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Lincoln Electric V300-PRO User's Manual

1. MRS PC BOARD ASSEMBLY CONTROL G2527 3 901 Je1Se A 0 uunjeHd DOL uonoes 0 uumeg rn 210 228 Ql
2. NOTE 5 14 51 52 5 4 5 6 C2 D1 D3 D4 D5 D6 D7 08 021 18 115 OCI2 14 P8 plugs into J 8 P15 plugs into J 15 R1 R2 R3 R13 R16 R5 R11 R12 R6 R8 R9 R10 R27 R7 R20 R14 R15 R18 R26 R28 R32 R19 R21 R23 R24 R25 R29 R30 R31 R33 R22 R34 R36 R35 R37 TERMINALS P8 P15 1 2 Identification CONNECTOR tab 1 4 CAPACITOR ceramic CAPACITOR tantim etc 27uf 35VDC DIODE 1A 400V DIODE 1A 1000V DIODE IN4740 Zener 10V 1W RECEPTACLE Molex mini 4 pin RECEPTACLE Molex mini 6 pin Isolator CNY 17 3 PLUG HOUSING Molex mini 4 pin PLUG HOUSING Molex mini 6 pin RESISTOR MF 25W 1 681K ohm RESIS
3. CONTROL INVERTEC 300 NIEN ST N Oe Eyer BE wwx Neu fta luo 89 Sr Kyo sr 901 4 18 0 DOL uonoeg 0 DOL 4 18 0 uunjeH DOL 0 2 5 0 Lincoln Electric assumes responsibility for resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Indivi
4. B12 B11 B9 B10 B3 B7 B5 B6 B2 B1 e D G gem ITEM REQ D PARTNO IDENTIFICATION E KEN X SCORCOC NC 61550607 4 15166685 055750 2 8 516668 4 2700 50 C3 C4 513490 112 047 1200 I D1 D2 D3 D4 D5 D6 D7 D8 10 T12705 34 1N4936 alg 09 010 DZ1 DZ2 DZ3 DZ12 T12702 27 1N4740 074 027 12702 29 1 4744 025 028 12702 53 1 4728 de 8 026 029 12702 40 1N4735 M i 5 01 02 03 010 12704 73 PKG MOSFET es C Q4 012 T12704 68 244401 m EL 05 06 07 08 09 011 6 12704 69 2 4403 9 5 24 4 19400 1 100 1 4 4 9194004000 10077 2 ole R2 R4 19400 2210 221 1 4W R6 R8 R9 R17 R19 R25 R26 519400 1080 10 1 4W o R27 R33 R34 ot tet R7 R30 S19400 1501 1 5K 1 4W O Q R10 R32 S19400 1502 15K 1 4W R11 R15 R22 R28 R43 R44 19400 2R00 2 00 1 4W 8 i i gaeng 5 R45 R46 R12 R14 R20 R21 4 519400 1001 1K 1 4W 3 O lt lt R13 R31 519400 2080 20 1 4W
5. POWER SWITCH SECTIONS MAIN 20KHZ TRANSFORMER CHOKE EK LEFT SWITCH BOARD Si e a FET MODULES 4 lt lt lt lt lt lt 4 9 gt 1 DIODE FET MODULES Hr gt E CURRENT 10 OR DETETCTION 5 TRANSFORMER 2 PRE CHARGE gt LINE INPUT DRIVER SWITCH RECTIFIER BOARD 4 CONTROL 5 DIODES 9 rmm lt 81 BOARD 1 AC1 BUSE PROTECTION H 2 1 2 H BOARD gt YY FEEDBACK H 3 TRAIN N 4 224 2 A LEAD T 1515 23149 1 84 AUXILIARY RIGHT SWITCH BOARD 1 x TRANSFORMER UE 2ND STEP PWM l 111 5 DIODES M gt SAE POWERBOARD im CAP P 14 FETMODULES PE I PIN lt 1 VDC 1 DIODE TO CHOKE CHOKE WIREFEEDER 1 i 1 4 F LOCAL MODE VOLTAGE FEEDBACK REMOTE METER 1ST STEP PWM VOLTAGE CURRENT FEEDBACK PROTECTION J SHUNT 15VDC CONTROL BOARD FUNCTION VOLTAGE 24VAC THERMOSTATS GUN TRIGGERING Return to Master TOC V300 PRO LINCOLN 2 THEORY OF OPERATION
6. F 38 Thermal Protection AC Trigger F 43 Power Board eis p i F 47 o 2 Replacement Procedures 5 Capacitor F 51 o Switch Board Replacement sss F 55 Test After Switch Board Capacitor F 57 5 c Output Diode Replacement eene nnn F 59 Retest After Any F 62 3 5 tc V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC O10 E gt 818 515 o a Return to Section Return to Master TOC Return to Master TOC 2 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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 This Troubleshooting Guide is provided to hel
7. d oc 9 z e J16 S Description cle 11 HEADER 2 2 19110 HEADER old T1 TRANSFORMER gt 116 HEADER R1 R2 R13 R14 20 WATT 250 OHM RESISTOR cle 021 022 1 4742 515 01 02 55 9 7 12 100 1 AW R3 R4 R5 R6 R8 R9 150K 1 4W R10 R11 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN machine PRO 6 15 ELECTRICAL DIAGRAMS G 15 SCHEMATIC SWITCH PC BOARD L8440 A SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT w O V COMMON CONNECTION EARTH GROUND CONNECTION 7177 FRAME CONNECTION INVERTEC V300 SWITCH BOARD SCHEMATIC Return to Section TOC Return to Master TOC we 1N4936 07 600 076 x 40V 2 4403 62 8 Q3 1 IRFD110 Q5 600mA IRFP460 09 A2 BYT12P600 POSITIVE INPUT SNUBBER RE
