
TRANSFORMER S
F
4, 5
SWITCH
BOARD
(LEFT)
401, 403
R W
12
F
TOP
OUTSIDE
S
S
BOTTOM
INSIDE
F
10
2W
R13
10
2W
R3
REMOTE
OUTPUT
CONTROL
MIN
75
75
76
77
31
F
E
J
76
77B
A
I
K
C
81
82
21
GND
SPARE
M
L
H
B
N
212
42
221122
212C
223B
21
GND
211B
WIRE
FEEDER
REMOTE
CONTROL
RECEPTACLE
N.D.
A
+
-
N.E.
6254
1 3 2 4
503A
224
204C
220
214
275B
225
226
227
275C
CHOKE
THERMOSTAT
J11
12B
12B
J13
380415V
440460V
H1
H2
H3
H4
H6
S6
WIRE FEEDER
285 WELDING
POLARITY
229
SWITCH
W R
W
402, 404
401, 403
H1
H3
4, 5
SWITCH
BOARD
(RIGHT)
12
H2
T3
CURRENT
TRANSFORMER
3 0 7 33 00 99
308 310
C1 +
25 2200 F
25W 450V
R4
H3
220230V
42A
9B
9B
R5
25
25W
200208V
CB1
6AMP
C6
S5
METER
FUNCTION
SWITCH
V
A
+5
GND
DPC
D P 1M E T E R
IN(+)
IN(-)
203
H3
FAN
MOTOR
J9
285
B W
J10
- ARC
286
TP4
DRIVER
BOARD
C4
C5
TP6
5 F
BOTTOM
OUTSIDE
S
1, 8
D1
D2
D3
D4
D5
S
TOP
F
S
TOP
INSIDE
S
TOP
AUX
F
J12
504
C3
10
2W
R2
10
2W
R10
.001/400
.001/400
C8
D6
L1
LEFT
4
6
501
42A
24V
503
0V
212B
42V
230
231
J17
24V
T1
AUXILIARY
TRANSFORMER
FAN
THERMOSTAT
311
313
224
1
2
J14
3
4
212C
212A
150 5W
210
N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "C".
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
N.E. D1 THRU D5 OUTPUT DIODES ARE A MATCHED SET.
D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET.
N.F. R1, R9 BLEEDER RESISTORS ARE A MATCHED SET.
N.G. C1, C2 CAPACITORS ARE A MATCHED SET.
N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 380-460V OPERATION.
7
POWER
8
BOARD
2
4 J7
5
J6
6
1
3
307
308
309
310
501
504
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
Y = YELLOW
2
7
6
3
8
1
4
5
9
10
305
301
302
303
304
275D
220
204A
76
203
206
211B
223A
227
213
214
225
226
1
J3
10
5
3
4
12
J4
11
2
9
6
8
J5
7
275F
2
3
1
5
6
4
7
8
18V
H4
H5
I
I
215
206
N.E.
275D
301
302
305
303
304
230
2
1
1
2
8
13
12
7
3
6
14
4
11
10
5
9
J1
1
3
J2
4
2
CONTROL
BOARD
231
W
B
502
229
228
207
208
276
218
75
77A
215
306
Y
Y
210
275A
1
2
3
4
5
204A
204B
213
218
77B
77A
276
275C
275B
275A
CC GTAW
CC SOFT
CC CRISP
CV FCAW
CV GMAW
CW (MAX)
10K
2W
LOCAL
228
204B
204C
S3
LOCAL/REMOTE
SWITCH
REMOTE
207
CW (MAX)
208
10K
2W
212A
212B
R12
ARC FORCE
/INDUCTANCE
CONTROL
ON
223B
223A
REMOTE
502
Y
503
503A
S2
MODE
SWITCH
R11
OUTPUT
CONTROL
21R
32
41
42
2
TRIGGER
N.C.
H1
7500
25W
51
32 51
314 315
317 316
N.G.
A
3 AMP
SLOW
BLOW
NOTES:
N.A.
N.H.
N.F.
42
VAC
+ ARC
229
229
11R
12C12D
9R
S7
RECONNECT
9B
9C
9B
12A
12C
12A
9B
12A
CR1(N0)
CR2(N0)
CR3(N0)
CR4(N0)
J16
12 3 4 5 6
INPUT
PER
N.A.
9D
9A
12B
12D
L3
CHOKE
D11
D10
D9
D8
D7
INPUT
S1
RECTIFIER 9C 9D
D13
POWER
OFF ON
AC1
+
W
H1
TP1
U
H1
AC2
R
V
H5
TP3
TP2
B
AC3
W
A
C7
.001/400
.001/400
F
BOTTOM
TP5
250
25W
400A
SHUNT
D12
F
BOTTOM
AUX
S
W 1, 8
229
29-11-9
PROTECTION
BOARD
52
14
53
51
H5
314
N.G.
52
14
53
51
H5
1
2
3
4
5
6
306
8398
313
275F
311
8R
G-3
ELECTRICAL DIAGRAMS
1R
G-3
S4
OUTPUT
TERMINAL
SWITCH
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
S2
MODE SWITCH
S4
OUTPUT TERMINAL SWITCH
J3
J6
J4
S5
METER FUNCTION SWITCH
S3
LOCAL/REMOTE SWITCH
J1, J7
J5
R11
OUTPUT CONTROL
R12
ARC FORCE/INDUCTANCE CONTROL
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
CONTROL PANEL
LAYOUT
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
V300-I
313
275F
306
N.G.
9A
52
52
14
14
53
53
PROTECTION
R7
52
H5
H5
7500
314
25W
BOARD
J15
316
315
12A
12A
317
2W
2W
INPUT
S1
OFF
W
9C
RECTIFIER
9D
310
309
309
ON
D9
H1
5 1
DRIVER
12B
9D
J11
J10
N.E.
CHOKE
BOARD
INPUT
TP3
RECONNECT
TP2
B
F -
12
13 14
6 2 5 4
T3
316
N.G.
9
W
25W
25
25W
51
C1
SWITCH
R4
401, 403
R2
2W
TOP
INSIDE
.001/400
1, 8
10
R10
2W
12
C8
D6
H1
J13
H3
MIN
G
200-
75
76
77
77B
31
212
MOTOR
H2
H3
H2
504
VAC
32
32
41
212
42
32A
K
C
H4
42V
380-
CB1
42
42A
415V
6AMP
21
12
2
2
212C
TRIGGER
H4
N.D.
24V
42A
H6
440-
223B
N.C.
M
L
0V
460V
21
GND
GND
211B
SPARE
S6
21
212D
229
WIRE
FEEDER
J4
229
13
228
275B
213
12
207
275A
208
225
8
7
3
J5
276
POWER
BOARD
309
310
501
J7
J6
311
AUXILIARY
313
224
WELDING
POLARITY
SWITCH
305
301
302
303
304
275D
211A
1
2
275F
275D
301
302
305
303
304
212B
212D
OUTPUT
2W
CONTROL
204B
S3
LOCAL/REMOTE
REMOTE
SWITCH
204C
215
207
CW (MAX)
306
5
9
208
R12
ARC FORCE
10K
/INDUCTANCE
2W
CONTROL
J1
3
J2
211B
10
228
10
R11
10K
LOCAL
218
75
77A
CV GMAW
275C
214
212A
210
212B
275A
ON
223B
CONTROL
REMOTE
223A
S4
OUTPUT
TERMINAL
SWITCH
BOARD
J14
502
THERMAL
OVERLOAD
INDICATOR
212C
212A
MODE
SWITCH
CW (MAX)
77A
CV FCAW
4
5
276
227
226
TRANSFORMER
285
FAN
WIRE FEEDER
504
503
T1
11
LEFT
H5
THERMOSTAT
81
82
307
308
218
77B
L1
110V
213
502
501
230V
32A
211A
11
4
VAC
42
12
18V
H3
220-
2AMP
14
H3
CB2
J12
H1
206
21R
110/115
208V
FAN
76
H1
5
3
223A
.001/400
AUX
12B
76
C3
10
203
D5
TOP
2
J3
10
204A
D4
(RIGHT)
450V
CC CRISP
204B
220
D3
TOP
BOARD
2200 F
BOTTOM
OUTSIDE
S2
204A
D2
CC SOFT
D1
12B
75
METER
CC GTAW
402, 404
25W
9R
7500
CONTROL
IN(-)
215
4,5
9B
25
OUTPUT
275C
206
TRANSFORMER
9B
REMOTE
IN(+)
N.E.