8. 101 45 3 E i E 0 Inu 28 E h nw 45 iJ CHEF Da 1 d MI SILIART Vasa oet 070 0 eo FILE em POLAFITY qu 2 2n TCI FEECE CONTROL mo 20 RECEPTACLE pee n ip E E 51 zi LL 2 11 FM DUTFLT MAPHIMES SUPPLIES 151 7 SABLE CHXDO ERY pi EXE SAR PSE AET Lead TD SADNO Ka DAL E ETTRIC CET ES DET mS ER m E I A M 1 EOE THREE FANSE REIK TO PIR NATICHE ELECTRIS 5 ji ae Lien bak LETEA GOMER ED KHITE LEATS GELA Z Grek 2 X t _ HILHES SUPPLIED WT 248 8 _ amanto reote Rien TE 1 AND LOCEL o BLL 1 H OLCPIT CONT ADL MER GHAD HAC FER MATIUMAL AHZ ELQECHCEAL CODES CANET J V amp A T3 TM Ner E OUH ETE OF aesa G GON B E ETE v Mg 11 78 11 MAREN
9. R30 078 R20 012 TN he US ms p 5 m A sit EE o e 2 a 9 4 5 9 9 c E Ee 15 8 8 o ojo 811 58 e 6 D 2 E TIE L8441 SWITCH alB Olo Q O O10 Fie 22 0159 Description Item Description 91 5 o z 1 ELECTRONIC MODULE ASSEMBLY R2 R4 RESISTOR MF 25W 1 221 ohm g A2 ELECTRONIC MODULE ASSEMBLY R6 R8 RY R17 R19 RESISTOR MF 25W 1 10 0 ohm 1 2 4 5 6 CONNECTOR tab QC edge offset R25 R26 R27 R33 R34 51 7 8 9 10 11 1 4 7 RESISTOR MF 25W 1 1 50K ohm cc B12 R10 R32 RESISTOR MF 25W 196 15 0K ohm C1 C5 C6 C7 CAPACITOR CEMO 022 50V 2096 R11 R15 R22 R28 RESISTOR CC 50W 5 1 ohm C2 C8 CAPACITOR CEMO 2700P 50V 596 R12 R14 R20 R21 RESISTOR MF 25W 1 1 00K ohm C3 CAPACITOR PPF 047 1200V 596 R13 R31 RESISTOR MF 25W 196 20 0 ohm D1 D2 D3 D4 D5 D6 DIODE AXLDS 1A 400V FR 1N4936 R16 R23 RESISTOR MF 25W 1 22 1K
10. Section G Parts Manual 4 4 P243 Series 300 1 LINCOLN Return to Master TOC Return to Master TOC o 2 5 Return to Master TOC Section A 1 TABLE OF CONTENTS Section A 1 INSTALLATION SECTION 5534534445444544434 Section Technical Specifications 10000 2 LOCATION 3 Electrical Installation nennen 3 e E 4 Wire feeder and Accessory A 4 A 5 10 11 101 14 16 1101 6 V300 PRO LINCOLN 2 2 INSTALLATION TECHNICAL SPECIFICATIONS V300 PRO K1349 3 K1349 4 INPUT THREE PHASE SINGLE PHASE Standard Input Current Code Standard Input Current Code Voltage at Rated Outpu Number Voltage at Rated Output Number 208 230 460 575 48 43 24 20 9825 9834 9965 208 230 460 69 62 38 9825 9936 9965 50 60 10034 10035 50 60 10034 10130 10130 10131 RATED OUTPUT THREE PHASE SINGLE PHASE Volts at Volts at Rated Rated Duty Cycle Amperes Duty Cycle Amperes 60 Duty Cycle 32 60 Duty Cycle
11. a MAE IRL Pole NA IGRAL SJ aL 2 i Rz Zum I 3 ORAE 531 0 SE nep FEHI 5 Ck TRE I PERE sis LLL Lieb e T pp vACHIEE FE abb Lila ELETRICA oE CAD 32 219 ZLFFLY 2 LLY 41231 SYR LS Doc kdb Va rari 519 coMPeeenTs 3 fale Ri TP ges ues vr HA YI FCAT Sacha est 37 ii hgh HY ASE 11 15211 o z aw POWEA 4 13 HUNK dE PS PAVAT 152 DJBS 4 5 T 8 8 211232 UL STS ORT 527 ud 5 0 21 515 ELECTRIC ri AUI DA LS NOTE This diagram is for reference only It may not be accurate for machines covered this manual The wiring diagram specific to your code is pasted inside one of enclosure panels of your machine LINCOLN 8 V300 PRO Return to Section Return to Master TOC Return to Section TOC ojo O10 E gt 81 8 e 5 5 ply ojo Return to Section TOC Return to Master TOC Return to Master TOC G 10 SCHEMATIC ENTIRE MACHINE SCHEMATIC DIAGRAM FOR TROUBLESHOOTING INVERTEC V300 PRO LINCOLN 8 208 10K 1 CW R12 ARC FORCE INDUCTANCE CONTROL 212A 212
12. ms pm 4 olo e o o 9 3170 20 olt 55 WT M 3 eA EE o qna E al Th E 5 THEA cle T ale 2 2 Ed CONTROL 4 GCA CRFULTE SVITEH 20 CM ar ri 4 ot 0 PME i i PIE E LR 010 n NN eda NS bel amp aoa ora 125 XXI BE T 1 8 8 REVITE CH p i ae a UE WEIG 1 yh 9 9 D 2 zhL Jr a ALA 4d 211 to E ST i s i Wy 08 20 5 NIRE CERE HAH 1 zu WELAF uU AM Hj cc s AE T AMT ll zm TT hh MEO SEITE Y 24 1 alb 5 Lid WAIT iier Te haika n SEE E BM ER amp LEADS 5452 073 wees Dei ATH TAPE T3 iic 22240 THZ E AECI ORFF a Fal auer 4 Arr RES 2 42 L 2 21 016 3 FOR LT tp I Se er oo erate 2
13. 4 24 830 16018 Return to Section Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 300 PRO 6 25 ELECTRICAL DIAGRAMS G 25 PC BOARD ASSEMBLY POWER L8033 7 8033 4 8033 4 POWER BOARD ma pej Return to Section TOC Return to Master TOC Q HE 2 2 3 8 Return to Master LINCOLN Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine pil S 040 71 R23 IDE O 9 2 8 3 Item Identification Item Identification Item Identification S 8 1 REGULATOR ASBLY TP1 TP2 15 R44 THERMISTOR cle 2 7 11 022 50 R11 R19 R26 R27 10K 1 AW ala J7 CONNECTOR R5 R6 R10 R22 100K 1 AW 2 X5 VOLT REG amp HEAT SINK ASBLY R4 1 5K 1 4W c3 150 50 R14 R41 15K 1 4W NOTE Individual pa