CURRENT
R5
BLOW
DP1
227
203
12D
12A
N.F.
SLOW
DPC
503A
224
N.H.
3 AMP
GND
317
9D
12B
315
12A
9B
12D
12D
52
314
12A
12C
12C
275B
225
226
9B
9C
9B
+5
11R
N.A.
THERMOSTAT
214
J9
J16
S7
H5
PER
12D
SWITCH
D7
H1
FUNCTION
308
CR2
9A
TP1
METER
220
D8
307
D +
S5
204C
TP4
310
9D
CR1
C6
D10
D13
POWER
BOTTOM
INSIDE
F
- ARC
285
B
D11
BOTTOM
286
CHOKE
C4
12
L3
R3
1, 8
TP6
.001/400
C5
25W
.001/400
10
AUX
OUTSIDE
401, 403
53
C7
+ ARC
229
229
TP5
250
R13
BOTTOM
TOP
(LEFT)
450V
SHUNT
BOARD
2200 F
25W
R6
5
6
25
14
10
SWITCH
400A
D12
TRANSFORMER
C2
229
RIGHT
MAIN
402, 404
25
25W
L2
T2
4
4, 5
51
51
J8
9A
N.F.
8R
G-4
ELECTRICAL DIAGRAMS
1R
G-4
150 5W
210
(V300-I ONLY)
503
503A
REMOTE
CONTROL
RECEPTACLE
NOTES:
N.A.
S4
1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO)
OUTPUT TERMINAL
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
J2, J8
J3
J11, J14
S2
SWITCH
MODE SWITCH
J1, J7
COLOR CODE:
S3
B = BLACK
LOCAL/REMOTE
G = GREEN
S5
SWITCH
METER FUNCTION
R = RED
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
W = WHITE
Y = YELLOW
SWITCH
J6
J4
J5, J16
R11
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
OUTPUT CONTROL
SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
N.C.
N.D.
N.E.
N.F.
R12
THERMAL
ARC FORCE/INDUCTANCE
OVERLOAD
ELECTRICAL
SYMBOLS
PER
E1537
CONTROL
INDICATOR
(V300-I ONLY)
N.G.
N.H.
CONTROL PANEL
LAYOUT
12-2-93L
L9299
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
V300-I
PROTECTION
BOARD
J15
B
G
309
9C
12C
9B
N.H.
51
H1
76
77
31
F
E
J
76
77B
212
32
{ 4421
TRIGGER
D
M
L
H
B
N
WIRE
FEEDER
NOTES:
N.A.
32
212
42
221122
212C
223B
21
GND
211B
81
82
21
GND
SPARE
N.C.
A
I
K
C
REMOTE
CONTROL
RECEPTACLE
+ ARC
J13
220230V
N.D.
A
+
-
C1 +
25 2200 F
4
5
0
V
25W
R4
12B
12B
H3
42A
9B
9B
R5
25
25W
380415V
440460V
H1
H2
4
2
H6
S6
WIRE FEEDER
285 WELDING
POLARITY
229
SWITCH
R3
F
BOTTOM
H3
6254
401, 403
24V
0V
T3
CURRENT
TRANSFORMER
55
4,5
Y I
I
5
F
BOTTOM
OUTSIDE
S
D1
D2
D3
D4
D5
TOP
F
S
TOP
AUX
F
10
2W
R2
10
2W
R10
C3
.001/400
.001/400
C8
D6
L1
LEFT
220
204A
76
203
206
211A
223A
227
213
214
225
226
501
307
308
309
310
501
504
42A
503
212D
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "C".
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
FAN
THERMOSTAT
224
212C
212A
150 5W
311
313
7
8
2
4
5
6
1
3
J7
1
2 J14
3
4
210
J3
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
Y = YELLOW
POWER
BOARD
J6
J6
2
7
6
3
8
1
4
5
9
10
J2, J8
J11, J14
305
301
302
303
304
275D
211A
211B
212B
212D
275F
1
10
5
3
4
12
11
2
9
6
8
7
275D
301
302
305
303
304
2
3
1
5
6
4
7
8
215
206
J3
1
2
8
13
12
7
J4
J5
2
1
3
6
14
4
11
10
5
9
J1
J2
1
3
4
2
W
B
502
229
228
207
208
276
218
75
77A
215
306
Y
Y
210
275A
CONTROL
BOARD
J4
J1, J7
J5, J16
A
+5
GND
DPC
D P 1M E T E R
IN(+)
IN(-)
CC GTAW
CC SOFT
1
2
3
4
5
204A
204B
213
218
77B
77A
276
275C
275B
275A
S2
MODE
SWITCH
CC CRISP
CV FCAW
CV GMAW
CW (MAX)
10K
2W
228
204B
204C
R11
OUTPUT
CONTROL
LOCAL
S3
LOCAL/REMOTE
SWITCH
REMOTE
207
CW (MAX)
208
10K
2W
212A
212B
R12
ARC FORCE
/INDUCTANCE
CONTROL
S4
OUTPUT
TERMINAL
SWITCH
ON
223B
223A
REMOTE
502
Y
503
503A
S5
METER
FUNCTION
SWITCH
203
503A
224
N.E.
S
TOP
INSIDE
1, 8
T1
AUXILIARY
TRANSFORMER
204C
220
214
275B
225
226
227
275C
18V
42V
C6
TP4
CHOKE
THERMOSTAT
J12
1
504
285
B W
D11
D10
D9
D8
D7
- ARC
286
CHOKE
C4
H4
H5
L3
.001/400
.001/400
C5
TP6
J9
12
H2
C7
N.E.
SWITCH
BOARD
(RIGHT)
10
2W
J11
8 12 13 14
9
W R
402, 404
H1
H3
H4
R13
229
229
1 2 3 4
317
314
9D
52
315 12B 12D 316
200208V
CB1
6AMP
J10
J16
H3
FAN
MOTOR
S
BOTTOM
INSIDE
F
D12
10
2W
TP5
250
25W
400A
SHUNT
21R
42
VAC
75
3 2 5 1
DRIVER
BOARD
N.G.
7500
25W
229
307 308
9B
9B
12A
12A
12A
W 1, 8
F
BOTTOM
AUX
S
F
TOP
OUTSIDE
S
310
12D
N.F.
MIN
75
401, 403
R W
12
S7
RECONNECT
12D
12D
SWITCH
BOARD
(LEFT)
12B
9D
TP3
TP2
F -
3 AMP
SLOW
BLOW
402, 404
L2
T2
RIGHT
MAIN
TRANSFORMER S
F
4, 5
CR2
CR1
9A
C2
25 2200 F
25W 450V
R6
12A
12A
310
309
12C
REMOTE
OUTPUT
CONTROL
317
D +
TP1
53
9C 9D 9D
H5
316
315
R7
25
25W
11R
52
7500
25W
14
9R
S1
POWER
OFF ON
W
H1
U
H1
9A
9A
N.F.
J8
52
14
53
51
H5
314
N.G.
52
14
53
51
H5
1
2
3
4
5
6
306
313
275F
311
8R
INPUT
PER
N.A.
G-5
ELECTRICAL DIAGRAMS
1R
G-5
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
S4
OUTPUT TERMINAL
SWITCH
S2
MODE SWITCH
S3
LOCAL/REMOTE
SWITCH
S5
METER FUNCTION
SWITCH
R11
OUTPUT CONTROL
R12
ARC FORCE/INDUCTANCE
CONTROL
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
CONTROL PANEL
LAYOUT
12-2-93L
L9300
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
V300-I
311
313
275F
306
N.G.
9A
52
52
14
14
53
53
PROTECTION
R7
52
H5
H5
7500
314
25W
BOARD
J15
316
315
25
450V
12A
12A
317
C7
2W
OUTSIDE
1, 8
9D
H1
220
A
D8
307
308
D7
TP1
5 1
DRIVER
12B
9D
214
J11
J10
N.E.
S7
H5
TP3
RECONNECT
TP2
B
F -
12
52
314
12A
12C
13 14
6 2 5 4
12D
215
N.G.
N.F.
9
W
25W
9R
7500
25
25W
51
A
R4
5
Y
C1
SWITCH
(RIGHT)
450V
10
TOP
TOP
INSIDE
401, 403
10
R10
2W
12
C8
D6
J13
H3
MIN
OUTPUT
75
CONTROL
200-
75
76
77
77B
31
MOTOR
212
H2
H3
H2
504
LEFT
VAC
32
32
41
212
42
32A
42V
42A
24V
42A
H6
440-
223B
N.C.
M
L
0V
460V
21
GND
SPARE
S6
21
GND
212D
285
229
WIRE
FEEDER
310
POWER
BOARD
J7
J6
311
AUXILIARY
313
224
77B
11
J4
229
13
228
275B
12
207
275A
208
214
275B
226
3
J5
276
WELDING
POLARITY
SWITCH
305
301
302
303
304
275D
211A
1
2
275F
5
6
305
303
304
212B
212D
CONTROL
S3
LOCAL/REMOTE
REMOTE
SWITCH
204C
207
CW (MAX)
306
208
R12
ARC FORCE
10K
/INDUCTANCE
2W
CONTROL
J1
3
J2
211B
10
204B
301
302
OUTPUT
2W
215
3
275D
228
10
R11
10K
LOCAL
218
75
77A
CV GMAW
275C
213
210
275A
212A
212B
ON
223B
CONTROL
REMOTE
223A
S4
OUTPUT
TERMINAL
SWITCH
BOARD
J14
502
THERMAL
OVERLOAD
INDICATOR
212C
212A
MODE
SWITCH
CW (MAX)
276
227
CV FCAW
4
5
77A
502
TRANSFORMER
211B
309
FAN
WIRE FEEDER
504
503
T1
H5
THERMOSTAT
81
82
307
308
501
415V
6AMP
21
12
2
2
501
H4
380-
CB1
42
212C
TRIGGER
H4
N.D.
12
11
4
110V
230V
32A
VAC
42
18V
H3
220-
2AMP
203
14
H3
CB2
L1
218
21R
110/115
208V
FAN
76
H1
J12
H1
213
206
223A
.001/400
211A
.001/400
AUX
1, 8
12B
12B
R2
2W
76
D5
C3
BOARD
J3
10
204A
D4
TOP
220
D3
BOTTOM
OUTSIDE
2200 F
S
F
204B
11R
25W
CC CRISP
204A
D2
402, 404
25
H1
S2
D1
4,5
9B
R5
REMOTE
CC SOFT
206
TRANSFORMER
9B
BLOW
CC GTAW
N.E.
CURRENT
N.H.
SLOW
203
T3
316
12A
9B
3 AMP
275C
503A
224
227
317
9D
12B
315
12A
12D
12D
12C
9B
9B
9C
THERMOSTAT
J9
J16
226
CHOKE
BOARD
12D
9A
D +
N.A.
310
METER
SWITCH
204C
D9
CR2
CR1
ON
PER
309
9D
H1
INPUT
310
309
PANEL
FUNCTION
C6
TP4
D13
POWER
OFF
9C
METER
D10
F
- ARC
S5
BOTTOM
BOTTOM
1
INPUT
RECTIFIER
285
B
D11
INSIDE
S1
286
CHOKE
C4
12
L3
R3
2W
TP6
.001/400
C5
25W
.001/400
10
AUX
+ ARC
229
229
TP5
250
R13
BOTTOM
TOP
401, 403
R6
53
SHUNT
BOARD
(LEFT)
10
SWITCH
2200 F
25W
14
400A
D12
TRANSFORMER
C2
229
RIGHT
MAIN
402, 404
25
25W
L2
T2
4
4, 5
51
51
J8
9A
N.F.
8R
G-6
ELECTRICAL DIAGRAMS
1R
G-6
150 5W
210
(V300-I ONLY)
503
503A
REMOTE
CONTROL
RECEPTACLE
NOTES:
N.A.
S4
1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO)
OUTPUT TERMINAL
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
J2, J8
J3
J11, J14
S2
SWITCH
MODE SWITCH
J1, J7
COLOR CODE:
S3
B = BLACK
LOCAL/REMOTE
G = GREEN
S5
SWITCH
METER FUNCTION
R = RED
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
W = WHITE
Y = YELLOW
SWITCH
J6
J4
J5, J16
R11
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
OUTPUT CONTROL
SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
N.E.
N.F.
R12
THERMAL
ARC FORCE/INDUCTANCE
OVERLOAD
ELECTRICAL
SYMBOLS
PER
E1537
CONTROL
INDICATOR
(V300-I ONLY)
N.G.
N.H.
CONTROL PANEL
LAYOUT
3-31-94C
L9567
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
V300-I
N.G.
52
14
53
51
H5
1
2
3
4
5
6
J8
PROTECTION
BOARD
J15
N.F.
52
7500
25W
14
316
315
53
317
H1
H1
TP1
12C
12C
9B
12D
12D
51
N.C.
75
C1
76
77
31
F
E
J
76
77B
212
32
41
42
2
A
I
K
C
81
82
21
GND
SPARE
M
L
H
B
N
WIRE
FEEDER
32
212
42
212
212
212C
223B
21
GND
211B
REMOTE
CONTROL
RECEPTACLE
FAN
MOTOR
H3
220230V
CB1
6AMP
N.D.
A
42A
+
-
380415V
+
-
440460V
H2
H2
H3
H3
S6
WIRE FEEDER
WELDING
285 POLARITY
SWITCH
229
W
402, 404
H4
401, 403
D11
D10
D9
D8
D7
F
BOTTOM
S
6254
0V
42A
503
212D
55
4,5
PANEL
METER
1
2
3
4
5
6
F
BOTTOM
OUTSIDE
S
TOP
F
S
TOP
INSIDE
S
TOP
AUX
F
8 F
C3
10
2W
R2
10
2W
R10
.001/400
.001/400
C8
D6
L1
LEFT
220
204A
76
203
206
211A
223A
227
213
214
275B
226
307
308
309
310
501
504
FAN
THERMOSTAT
224
212C
212A
150 5W
311
313
7
8
2
4
5
6
1
3
POWER
BOARD
J7
1
2 J14
3
4
J6
2
7
6
3
8
1
4
5
9
10
305
301
302
303
304
275D
211A
211B
212B
212D
275F
275D
301
302
305
303
304
1
2
J3
10
1
5
3
1
4
2
12
8
11 J4
13
2
12
9
7
6
8
3
J5
6
7
14
4
11
10
2
5
3
9
1
5
J1
6
1
4
3
J2 4
7
8
2
W
B
502
229
228
207
208
276
218
75
77A
215
306
Y
Y
210
275A
CONTROL
BOARD
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
Y = YELLOW
204A
204B
213
218
77B
77A
276
275C
275B
275A
228
204B
204C
J6
J4
J1, J7
J5, J16
CV FCAW
CV GMAW
R11
OUTPUT
CONTROL
LOCAL
S3
LOCAL/REMOTE
SWITCH
REMOTE
207
CW (MAX)
208
10K
2W
212A
212B
R12
ARC FORCE
/INDUCTANCE
CONTROL
S4
OUTPUT
TERMINAL
SWITCH
ON
223B
223A
503
503A
S2
MODE
SWITCH
CC CRISP
CW (MAX)
10K
2W
REMOTE
J2, J8
J11, J14
CC GTAW
CC SOFT
1
2
3
4
5
502
210
J3
1
2
3
4
5
6
203
215
206
D1
D2
D3
D4
D5
I
5
Y I
227
275C
503A
224
N.E.
501
204C
220
CHOKE
THERMOSTAT
T3
CURRENT
TRANSFORMER
1, 8
T1
AUXILIARY
TRANSFORMER
C6
S5
METER
FUNCTION
SWITCH
214
18V
42V
- ARC
285
B W
TP4
TP6
226
J12
504
1
24V
H5
CHOKE
C4
NOTES:
N.A.
R3
L3
.001/400
.001/400
C5
250
25W
286
+ ARC
229
229
N.E.
SWITCH
BOARD
(RIGHT)
H1
H6
10
2W
C7
TP5
J9
12
H1
H4
R13
J11
J13
200208V
10
2W
1 2 3 4
J10
7 8 12 13 14
2 3
9B
9B
25
25W 2200 F
R4 450V
H3
F
BOTTOM
AUX
S
S
BOTTOM
INSIDE
F
52
317
314
9D
315 12B 12D 316
N.G.
R5
25
25W
229
400A
SHUNT
D12
21R
TRIGGER
H1
G
J16
12B
12B
MIN
75
3 2 5 1
DRIVER
BOARD
N.H.
7500
25W
L2
RIGHT
307 308
9B
9B
12A
12A
12A
W 1, 8
310
12D
N.F.