14. a gt 2 2 5 5 o ojo Return to Section TOC Return to Master TOC eu ELECTRICAL DIAGRAMS SCHEMATIC DRIVER PC BOARD S20799 TO 3 SWITCH 5 3 BOARD G gam DRIVE ATE 55 d TO POWER BOARD it 2 FROM PROTECTION Power Switch Drive Transformer Copacitor Pre charging Circuits BD 225 J16 150 150K 20 FROM PROTECTION NOTES SINCE COMPONENTS OR CIRCUITRY A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER INVERTER WELDERS SCHEMATIC URIVER BOARD 6 25 93C 20799 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 PRO 6 14 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY DRIVER 9134 1 T amp DRIVER 9134 R13 RE E 8 L X D O XXKX R14 22 Return to Section 071 Return to Master R5 R10 o 2 5 2 3 8 Return to Master
15. 512 c 1DIODE 10 OR DETETCTION H5 CURRENT 1DIODE 24VAC a MODULES lt 1 VDC 900 iam TRANSFORMER PRE CHARGE S Sun RECTIFIER 3 SWITCH BOARD CONTROL 1 5DIODES i ent BOARD Ht 1 1 PULSE PROTECTION H 2 01 Ac2 N BOARD 1 3 YY FEEDBACK 3 oo TRAIN N H cR2 i cria ALEAD T ree 0 X 7 e 24VDC 5 RIGHT SWITCH BOARD 1 DIODE 815 TRANSFORMER 2ND STEP PWM Fermopuces Ole 18VAC o TU 0 12 POWERBOARD 1 a E E 5 o TO CHOKE CHOKE WIREFEEDER LOCAL VOLTAGE FEEDBACK REMOTE METER MODE ror ror 4 1ST STEP PWM VOLTAGE CURRENT FEEDBACK PROTECTION 15VDC CONTROL BOARD FUNCTION VOLTAGE 24VAC THERMOSTATS GUN TRIGGERING PRECHARGE amp PROTECTION CIRCUITS Another function of the Protection Board is to detect whether the input voltage is sing
16. Lathe REC B SEITE pane 4 me e li 2 205 MADDAES TERED ViTe Ika DaBLE A 2 2124 WADE AM 2021 ELZCTZIZAL m atomi UE puru E DE Lace zonzs I CORES TERMS UY 2 EUFL warnan 15 28 2 PRINTED GAUT SCARE E E ALCHOLT 3 EN Inr Dave MEER en eee Ni EJ n TIT DI ha h AIRE FECES LEE ta C 12 NeT x m L m air Re PES a 2 h ct LEAC 28 n PRERE 224 pPeH PU VI TOE ELECTRICA xYTB2 2 CIR 21 21 COMMELTI hicks WHE M ru sa COT T Ril 5 M 2 KE Es SERRE DS ICH A4 2 2 a CARAS TOES USTOMED 557 T SACH 2 PIITM KPI VOLTAGE fo SGL FAHZL 1 94 25 2 520 70 CFERATOCH e ea E ELECTRIC USA NOTE This diagram is for reference only may not be accurate for ma
17. O o 5 5 9 gt 815 e 5 2 ol Return to Section Return to Master TOC TROUBLESHOOTING amp REPAIR FS THERMAL PROTECTION AC TRIGGER CIRCUIT cont FIGURE F 20 PC BOARDS MOVED FOR ACCESS CONTROL BOARD TEST PROCEDURE 1 Turn main power OFF 2 Perform Input Filter Capacitor Discharge proce dure detailed in this section 3 Detach the following PC boards so you can gain access to and have ample room to perform the tests Do not disconnect from wiring harness Power Board Control Board NOTE Do not disconnect any wires The machine must be functional to perform test V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC 9 1 0 iz 212 515 ply o Return to Section Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR pe THERMAL PROTECTION AC TRIGGER CIRCUIT cont FIGURE F 21 THERMAL PROTECTION AC TRIGGER CIRCUIT CHOKE THERMOSTAT FAN THERMOSTAT Ti 10J6 POWER EXTERNAL BOARD TRIGGER UNE 212 212A 2 54 OUTPUT TERMINAL 4 SWITCH 223 223B PART OF 14 PIN AMPHENOL 4 Locate the Auxiliary Transformer T1 and leads used for test See Figure F 21 5 Turn main power ON 6 Test Auxiliary Transformer v
18. 24VAC THERMOSTATS GUN TRIGGERING OUTPUT AND CONTROL CIRCUITS The AC output of the transformer is changed to DC by When weld output is requested the Control Board the Output Rectifier The Output Choke between the Compares inputintormalon tg signals negative side of the rectifier and the negative output and provides the correct PWM signals to the Switch stud provides the necessary filtering for DC welding 2 2 Switch nud The two smaller chokes and their series diodes are the etermines which feedback signal voltage or current OCV boost circuit used to help provide good weld will have the most relevance However both signals starts are used in all modes o e olg iz 212 515 ply o The Control Board also monitors signals from the ther mostats and the Protection Board and if necessary shuts off the weld output The protection circuit infor mation is discussed in more detail later in this section Current feedback to the Control Board is provided by the shunt in the negative output circuit It is used for weld control overcurrent protection and actual amme ter readings The Voltage feedback lead at the positive output stud also provides information for weld control and actual voltmeter readings The Control Board monitors input from the front panel controls output arc control mode switch etc The software on the board processe