3 AMP
SLOW
BLOW
F
TOP
OUTSIDE
S
12B
9C
401, 403
R W
12
S7
RECONNECT
TP3
TP2
F -
SWITCH
BOARD
(LEFT)
CR2
9D
H5
309
T2
MAIN
TRANSFORMER
4, 5
402, 404
C2
25 2200 F
25W 450V
R6
12A
12A
CR1
9A
D +
R7
25
25W
310
309
9A
9A
11R
INPUT
PER
N.A.
52
14
53
51
H5
314
9C 9D 9D
S1
POWER
OFF ON
W U
42
VAC
306
REMOTE
OUTPUT
CONTROL
313
9R
275F
8R
G-7
ELECTRICAL DIAGRAMS
1R
G-7
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
S4
OUTPUT TERMINAL
SWITCH
S2
MODE SWITCH
S3
LOCAL/REMOTE
SWITCH
S5
METER FUNCTION
SWITCH
R11
OUTPUT CONTROL
R12
ARC FORCE/INDUCTANCE
CONTROL
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
CONTROL PANEL
LAYOUT
2-11-94F
L9568
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
V300-I
311
1
313 306
3
N.G.
52
14
53
51
H5
1
2
3
4
5
6
J8
PROTECTION
BOARD
J15
INPUT
PER
N.A.
N.F.
52
7500
25W
14
316
315
53
317
309
9C 9D 9D
INPUT
S1
RECTIFIER
D13
POWER
OFF ON
D+
A
W
U
H1
TP1
H1
B
R
V
H5
TP3
TP2
B
FW
A C
G
12C
12D
MIN
75
75
76 F
77
E
110/115 31 J
VAC
32
A
42
41 I
VAC 42 K
2 C
TRIGGER 4
D
76
77B
212
N.C.
81
82
21
GND
SPARE
WIRE
FEEDER
M
L
H
B
N
32
212
42
212
212C
223B
21
GND
211B
REMOTE
CONTROL
RECEPTACLE
12
7500
25W
FAN
MOTOR
CB2
2AMP
H3
220230V
32A
CB1
6AMP
42A
+
-
N.D.
A
R W 1,8
R W
380415V
440460V
32 51
J10
J13
H1
H2
H3
H2
H3
62 54
H4
H6
S6
WIRE FEEDER
285 WELDING
POLARITY
229
SWITCH
3
6
H4
H5
C9 C6
42V
T3
CURRENT
TRANSFORMER
5
Y I
I
5
F
BOTTOM
OUTSIDE
S
TOP
F
TOP
INSIDE
F
D3
S
TOP
AUX
F
D1B
L1
LEFT
220
204A
76
203
206
211A
223A
227
213
214
275B
226
501
32A
42A
0V
503
212D
T1
AUXILIARY
TRANSFORMER
NOTES:
N.A.
1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO)
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I)
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "I".
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
N.F. R1, R9 BLEEDER RESISTORS ARE A MATCHED SET.
N.G. C1, C2 CAPACITORS ARE A MATCHED SET.
N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 380-460V OPERATION.
307
308
309
310
501
504
FAN
THERMOSTAT
224
212C
212A
150 5W
311
313
7
8
2
4
5
6
1
3
J7
1
2
3
4
J14
2
7
6
3
8
J6 1
4
5
9
10
POWER
BOARD
305
301
302
303
304
275D
211A
211B
212B
212D
275F
275D
301
302
305
303
304
1
J3 21
10
5
3
4
1
12
2
8
11 J4
13
2
12
9
7
6
3
8
J5
6
7
14
4
11
10
2
5
3
9
1
5
J1
6
1
4
3
J2 4
7
8
2
W
R
502
229
228
207
208
276
218
75
77A
215
306
Y
Y
210
275A
CONTROL
BOARD
2
3
4
5
218
77B
77A
276
275C
275B
275A
2
3
CC GTAW
CC SOFT
CC CRISP
CV FCAW
CV GMAW
CW (MAX)
10K
2W
LOCAL
228
204B
204C
207
208
212A
212B
S3
LOCAL/REMOTE
SWITCH
CW (MAX)
10K
2W
R12
ARC FORCE
/INDUCTANCE
CONTROL
REMOTE
502
J3
J6
J4
J1, J7
J5, J16
S4
OUTPUT
TERMINAL
SWITCH
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
503
503A
J2, J8
J11, J14
1
2
3
4
5
6
S2
MODE
SWITCH
REMOTE
ON
223B
223A
R11
OUTPUT
CONTROL
210
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
Y = YELLOW
204A
204B
213
PANEL
METER
4
5
6
203
215
206
1,8
V
A
S5
METER
FUNCTION
SWITCH
226
227
275C
L4
503A
224
SWITCH
BOARD
(RIGHT)
24V
204C
220
TP4
18V
4
6
- ARC
285
R W
J12
504
1
110V
TP6
286
CHOKE
F
BOTTOM
CHOKE
THERMOSTAT
4,5
W R
12
H1
W R
402, 404
401, 403
D2
C5
+ ARC
229
229
214
314 52
9D 317
315 12B 12D 316
229
TP5
250
25W
L3
J9
1 2 3 7 8 12 13 14
400A
SHUNT
1 2 3 4
J11
J16
D1A
F
BOTTOM
AUX
S
TOP
OUTSIDE
S
S
BOTTOM
INSIDE
1 F
L5
DRIVER
BOARD
9B
9B
12A
12A
12A
200208V
4 F
307 308
12D
H1 H3
G
SWITCH
BOARD
(LEFT)
- 401, 403
9B
N.G.
9B
R5
25
25W
C1 +
25 2200 F
25W 450V
R4
12B
12B
N.H.
N.F.
L2
T2
RIGHT
MAIN
TRANSFORMER S
F
310
12B
9B
51
S7
RECONNECT
9C
12C
12D
309
4,5
402, 404
CR2
9D
A
3 AMP
SLOW
BLOW
310
CR1
9A
9A
9A
R7
25
25W
C2 +
25 2200 F
25W 450V
R6
12A
12A
21R
52
14
53
51
H5
314
11R
275F
8R
9R
REMOTE
OUTPUT
CONTROL
G-8
ELECTRICAL DIAGRAMS
1R
G-8
S4
OUTPUT TERMINAL
SWITCH
S2S2
MODE SWITCH
S3
LOCAL/REMOTE
SWITCH
S5
METER FUNCTION
SWITCH
R11
OUTPUT CONTROL
R12
ARC FORCE/INDUCTANCE
CONTROL
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
CONTROL PANEL
LAYOUT
L10189
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
V300-I
PROTECTION
BOARD
R7
25
25W
52
7500
25W
25 2200F
25W 450V
R6
12A
12A
14
316
315
C2 +
53
317
402, 404
SWITCH
BOARD
(LEFT)
401, 403
R W
12
F
TOP
OUTSIDE
S
W 1, 8
S
BOTTOM
INSIDE
F
L8
9C 9D 9D
C1
12C
9B
12D
12D
7500
25W
R9
3 AMP
SLOW
BLOW
51
9B
9B
R5
25
25W
C1 +
25 2200F
25W 450V
R4
12B
12B
H1
76
77
31
42
VAC
N.C.
81
82
21
GND
SPARE
WIRE
FEEDER
F
E
J
A
I
K
C
D
M
L
H
B
N
H3
76
77B
212
32
212
42
212
212C
223B
FAN
MOTOR
H3
220230V
CB1
6AMP
N.D.
H1
H2
H3
H4
440460V
+
-
21
GND
211B
S6
WIRE FEEDER
285 WELDING
POLARITY
229
SWITCH
REMOTE
CONTROL
RECEPTACLE
F
BOTTOM
OUTSIDE
S
S
TOP
INSIDE
8 F
FAN
SHROUD
CASE
BACK
CASE
BOTTOM
J12
504
D3
D4
D5
C3
S
TOP
AUX
F
10
2W
R2
10
2W
R10
N.C.
N.D.
N.E.
.001/400
.001/400
C8
1
J3
10
5
3
4
12
J4
11
2
9
6
8
J5
7
220
204A
76
203
206
211A
223A
227
213
214
275B
226
L1
LEFT
501
42V
0V
42A
503
212D
T1
AUXILIARY
TRANSFORMER
307
308
309
310
501
504
FAN
THERMOSTAT
224
212C
212A
150 5W
311
313
7
POWER
8
BOARD
2
4
J7
5
J6
6
1
3
1
2 J14
3
4
2
7
6
3
8
1
4
5
9
10
2
3
1
5
6
4
7
8
275F
305
301
302
303
304
275D
211A
211B
212B
212D
275D
301
302
305
303
304
J1
J2
2
1
1
2
8
13
12
7
3
6
14
4
11
10
5
9
1
3
4
2
W
R
502
229
228
207
208
276
218
75
77A
215
204A
204B
213
CW (MAX)
208
Y
Y
210
275A
212A
212B
R12
ARC FORCE
/INDUCTANCE
CONTROL
10K
2W
S4
OUTPUT
TERMINAL
REMOTE SWITCH
ON
502
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
S4
OUTPUT TERMINAL
SWITCH
J1, J7
R11
OUTPUT
CONTROL
S3
LOCAL/REMOTE
SWITCH
207
503
503A
CW (MAX)
10K
2W
REMOTE
223B
223A
CV FCAW
CV GMAW
LOCAL
306
S2
MODE
SWITCH
CC CRISP
228
204B
204C
J2, J8
J11, J14
CC GTAW
CC SOFT
1
2
3
4
5
77B
77A
276
275C
275B
275A
CONTROL
BOARD
J3
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
Y = YELLOW
215
206
218
210
FRONT
PANEL
N.A.
N.B.
203
L5
D6
H4
H5
1
2
3
4
5
6
227
275C
503A
D1
D2
TOP
F
1
2
3
4
5
6
226
18V
24V
H6
H3
380415V
42A
PANEL
METER
214
N.E.
4,5
R
1, 8
H2
T3
CURRENT
TRANSFORMER
V
A
401, 403
H1
204C
220
C10
TP4
CHOKE
THERMOSTAT
6 2 54
SWITCH
BOARD
(RIGHT)
J13
200208V
75
C6
S5
METER
FUNCTION
SWITCH
- ARC
285
RW
J9
9
W
402, 404
C9
TP6
CHOKE
C4
C5
286
N.E.
12
TRIGGER
32
41
42
2
L3
1 2 3 4
317
9D
314
52
315 12B 12D 316
N.G.
TP5
224
N.H.
N.F.
MIN
75
+ ARC
229
229
229
400A
SHUNT
D11
D10
D9
D8
D7
F
BOTTOM
12C
R3
J11
1 2 3 7 8 12 13 14
9B
9B
12A
12A
12A
9C
J10
J16
S7
RECONNECT
TP3
TP2
F-
REMOTE
OUTPUT
CONTROL
12D
3 2 51
DRIVER
BOARD
12B
9D
9A
TP1
POWER
B1 LINE
B
FILTER
H5
10
2W
L7
.001/400
.001/400
307 308
D+
A
H1
H1
F
BOTTOM
AUX
S
C7
R13
CR2
CR1
D12
10
2W
310
309
310
S1
POWER
OFF ON
A1
W
U
INPUT
PER
N.A.
309
250
25W
L2
T2
RIGHT
MAIN
TRANSFORMER S
F
4, 5
R11
J8
9A
9A
N.F.
R8
52
14
53
51
H5
314
R1
N.G.
52
14
53
51
H5
1
2
3
4
5
6
R12
311
313
306
275F
J15
G-9
ELECTRICAL DIAGRAMS
G-9
S2
MODE SWITCH
J6
1
J4
5
J5, J16
6
S3
LOCAL/REMOTE
SWITCH
A
10
12
14
R11
OUTPUT CONTROL
S5
METER FUNCTION
SWITCH
R12
ARC FORCE/INDUCTANCE
CONTROL
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
CONTROL PANEL
LAYOUT
A
L10205
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
V300-I
SCHEMATIC DIAGRAM FOR TROUBLESHOOTING INVERTEC V300-I (FOR CODES 9826, 9827, SPLC6792)
S7
RECONNECT
SWITCH
12C
9B
R7
52
7500
25W
14
53
H5
9A
9D
12D
12B
TP3
A AC3
H1
H1
H5
D13
INPUT
1 2 3
12D
51
53
3 2 51
R13
J8
PROTECTION
BOARD
J15
1
2
3
4
1
2
3
4
5
6
BOTTOM
D11
D10
J11
6254
200208V
316
315
H3
317
220230V
380415V
440460V
9
W R
402, 404
SWITCH
12B
12B
(RIGHT)
401, 403
1, 8
12
H1
H2
H3
H1
H2
H3
H4
H4
110V
42V
24V
H6
J12
504
H6
0V
4
6
501
32A
42A
503
212D
13
11
14
75
D2
CHOKE
229
C5
285
TOP
F AUX
- ARC
1
2
3 J14 10
4
311
313
2
8
10
204A 2 2 0
76
CHOKE
THERMOSTAT
210
R12
10K
CW (MAX)
2W
R12
ARC FORCE
/INDUCTANCE
CONTROL
REMOTE
S4
OUTPUT
TERMINAL
SWITCH
4
275A 275B 275C 2 7 6 7 7 A 7 7 B
1
10K
2W
R11
CW (MAX)
R11
OUTPUT
CONTROL
CV FCAW
2 2 6 2 2 7 275C
METER
CV GMAW
LOCAL
229/275F
303/275D
OUTPUT FEEDBACK
13 V DC
NO LOAD
8 V DC
304/275D
NO LOAD
8 V DC
212C 212A
Y/Y
5 V AC
210/223A
24 V AC
214/275D
5 V DC
311/313
J6
9
10
501/504
11
302/275D
1 4
6
12
211A
7
4
J1
8
5
J2
47
15 V DC
.75 V DC
12
211B
211A
1 V DC
18 V AC
J3
307/275D
NO LOAD
6 V DC
FULL LOAD
.75 V DC
B
W
1
2
2
13
275A 210
308/275D
14
285
S5
METER
FUNCTION
SWITCH
6 V DC
305/301
15
SW BOARDS
R/W
.75 V DC
NO LOAD
16
309/310
24 V DC
CB2
2AMP
CB1
6AMP
32
212
42
212
223B
212
212C
A
J
K
I
D
C
M
L
21
H
G N DB
203
204C 220
NO LOAD
FULL LOAD
16
V
CC CRISP
S2
MODE
SWITCH
0 V AT 0 AMP
50 mV AT 400 AMP
LINEAR FEEDBACK
21 229
3 CC SOFT
REMOTE
S3
LOCAL/REMOTE
SWITCH
CC GTAW
B/W
502
503
S6
WIRE FEEDER
WELDING
POLARITY
SWITCH
THERMAL
OVERLOAD
INDICATOR
(V300-I ONLY)
207
FULL LOAD
208
215
1
VOLTAGE
13 V DC
503A
42A
2 1 8 2 0 4 B 2 0 4 A2 0 6
5
0 - 4.5 V DC
FULL LOAD
32A
213
175/176
224
WIRE
NUMBERS
R11
BOARD
J4
8
7
11
LOCATION
TEST
POINT
C6
TP4
FAN
THERMOSTAT
D6
POWER
14
MULTI LINES
TP6
286
B W
C3
R2
10 .001/400
2W
.001/400
10
R10
2W
C8
7 12
8
13
2
4
6 J7
5 10
1
3
307
308
309
310
504
501
212D
212B
275F
11
L3
250
25W TP5
150 5W
4 10 1 2
+ ARC
D5
TOP
F
8F
18V
J5
306
5
F
BOTTOM
OUTSIDE
S
S
TOP
INSIDE
400A
SHUNT
D1
D4
BOARD
SINGLE LINE
D3
4, 5
T3
CURRENT
TRANSFORMER
CONNECTION
CONNECTION
QUICK
CONTROL BOARD
12
J5
229
T1
AUXILIARY
TRANSFORMER
5 9 7
W = WHITE
229
C1 +
25 2200 F
25W 450V
R4
J13
314
R = RED
G = GREEN
SOLDERED
16
L1 S
LEFT
311
275F
313
306
J4
J6
C4
B = BLACK
Y = YELLOW
R3
BOARD
J9
9B
9B
R5
25
25W
COLOR CODE:
J1, J7
DRIVER
J10
4 5 6
52
14
9R
7500
25W
51
H5
F
BOTTOM
10
AUX
2W
S
C7
D8
12C
RECTIFIER
10
2W
J2, J8
J11, J14
D7
J16
J3
D9
CR2(N0)
CR1(N0)
CR4(N0)
CR3(N0)
3 AMP
SLOW
BLOW
FAN
MOTOR
12A
1, 8
401, 403
R W
12
D12
8R
TP2
4
F
TOP
OUTSIDE
S
S
BOTTOM
INSIDE
F
1
BOARD
(LEFT)
9D
AC2
TP1
H1
25
2200 F
25W
450V
R6
12A
SWITCH
C2
L2
RIGHT
15
AC1
25
25W
4, 5
402, 404
9C
S1
POWER
OFF ON
W
9B
9B
12A
12A
12A
9C
T2
MAIN
TRANSFORMER
9A
9A
503A
211B
75
N
G
76
77B
F
E
1 V DC
32
31
42
41
4
2
81
82
21
GND
{
{
{
INPUT
G-10
ELECTRICAL DIAGRAMS
1R
G-10
110/115
VAC
42
VAC
TRIGGER
WIRE
FEEDER
SPARE
75
MIN
76
77
REMOTE
OUTPUT
CONTROL
REMOTE
CONTROL
RECEPTACLE
DAD 5-20-94
V300-I SCH
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
V300-I
G-11
G-11
ELECTRICAL DIAGRAMS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
V300-I
G-12
G-12
ELECTRICAL DIAGRAMS
DZ1
Q1
R13
R14
J16
DZ2
Q2
Item
CR1, CR2, CR3, CR4
D1
DZ1, DZ2
J9, J10, J16
J11
P9, P10, P16 (plugs into
J9, J10, J16)
P11 (plugs into J11)
Q1, Q2
R1, R2, R13, R14
R3, R4, R5, R6, R8, R9,
R7, R12
T1
Identification
RELAY, SPNO 24VDC 6000 ohms
AG-CDO
DIODE, AXLDS 1A 400V
DIODE, Zener 1W 12V 5%
1N4742A
CONNECTOR, Molex mini PCB
6 pin
CONNECTOR, Molex mini PCB
4 pin
PLUG, Molex mini 6 pin
PLUG, Molex mini 4 pin
TRANSISTOR, NMFT247 4A 900V
RESISTOR, WW 20W 5% 250K
RESISTOR, MF .25W 1% 150K
RESISTOR, MF .25W 1% 100K
TRANSFORMER, PCB
NOTE: Individual parts listed are not available from Lincoln Electric.