19. 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 cur rent 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 The DC current of the primaries is clamped back to the respective capacitors through diodes on the board when the FETs turn off This protects against inductive voltage spikes due to the inductance of the windings and also helps maintain capacitor balance The boards are fired during a 50 microsecond interval with respect to a Pulse Width Modulated PWM signal from the Control Board through the Driver Board This creates a constant 20Khz output in the secondary Along with ease of control the 20Khz operating fre quency allows for a much smaller and lighter trans former 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 NOTE Unshaded areas of block logic diagram are the subject of discussion V300 PRO LINCOLN THEORY OPERATION FIGURE 5 amp CONTROL CIRCUITS PO
20. Move the Output Terminal Switch S4 to the ON posi tion closed V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST cont FIGURE F 17 PROTECTION BOARD TEST POINT L7915 PROTECTION 306 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 b If 15 VDC is present go to step 11 V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OJO 9 1 0 iz 212 515 ply Return to Section Return to Master TOC TROUBLESHOOTING amp REPAIR OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST cont FIGURE F 18 POWER BOARD TEST POINTS 8 Test for 15 VDC supply voltage between leads 302 10 Test for 0 1 VDC between leads 301 275D on and 275D on Power Board Power Board a If 15 VDC is present test is OK Go to step 9 a If 0 1 VDC is present AC trigger Control Board and Power Board are operating prop
21. Machine does not produce more than 250 amps on meter while welding when connected to 3 phase supply Check input voltages fuses and input voltage reconnect procedures See Installation section of this man ual See Protection Board Output Voltage See Control Board test See Input Rectifier test com ponent D13 achine does not produce more han 250 amps on meter while elding while connected to single phase supply Normal operation Nothing is wrong No test necessary The single phase operation is detected by the Protection Board and the output cur rent is limited accordingly Machine operates okay at 230 VAC or lower No output at 380 VAC or higher Check input voltage and input volt age reconnect procedures See Installation sectionjof this manual Check Re connect Switches See Protection Board Output test See Capacitor Balance tests See Snubber Resistor test See Switch PC Board est CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 V300 PRO LINCOLN TROUBLESHOOTING amp REPAIR DE TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMEN
22. PROCEDURE NOTES Whg le placing remove Tae 1 Perform the Input Filter Capacitor Discharge 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 Return to Section TOC Return to Master TOC 2 Remove the two 3 8 hex nuts from the top of the through bolts The hex nuts are located on top of the fan shroud See Figure F 25 FIGURE F 25 REMOVING HEX NUTS HEX NUT Return to Section TOC Return to Master TOC 3 Turn the machine on it s side as shown in Figure 26 Slide the plastic insulators that go through the base to one side and pull out the through bolts being careful to save all of the insulation and stand off material Set aside and save for reassembly FIGURE F26 REMOVING THROUGH BOLTS olo O o 5 5 9 gt 815 mlt 5 2 Return to Section Return to Master TOC V300 PRO LINCOLN 53 TROUBLESHOOTING amp REPAIR pos CAPACITOR REMOVAL AND REPLACEMENT cont FIGURE F 27 REMOVING CAPACITOR NUTS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 Remove the two 1 4 28 hex head bolts that hold 5 Loosen the set screw of the Capacitor clamp ring the Capacitor to the PC board See Figure F 27 and remove the Capacitor from the clamp ring See Figure F 28 FIGU