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 provided 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.
V300-I
ELECTRICAL DIAGRAMS
G-13
G-13
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
V300-I
G-14
G-14
ELECTRICAL DIAGRAMS
XXXX
XXXX
XXXX
XXXX
DRIVER L9134
XXXX
XXXXX
XXXXXXX
XXXX
NOTE:
XXXX
XXXX
XXXX
Item
Description
J11
J9,J10
T1
J16
R1,R2,R13,R14
DZ1,DZ2
Q1,Q2
R7,R12
R3,R4,R5,R6,R8,R9,
R10,R11
HEADER
HEADER
TRANSFORMER
HEADER
20 WATT 250 OHM RESISTOR
1N4742A
FET (SS)
100 1/4W
150K 1/4W
XXXXXXX
XXXXX
XXXX
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 provided 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.
V300-I
01R
R6
10.0
475
R33
10.0
C3
.047
1200V
5R
C7
4- TRANSFORMER
5 PRIMARY
A2
BYT30P600
2R
1R
02R
C5
1.00K
Q10
A1
BYT30P600
Q8
600mA
40V
2N4403
1 TRANSFORMER
8- PRIMARY
Q9
600mA
40V
2N4403
R19
10.0
DZ7
15V
1W
R26
10.0
15.0K
23R
475
R25
10.0
475
R27
10.0
92R
C8
2700p
50V
73R
100
DZ12
10V 1W
INPUT
FILTER
CAPACITOR
42R
C6
R34
10.0
D1 D2 D3 D4 D5
G1
G2
G3
G4
G5 S1 S2 S3 S4 S5
C4
.047
1200V
A1
: SETON
DZ2
10V
1W
1
1/2W
R39
39.2K
R40
39.2K
A2
D10
1N4936
82R
03R
1.50K
20
Q12
600mA
40V
2N4401
13R
D8
1N4936
1W
1A
100V
IRFD110
DZ8
3.3V
1W
C2
47.5
1
1/2W
DZ9
6.2V
D7
1N4936
1A
100V
IRFD110
63R
12R
1.00K
Q11
600m A
40V
2N4403
Q1
22R
221
100
22.1K
R23
R38
39.2K
R41
39.2K
D1
1N4936
401
--403
IRFP460
SNUBBER
RESISTOR
A1
A1
C1
.REBMUN
EDOC NOMMOC A GNIVAH SLORTNOC FO YRTIUCRIC RO STNENOPMOC TCAXE EHT WOHS TON
YAM MARGAID SIHT ,DRAOB ETELPMOC A FO YTILIBAEGNAHCRETNI EHT GNITCEFFA TUOHTIW
EGNAHC YAM DRAOB TIUCRIC DETNIRP A NO YRTIUCRIC RO STNENOPMOC ECNIS .A.N
C2
D6
1N4936
C1
SNUBBER
RESISTOR
A2
BYT12P600
402
--404
A2
A1
R9
10.0
81R
475
24R
100
R17
10.0
15.0K
C2
2700p
50V
31R
7R
DZ4
15V
1W
D1 D2 D3 D4 D5
G1
G2
A2
IRFP460
G3
G4
G5 S1 S2 S3 S4 S5
A39-8-01
1
1/2W
Q5
600mA
40V
2N4403
R8
10.0
NOITAMROFNI LARENEG
DZ3
10V 1W
11R
20
D5
1N4936
Q4
600mA
40V
2N4401
Q6
600mA
40V
2N4403
DZ1
10V
1W
1A
100V
IRFD110
POSITIVE
INPUT
0448 L
D9
1N4936
Q3
DZ5
3.3V
1W
1.50K
1W
C1
53R
6.2V
47.5
1
1/2W
DZ6
21R
1.00K
D3
1N4936
1A
100V
IRFD110
51R
41R
1.00K
Q7
600mA
40V
2N4403
Q2
221
100
SLEBAL
D2
1N4936
01 -D
8 -C
24 -R
DESU .ON TSAL
D4
1N4936
4R
22.1K
R16
G-15
ELECTRICAL DIAGRAMS
3R
G-15
BYT12P600
12
NEGATIVE
INPUT
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
V300-I
G-16
ELECTRICAL DIAGRAMS
G-16
Item
Description
A1
A2
B1, B2, B3, B4, B5, B6,
B7, B8, B9, B10, B11,
B12
C1, C5, C6, C7
C2, C8
C3, C4
D1, D2, D3, D4, D5, D6,
D7, D8, D9, D10
DZ1, DZ2, DZ3, DZ12
DZ4, DZ7
DZ5, DZ6, DZ8, DZ9
Q1, Q2, Q3, Q10
Q4, Q12
Q5, Q6, Q7, Q8, Q9, Q11
R1, R3, R5, R24
NOTE:
Item
R2, R4
R6, R8, R9, R17, R19,
R25, R26, R27, R33, R34
R7, R30
R10, R32
R11, R15, R22, R28
R12, R14, R20, R21
R13, R31
R16, R23
R18, R29, R37, R42
R35, R36
R38, R39, R40, R41
Description
RESISTOR-MF, .25W 1% 221 ohm
RESISTOR-MF, .25W 1% 10.0 ohm
RESISTOR-MF, .25W 1% 1.50K ohm
RESISTOR-MF, .25W 1% 15.0K ohm
RESISTOR-CC, .50W 5% 1 ohm
RESISTOR-MF, .25W 1% 1.00K ohm
RESISTOR-MF, .25W 1% 20.0 ohm
RESISTOR-MF, .25W 1% 22.1K ohm
RESISTOR-MF, .25W 1% 475 ohm
RESISTOR-MF, .25W 1% 47.5 ohm
RESISTOR-MF, .25W 1% 39.2K ohm
NOTE: Individual parts listed are not available from Lincoln Electric.
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 provided 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.
V300-I
ELECTRICAL DIAGRAMS
G-17
G-17
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
V300-I
G-18
G-18
ELECTRICAL DIAGRAMS
B12
B9
B11
B10
B3
B7
B5
B6
B2
B1
6.40
ITEM
D6
Q11
Q12
DZ12
R31
D1
R21
R1
R20
DZ8
D7
DZ9
.022/50
2700pF/50
.047/1200
1N4936
4
2
2
2
T12702-27
T12702-29
T12702-53
T12702-40
1N4740
1N4744A
1N4728A
1N4735
4
2
6
4
T12704-73
T12704-68
T12704-69
S19400-1000
IC PKG MOSFET
2N4401
2N4403
100 1/4W
R2,R4
R6,R8,R9,R17,R19,R25,R26
R27,R33,R34
2
10
S19400-2210
S19400-10R0
221 1/4W
10 1/4W
R7,R30
R10,R32
R11,R15,R22,R28,R43,R44
R45,R46
R12,R14,R20,R21
2
2
8
S19400-1501
S19400-1502
S19400-2R00
1.5K 1/4W
15K 1/4W
2.00 1/4W
S19400-1001
1K 1/4W
R13,R31
R16,R23
2
2
S19400-20R0
S19400-2212
20 1/4W
22.1K 1/4W
R18,R29,R37,R42
R35,R36
R38,R39,R40,R41
4
2
4
S19400-4750
S19400-47R5
S19400-3922
475 1/4W
47.5 1/4W
39.2K 1/4W
C8
DZ2
SWITCH
D10
L10958-1
R32
Q8
DZ7
R29
R37
C6
R36
R27
R25
R34
R19
R26
IDENTIFICATION
S16668-5
S16668-4
S13490-112
T12705-34
Q1,Q2,Q3,Q10
Q4,Q12
Q5,Q6,Q7,Q8,Q9,Q11
R1,R3,R5,R24
A1
R40
Q5
Q6
R10
PART NO.
4
2
2
10
D9,D10
DZ1,DZ2,DZ3,DZ12
DZ4,DZ7
DZ5,DZ8
DZ6,DZ9
R41
R39
R38
A2
R17
R8
R33
R6
R9
R35
C2
Q10
R46
R28
R2
R24
R22
R45
R15
R43
R5
R4
R11
R44
DZ3
D3
DZ6
C7
R42
R18
D9
DZ1
R23
C5
D8
R30
Q1
Q2
Q9
D4
R14
C1
B4
R7
DZ5
B8
Q3
DZ4
C1,C5,C6,C7
C2,C8
C3,C4
D1,D2,D3,D4,D5,D6,D7,D8,
C4
D5
R3
D2
R13
Q4
R12
Q7
R16
C3
REQ'D
A
Return to Master TOC
11/01/2002
8.50
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 provided 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.
L10958-1
V300-I
J4
12
to TEMP.LED
J5
D51
4
R17
DZ12
43V
1W
+t
.13
60V
D12
10K
D11
680
2W
D13
R15
J4
11
C11
20
50V
DZ1
3V
500mW
R11
267
X1 B
C60
.022
50V
10K
16R
47.5K
H
R100
56
13
10
R43
10K
CRISP
X7
X10 A 1
FC
150K
AMPS
9
R140
R125
10K
22.1K
43.2K
26.7K
R38
10K
X1 A
R34
100K
14
R33
3.32K
DZ14
5.1V
1W
X10 B 3
CC
DZ8
3V
500mW
C65
4.7
35V
D23
1N5818
X7
C62
1.0
35V
8
3
301
X10 C
PRESET
TO
METER
X1 D
DZ2
10V
1W
10K
10
X5 D 4
5
FCAW
C64
.022
50V
D24
1N914
4.75K
D22
C68
2.7
50V
Vref
267K
+15V
13
C42
4.7
35V
OCV
HOLD DOWN
C66
.022
50 V
6
5
X1 C
Q1
600mA
40V
R114
100K
22.1K
33.2K
+ ARC
100K
150K
J5
C40
0.33
50 V
TO PROTECTION
BOARD
1 PHASE DET.
C18
.0047
50V
R59
82.5K
R57
10K
10
3
1
J4
8
14
VOLTAGE NET
J2
Vref
test points
SUPPLY
J1
LABELS
J3
2
TEST_PT_E
(more notes)
R58
33.2K
C2
.022
50 V
DZ13
5.1V
1W
X5 C 2
GENERAL INFORMATION
+ ARC
33.2K
13
SET
D33
821R
CURRENT
SETTING
13
R72
221K
C43
2.7
50V
J1
SHORTING
DETECTOR
COMMON CONNECTION
FRAME CONNECTION
EARTH GROUND CONNECTION
J5
6
475K
921R
D20
X11 B
12
R51
10K
621R
TIG
65R
OCV
89R
22.1K
R118
100K
C48
4.7
35V
+15V
NOTES :
SHORT
22.1K
22.1K
13
721R
X9 B 8
10K
C 5 4 CW
.022
50V
X7 E
R122
26.7K
C67
.022
50V
D18
R146
28.0K
R63
1.00K
88R
C35
.022
50V
59R
4.75K
R136
33.2K
301
19R
OCV
97R
150K
11
D42
Vref
2
J5
ARC FORCE/PINCH
D52
R124
100K
4.75K
2.67K
57R
X8 C
R62
8.25K
X 5 B 10
GMAW
021R
ACTUAL
8
X8
681K
681K
23R
VOLTS
12
12
D27
R112
22.1K
10K
12
R121
R123
100K
911R
DPC
D 10
68.1K
Vref
VI
58R
J4
C26
0.1
50V
29R
79R
4.75K
J4
4.75K
R113
332K
OCV
OVERCURRENT
FOLDBACK
681K
D29
12
11
X7 D
R74
24.3K
R117
332K
R116
47.5K
131R
C50
.022
50V
TO
METER
2
X11 A
R139
10K
11
J1
511R
C74
47.5K
10
R55
33.2K
Vref
R52
221K
C38
.022
50V
C63
.022
50V
CW
825
D5
06R
DP1
J5
VOLTAGE
SETTING
+ ARC
56.2K
R130
4
A
X5
X3 A
J1
D25
X3 D
011R
301
22.1K
R70
26.7K
C39
4.7
35V
R73
2.67K
28R
DZ9
5.1V
1W
VOLTS
C28
1.0
35V
Vref
69R
J4
+ ARC
941R
J5
X9
Vref
AMPS
D26
33.2K
D47
J4
J4
10
R66
150K
D37
GMAW (CV)
X4 C
12
C22
330p 50V
R40
100K
6
DZ6
5.1V
1W
.022
50 V
R13
100K
DZ10
5.1V
1W
TO DRIVER
BOARD
+ ARC
R10
475K
X4 A
C56
.022
50V
111R
TIG
R39
221K
VI
D50
+15V
R101
100
VI
D40
C36
.022
50V
VOLTAGE
CONTROL
AMPLIFIER
76R
J4
D8
R87
10K
38R
10
CRISP
X 6 B 10
73R
FCAW (CV)
J5
D15
J4
11
2.67K
J4
BOARD
701R
D17
CRISP (CC)
MODE
SWITCH
R42
475K
J1
POWER
13
4.75K
C41
0.1
50V
3V
500mW
J1
26.7K
C1
13R
C12
.018
50V
10
C25
330p
100V
X6 D 8
DZ3
1N914
RT
SG3847
2.67K
+5V
TO
METER
11
BOARD
332K
D19
CT
74R
PINCH
CONTROL
SYNC
COMP
12
801R
J4
11
OUTA
13
PROTECTION
14R
GND
V-
X9 C 2
D10
Vc
V+
C20
.022
50V
R49
681K
09R
SOFT (CC)
J5
C52
.022
50V
GMAW
C10
1.8
20V
475K
I+
C19
4.7
35V
CONTROL
SELECT
12
R86
221K
TIG
C13
330p
50V
56.2K
C14
.022
50V
X 9 D 11
4.75K
TRIG
62R
115VAC
100K
501R
OCV
CRISP
OCV
115VAC, 42VAC
are common
t o 4P2
22.1K
R53
33.2K
10K
R141
D39
I
42VAC
D48
Q2
600mA
40V
OCV
C72
100
20V
C71
39
C30 20V
.022
50V
100K
D9
X 6A
C73
0.1
50V
49R
C46
.1
50V
+15V
+15V
14
201R
D41
X4 B
33.2K
OUTB
12R
I-
J5
J1
15
Vin
Vref
4066B
11
PWM
CONTROL
16
SHUT
22R
R104
56
D38
26.7
42R
J5
J5
4.75K
R142
26.7
X2
CLIM
R45
10K
10K
D16
1N914
C32
.022
50V
DZ5
6.2V
1W
OCV
C70
.022
50V
14
X10
LM224
10
C75
150p
50V
Vref
C29
1.8
20V
D1
1N4936
C23
150p
100V
C69
.022
50V
X11
14
UNUSED
R151
10K
C33
1.8
20V
TEST_PT_B
D2
1N4936
26.7
R3
475K
R36
150K
D46
ARC FORCE
D31
26.7
R44
100
16.2K
45R
4
14
PRIMARY
CURRENT
FEEDBACK
R14
C3
.022
50V
52R
Vref
+ARC
1
1/2W
32R
D30
R133
22.1K
SOFT
X8 A 2
D7
1N4936
C5
.33
200V
1
1/2W
5K
72R
J2
+15V
18.2K
D3
1N4936
5R
CW
MAX
C8
.022
50V
26.7K
X11C
X11 D
13
CW
6R
10K
R137
26.7K
C55
.022
50V
+15V
551R
J5
R138
12
13
10K
X10 D 10
10K
R50
100K
DZ7
10V
1W
39R
11
C24
.022
50V
86R
X 7A
DZ4
5.1V
1W
CURRENT
CONTROL
AMPLIFIER
Vref
47.5K
231R
99R
OUTPUT
CONTROL
341R
C61
.022
50V
4.75K
6 Pin
Remote
Control
Receptacle
D
SOFT
SCALING
4066B
J2
351R
REMOTE
14 Pin
Remote
Control
Receptacle
N
J5
13
10K
R64
10K
SHORT
4066B
10
J2
D34
4066B
1
CURRENT
TRANS.