23. TO TO 1 LI 4 4 Jl FROM INPUT RECTIFIER 30 t1 R3 R4 150K 51 250 62 2 SWITCH s3 BOARD 63 01 4 54 0 c wD 4 0 BOARD c A S NN NN NN V NN NN NN FROM PROTECTION BD POWER BOARD 24 242 N 416 Jll gt TO LEFT SWITCH BD c C4 FROM RIGHT SWITCH BOARD 24 VDC 24 VDC 24 24 62 z 411 POWER BOARD Y V 4 FROM PROTECTION 1 gt 3 S BD J16 O NOTES 5 22022 INPUT RECTIFIER SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANCE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON NUMBER 4 gt 6 J9 J10 J16 INVERTEC DRIVER BOARD SCHEMATIC S 20215 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual V300 PRO ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY DRIVER L8660 8660 V300 DRIVER Return to Section Return to Master TOC o 2 5 2
24. 3 8 Return to Master 818 2 B 2 Identification 5 o 5 1 2 4 RELAY SPNO 24VDC 6000 ohms 2 p AG CDO 5 3 D1 DIODE AXLDS 1A 400V E 2 DZ1 072 DIODE Zener 1 12 5 1 4742 9 10 16 CONNECTOR Molex mini 6 pin CONNECTOR Molex mini 4 pin 9 P10 P16 plugs into PLUG Molex mini 6 pin J9 J 10 J 16 11 plugs into J 11 PLUG Molex mini 4 pin 01 Q2 TRANSISTOR NMFT247 4A 900V 1 R2 R13 R14 RESISTOR WW 20W 5 250K R3 R5 R6 R8 R9 RESISTOR MF 25W 196 150K R7 R12 RESISTOR MF 25W 1 100K TL TRANSFORMER PCB NOTE Individual parts listed are not available from Lincoln Electric Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN machine V300 PRO Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo O10 E
25. 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame ATTENTION Static Sensitive Devices If you don t have a wrist strap Handle only at touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shielding bag fthe PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow proper failure analysis 4 Test the machine to
26. 9 2 a i mi f 81 _ 918 a HH IN r ole 5 4 5 Se 515 ize pu a GANAU 9 15 i 4 TSA cc 2213 45 yt FTE 2083 46 51 i r 1 02 m 2247 Tear 7 1 we rz PES Y Reus shod ii S Z T A uo tory WCE d 141 41 313 DOR TRL a ark 3 ie 11 up Tux olo a Tm Taks e o i 25 0 i Bd a TER 0919 165 802 ak ELE ZEE cs 4 DER 519 MENS IE ph ial Ba B 1 9 5 9 T aa oper i 2 E MFE CTE 1 ima 0 9 202001 14884 SB emos 22022002200 X E gt 818 2 Hut MEGI WAEIMES WITE pum m ra Sal E CARET 1543 BOLHI RATIONAL 22018223 GODE t SAITE tli m 22 ae RET Ea FITH n E Insti i in a mue Ej ASE PEE CURE 20 UN Bap 99 Tre Lust
27. Drawing B above shows the FET in an active mode When the gate signal a positive DC voltage relative to the source is applied to the gate terminal of the FET it is capable of conducting current A voltage supply con nected to the drain terminal will allow the FET to con duct and henceforth supply current to downstream components Current will flow through the conducting FET to downstream components as long as the gate signal is present This is similar to turning on a light switch V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC 5 THEORY OPERATION ET PULSE WIDTH MODULATION FIGURE E 6 TYPICAL FET OUTPUTS lusec 48 u sec 50 sec C E l usec MINIMUM OUTPUT 24 C 2usec 50 usec MAXIMUM OUTPUT The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the positive and negative portions of the cycle Changing the pulse width is known MODULA TION Pulse Width Modulation PWM is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine MINIMUM OUTPUT By controlling the duration of the gate signal the FET is turned on and off for different durations during a