C51
.022
50V
X6
12
451R
LOCAL
D36
B 4
X8
X3
VI
R109
X9
OCV
R80
681K
14
X5
11
R46
10K
X6 C 4
C47
.022
50V
14
10
251R
R103
56
C59
0.1
50V
LT1014
11
C58
.022
50V
14
X4
LM224
11
C49
.022
50V
X3
LM224
C53
.022
50V
C16
.022
50V
C45
.022
50V
SOFT
X7 B
96R
C17
.022
50V
X1
X7
HEXTRGR
4066B
332K
TEST_PT_E
K001
84R
R16
332K
+15V
D35
OCV
C57
.022
50V
14
4.75K
TRIG
92R
R19
332K
J4
C4
150p
100V
47.5K
C6
.022
50V
OPEN
CIRCUIT
DETECTOR
VI
D45
X8
82R
14
X4 D
12
C34
2700p
50V
TEST PT D
C15
.022
50V
+15V
9R
R65
475
C31
.33
50V
10.0
D21
C44
.022
50V
14
R81
100K
392K
Vref
R84
4 7 .5 K
X3 B
12
17R
10.0
741R
10.0
841R
47.5K
13
R77
475
J3
C27
10K .022
50V
14
CNY17-3
4R
J3
OCI1
D4
TRIGGER
INTERFACE
13
R30
47.5K
R8
10K
SHUNT
AMPLIFIER
SHUNT
R12
22.1K
J1
D14
56
J1
7R
+t
REMOTE
D28
+15V
531R
OUT P UT
TERMINAL
HOT
TRIGGER
2R
24VAC F R O M
XFRM
R35
390
1W
+15V
TO
PROTECTION
BOARD
TRIGGER
CIRCUIT
DZ11
43V
1W
R144
2.67K
J2
02R
C37
2700p
50V
G-19
ELECTRICAL DIAGRAMS
81R
G-19
OCV
10
INVERTEC V300
CONTROL P.C. BOARD SCHEMATIC
AUSTRALIA
CANADA
6-25-93A
G2525
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
V300-I
G-20
ELECTRICAL DIAGRAMS
ORP
G-20
INVERTEC-300
CONTROL
G2527
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 provided 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.
V300-I
G-21
Item
Identification
C5
C10, C29, C33
C11
C12
C13, C22, C25
C18
C19, C39, C42, C48, C65
C25
C26,
C28,
C31,
C34,
C43, C68
C71
C72
D1, D2, D3, D7
D4, D5, D8, D9, D10, D11,
D12, D13, D14, D15,
D17, D18, D20, D21,
D22, D25, D26, D27, D28,
D29, D30, D31, D33, D34,
D35, D36, D37, D38, D39,
D40, D41, D42, D45, D46,
D47, D48, D50, D51, D52
D16, D19, D24
D23
DZ1, DZ3, DZ8
DZ2, DZ7
DZ4, DZ6, DZ9, DZ10,
DZ13, DZ14
DZ5
DZ11, DZ12
G-21
ELECTRICAL DIAGRAMS
Item
Identification
J1
J2
J3
J4
J5
OCI1
P1 (plugs
P2 (plugs
P3 (plugs
P4 (plugs
P5 (plugs
Q1, Q2
into
into
into
into
into
J1)
J2)
J3)
J4)
J5)
Item
R61, R147, R148
R62
R63
R65, R77
R69
R74
R82, R120, R128
R83
R95
R96
R131
R146
R152, R153, R154, R155
TERMINALS (P1, P2, P3,
P4, P5)
X1, X3, X11
X2
X4
X5, X6, X8, X9, X10
X7
Identification
RESISTOR-MF, .25W 1% 10.0
RESISTOR-MF, .25W 1% 8.25K
RESISTOR-MF, .25W 1% 1.00K
RESISTOR-MF, .25W 1% 475
RESISTOR-MF, .25W 1% 18.2K
RESISTOR-MF, .25W 1% 24.3K
RESISTOR-MF, .25W 1% 301
RESISTOR-MF, .25W 1% 267K
TRIMMER-ST, .50W 10% 10K
linear
RESISTOR-MF, .25W1 825 %
RESISTOR-MF, .25W 1% 68.1K
RESISTOR-MF, .25W 1% 28.0K
RESISTOR-MF,.25W 1% 26.7K
TERMINALS, Molex mini
QUAD, IC-OP-AMP. gen. purpose
224J
CONTROLLER, IC-PWM I-mode
3847
QUAD, IC-OP-AMP high-perf 1014
SWITCH, IC-CMOS analog quad
4066
INVERTER,IC-CMOS Schmitt h
ex 4584
NOTE: Individual parts listed are not available from Lincoln Electric.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
V300-I
ELECTRICAL DIAGRAMS
G-22
G-22
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
V300-I
G-23
ELECTRICAL DIAGRAMS
Item
B5, B14, B51, B52, B53
C1, C3, C4, C5, C6
C2
D1, D3, D4, D5, D6, D7
D8
DZ1
J8
J15
OCI1, OCI2, OCI3, OCI4
P8 (plugs into J8)
P15 (plugs into J15)
R1, R2
R3, R13, R16
G-23
R19
R34, R36
R35, R37
TERMINALS (P8, P15)
X1
X2
NOTE:
H5
NOTE: Individual parts listed are not available from Lincoln Electric.
52
51
Identification
53
14
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 provided 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.
V300-I
ELECTRICAL DIAGRAMS
G-24
G-24
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
V300-I
G-25
ELECTRICAL DIAGRAMS
POWER BOARD
L8033-4
G-25
B
D
Item
Identification
Item
Identification
Item
Identification
X1
C2,C7,C11
J7
X5
C3
D1,D2,D3,D4,D5,D8,D9,
D10,D11,D12,D13
C6
C4
C5
C1
OCI1
X2,X3
C8,C9,C12,C13
J6
C10
DZ1
DZ2,DZ3
Q1,Q3
Q2,Q4
Q5
D6,D7
R1
REGULATOR ASBLY
.022/50
CONNECTOR
VOLT. REG. & HEAT SINK ASBLY.
150/50
1N4004
TP1,TP2
R11,R19,R26,R27
R5,R6,R10,R22
R4
R14,R41
R9
R21
R3
R7,R8,R24
R2
R18
R20
R13,R15,R16,R17
R23
R12
R25
X4
J14
Q40
R42,R43
DZ4,DZ5
R28,R29
D14
15J
10K 1/4W
100K 1/4W
1.5K 1/4W
15K 1/4W
1150K 1/4W
2.21K 1/4W
243 1/4W
267 1/4W
2.67K 1/4W
26.7K 1/4W
267K 1/4W
33.2K 1/4W
4.75K
475K 1/4W
5.11K 1/4W
LM224 OP-AMP
HEADER
2N4401
100 1/4W
1N4742A
10 1/4W
1N4936
R44
THERMISTOR
NOTE:
1.8/20
4.7/35
39uF/20VDC
3300/50
OPTO ISOLATOR
8 PIN I.C. (SS)
.1/50
HEADER
500/50
1N4744A
1N4746A
3A/60V. TRANSISTOR
3A ,60V. PNP TRANSISTOR
3.5A. 60V. MOSFET (SS)
1N5822 SCHOTTKY BARRIER DIODE
.0 OHM, 5W RESISTOR
NOTE: Individual parts listed are not available from Lincoln Electric.
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 provided 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.
V300-I