28. MI SYMBOLS EIT n WE EKES Fl4z CE 5 K z DI 55 CUT UT DIODES x SET E Dr QCT7LT 200025 WATCHED 1 BF nz CIS EH ANI AS VATED GIT LINCOLN PaE 1 53 gt Foe NOTE This diagram is for reference only It may not be accurate for machines covered by this manual wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN 8 V300 PRO iid gha Return to Section Return to Master TOC Return to Section TOC O o Fle HE 315 43 Return to Section Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS WIRING DIAGRAM ENTIRE MACHINE CODE 10256 1 10189 i i in sr ras IFJ ABET es a X eth Wedge du ta cum Sat CH ans ie aii DL oa 2l e 5 1 TTE E ii 21 bee Te a Da JT ce N ras Gr LMC T ad M ra Crt MI h an det een 4 th owns 2 oua a ae i SPT TS Q
29. and K 39 44 VAC 115 VAC without load measure across pins A and J 109 120 VAC Return to Section TOC Return to Master TOC V300 PRO LINCOLN Section G 1 TABLE OF CONTENTS Section G 1 ELECTRICAL DIAGRAMS SECTION 2 9 gt Electrical DIagEalms ni 5 cenas uas aai daidai aeu ak Section 5 Wiring Diagram 18657 for Code 9825 amp 9965 G 2 Wiring Diagram 18841 for Code 9934 G 3 Wiring Diagram 19299 for Code 10034 G 4 Wiring Diagram L9301 for Code 10035 G 5 Wiring Diagram 19567 for Code 10130 G 6 Wiring Diagram 19569 for Code 10131 G 7 6 Wiring Diagram L10189 for Code 10256 G 8 e Wiring Diagram L10191 for Code 10257 G 9 5 Entire Machine Schematic G 10 gt Driver PC Board Schematic 820216 G 11 5 Driver PC Board Assembly L8660 G 12 5 Driver Board Schematic 520799 G 13 c Driver PC Board Assembly L9134 G 14 Switch Board Schematic L8440 G
30. l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN 8 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 RETURN MAIN MENU MASTER TABLE OF CONTENTS FOR ALL SECTIONS Crime m i iv 22 4 2 4 Section Operation ET DE Section B Accessories Xem mde xem eee ee eh eee Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagrams
31. 06 214 6 208 MIN 225 Eun 15 25 216 LOCAL 83 226 4 7 6 218 228 LOCAL REMOTE 75 gt G gt 75 14 9 15 2048 3 MOTO 4 204C 1 11 395 215 CB2 277 82208 75 2 10 gt P 207 9 CW 7 2 12 110 115 319 J3 212 2AMP ud 8 POWER 5 3 5 10K ARC FORCE 32 BOARD 112322 p 208 2W INDUCTANCE 42 41105212 4 32A 310 os 3 EE gt pul B hy CONTROL To dam eek 501 4 5 1818 9 94 305 aa 212 olo 2 Op 504 4 6 2 50 E E 2128 T S 212C 0 1 4 0 OUTPUT o TRIGGER4 4 5p 223 FAN DE 5 S 211 304 4 8 275 Fie THERMOSTAT 1 9 2128 1144 ee 238 z REMOTE SWITCH 6 BEM 311 amp 1 1 5120 CONTROL 228A 812 82 313 4 2 14 ot BOARD 56 AUXILIARY 3 502 Old 21 H TRANSFORMER d Ne THERMAL NOM GND B gt GND 2 05 11 4 14 1 IE See ee ee 4 OVERLOAD o 5 SPARE N gt 211B n LS INDICATOR g YN 229 SWITCH 503 300 1 ONLY cle WIRE REMOTE 503A FEEDER CONTROL A 2 A ala RECEPTACLE ojo NOTES 52 SWITCH 1 FOR MACHINES SUPPLIED WITH INPUT CABLE V300 PRO T FOR SINGLE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE CONNECT BLACR amp WHITELEADS TO SUPPLY CIRCUIT OUTPUT TERMINAL SWITCH WRAP RED LEAD WITH TAPE TO PR
32. 1 8 3 45 7 PG PILOT CONTROL PWM PWM Jb 46 46 JT 7564428 END MIP3JA TD PULSE TRAN SFORMER JT PT Vv LIGHT BOARD SIGNAL CONTRDL PILOT IH BaARD LIGHT 24V Pp 014 IN4936 n yid RELAY COILS Qe s 100 FROM PROTECTION BD 47 7 05 IRF573 071 5 iy wo 33 2 By 25 414 EL 2 2 lt lt We DM aca 17 1 N x VE 8 CONTROL TRIGGER NOTES N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED BOARD MAY CHANCE WUTHOUT AFFECTING THE INTERCHANDEABJL TY OF A COMPLETE BOARD THIS DIAGRAN MAY NOT SHOW THE EXACT COMPONENTS OR CJRCUJIRY CONTROLS HAVING A COMMON CODE NUNBER ojo O10 E gt 23 e 5 5 ply ajo GENERAL INFORMATION ELECTRICAL SYMBOLS PER 1537 CAPACITORS MFO 1022 SOV UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 44 UNLESS OTHERWISE SPECIFIED LABELS DIODES JA 400V UNLESS OTHEARISE SPECIFIED SUPPLY VOLTAGE NET Q PORER SUPPLY SOURCE POINT VV COMMON CONNECTJDN 177 F RANE CONNECTION EARTH GROUND CONNECTION 5
33. Boards must be replaced at the same time In addition faces of the new PC board and to the Capacitor to replacing the Switch Boards Capacitors C1 and C2 terminals DO NOT allow the compound to enter plus C14 and C15 on 575 VAC models must also be the mounting screw holes because it can distort the replaced if the following conditions exist torque values a The part number of the Switch Boards is something 8 Prepare to mount the new PC board on the heat other than L10985 sink by first lining up the mounting holes Then press the PC board into place b The machine was operating from 380 VAC or high er when the failure occurred 9 Insert each of the four socket head screws into the mounting holes and thread finger tight The c Burned areas are visible on the Switch Boards threads are soft be careful not to cross thread the screws PROCEDURE 10 Loosen the capacitor mounting bracket tightening 11 Torque both sets of screws 10 inch pound ments using a diagonal tightening sequence 2 Remove the Switch Board assembly from the Torque the four socket head screws to 44 inch machine as directed in CAPACITOR pounds 5 Nm Torque the two hex head capaci tor screws to 55 inch pounds 6 Nm 3 Remove the four socket head screws that hold the 12 Tighten the capacitor mounting bracket mounting Switch Board to the heat sink screw 4 Remove the 1 4 28 hex head capacitor mounting 13 Remount the assembly into the mach
34. 15 Switch Board Assembly 18441 G 16 Switch Board Schematic 110956 G 17 Switch Board Assembly L10958 1 G 18 4 Control PC Board Schematic 02525 G 19 2 Control Board Assembly 2527 3 G 20 G 21 Protection Board Schematic M16097 G 22 gt Protectoin Board Assembly 17915 2 G 23 Power Board Schematic M16018 G 24 5 Power Board Assembly 18033 7 G 25 NOTE Many Board Assemblies are now totally encapsulated are therefore consid ered to be unserviceable The Assembly drawings are provided for reference only HF 2 0 5 300 LINCOLN G 2 ELECTRICAL DIAGRAMS a WIRING DIAGRAM ENTIRE MACHINE CODE 9825 6 9965 1 8657 5 O 311 313 1 275 306 N G A R C 51 2 s TT TT 2 3 52 H T2 gt 14 9 14 4 5 RIGHT o s hy eo IL n 0 9
35. 15 minute period If the fan is not turning or the air intake louvers were obstructed then the power must be switched off for 15 minutes in order to reset The fan problem or air obstruction must also be corrected V300 PRO LINCOLN Section F 1 TABLE OF CONTENTS Section F 1 TROUBLESHOOTING amp REPAIR SECTION He 8 gt Troubleshooting amp Repair Section Section F E How to Use Troubleshooting Guide eene enn F 2 PC Board Troubleshooting Procedures and F 3 Additional Troubleshooting F 4 Troubleshooting GUID F 5 Test Procedures Input Filter Capacitor Discharge 0 F 11 6 Output POE CIRCUIT Test 13 Protection Board Output 17 2 Capacitor Balance et e xo 21 2 25 5 onubber Resistor 29 5 Output Diode 31 E INPUt ep F 33 OverCurrent Protection Current Trigger 00 F 35 Overvoltage Protection DC Trigger Circuit
36. 22 d 6J4 94 8233 13 36 2 POWER Se A BOARD 1 3 5 ohms 212 405 2131 12 4 1 5 36 V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 a gt 2 2 5 5 ojo Return to Section TOC Return to Master TOC F 51 TROUBLESHOOTING amp REPAIR CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE 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 pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid in the relpacement of the Input Filter Capacitors MATERIALS NEEDED Mlsc Hand Tools Torque Wrench 60 Wiring Diagram Section G NOTE CAPACITORS MUST ALL BE CHANGED AS A SET IF ANY ARE DEFECTIVE V300 PRO LINCOLN F 51 Fue TROUBLESHOOTING amp REPAIR CAPACITOR REMOVAL REPLACEMENT cont
37. 25W 1 221K DZ4 DZ6 DZ9 DZ10 DIODE Zener 1W 5 1V 5 R44 R101 RESISTOR MF 25W 1 100 R49 R67 80 R107 RESISTOR MF 25W 1 681K Dzs R54 RESISTOR MF 25W 1 16 2K TMATSISA R56 RESISTOR MF 25W 196 43 2K 0711 DZ12 DIODE Zener 1W 43V 596 RES RESISTOR MF 25W 196 82 5K 1N4755A 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 ELECTRIC 22 ELECTRICAL DIAGRAMS G 22 SCHEMATIC PROTECTION PC BOARD M16097 FROM 1 UPPER CAPACITOR 852 Return to Section Return to Master TOC T gt 002 17 Td POWER BD Over 2123 FROM BLEEDER RESISTOR 5 gt gt BIA DRIVER BD Over Voltage 242 Return to Section Return to Master TOC JIS 2 2 BS3 FROM 1 UPPER CAPACITOR 2 2 415 TO DRIVER BD Over Valtagel FRON 1 LOVER CAPACITOR 252 ae L OJO iz g 2 5 3 Bs 08 FROM CENTER LEC OF NPUT UNADOT 8 0 rzs rs fra feras H5 50K 15 0K 15 0K 15 0k TO CONTROL BD G
38. 8 302 46 1 amp pin 6 on Power Board 8 If 24 VDC is not present check the voltage from If 15 VDC output is not present replace Power lead 311 to lead 313 514 2 Board If the voltage is greater than 1VDC perform the NOTE If relays energized in Step 4a skip to Step 10 Protection Board test 8 Test for 24 VAC from lead 211A to lead 212A J6 If the voltage is approximately 1vdc and the 24vdc pin 4 amp pin 9 is not present between leads 309 amp 310 the Power Board is defective If 24VAC is not present test the Auxiliary trans former and associated wires The Control Board or thermostats may also be defective See Fig F 24 Return to Section TOC Return to Master TOC V300 PRO LINCOLN Return to Section Return to Section TOC O o 9 1 0 iz 212 515 ply Return to Section Return to Master TOC Return to Master TOC Return to Master TOC dis TROUBLESHOOTING amp REPAIR pron POWER BOARD TEST cont FIGURE F 24 SIMPLIFIED TRIGGER CICUIT SIMPLIFIED TRIGGER CIRCUIT POWER BOARD CONTROL BOARD 301 76 FROM PROTECTION BOARD OVERVOLTAGE gt 26 X lt PWM OUTPUTS REMOTE TO POWER PROTECTION BOARD STT ONLY STT Il Only 1 21 T1 AUXILIARY 1 2 Nt 14 AMPHENOL TRANSFORMER 379 1 1 3 5 ohms 224 11 223 NWVN 413 lt 6
39. Capacitors from charging MATERIALS NEEDED Volt Ohm Meter multi meter Misc Hand Tools Wiring Diagram Section G V300 PRO LINCOLN F 17 Retum to Section Retum to Section TOC Retum to Master TOC 8 9 8 Return to Section TOC Retum to Master Y 4 2 8 Retum to Master TROUBLESHOOTING amp REPAIR PROTECTION BOARD OUTPUT TEST cont TEST PROCEDURE 1 TURN POWER SWITCH OFF 5 Slide the through bolts toward the Control Panel until the brackets are disconnected and resistors are loose Be careful when loosening these through bolts as they secure the two resistors As the through bolts are removed carefully place the resis tors and the connected wires to the side 2 Remove sheetmetal wraparound 3 Perform Input Filter Capacitor Discharge procedure detailed in Maintenance section 4 Remove the two through bolts that attach the Power Driver Board bracket to Protection Input Rectifier bracket Each through bolt also supports a resistor FIGURE F 4 REMOVING THROUGH BOLTS amp MOUNTING SCREWS RESISTOR PROTECTION px BOARD ani gt Fi INPUT RECTIFIER PROTECTION BOARD INPUT RECTIFIER MOUNTING SCREW 6 Remove the two screws attaching the Protection 7 Tilt the top of the Protection Board bracket toward Board Input Rectifier bracket to main assembly the Power Panel to gain access to test point
40. Fa ADDITIONAL INFORMATION OSCILLOSCOPE WARNING Do not use oscilloscopes and other pieces of test equipment that are powered by 115 VAC This equipment should not be used with inverter type machines such as Invertec V300 PRO There are high voltages present which are floating off case ground floating ground Connecting the ground lead of a test probe which may be connected to the case of the test equipment to a high voltage potential presents a shock hazard as well as the possibility of damage to the equip ment in question INPUT FILTER CAPACITOR CONDITION ING Capacitor conditioning may be required if the machine will not produce output after power is applied and the following two conditions exist The machine is connected to a supply of 380 v a c or higher and Power has not been applied to the machine for an extended period of time months To condition the input filter capacitors 1 Turn the Power Switch OFF 2 Remove any load and do not load the machine until the capacitor conditioning is completed 3 Turn the Power Switch ON and leave the machine energized for at least 30 minutes 4 Cycle the Power Switch OFF and on again The machine should now work normally If not contin ue with the Troubleshooting Section of this manual MATCHED PARTS The following parts must be replaced in matched sets Output Diodes D1 D2 D3 D4 and D5 Output Diodes D7 D8 D9 D10 and D11 Note On newer codes
41. PER NATIONAL ELECTRIC CODE B BLACK LOCAL REMOTE CONNECT BLACK RED amp WHITE LEADS TO SUPPLY CIRCUIT G GREEN 0 0000 SWITCH TER EUNGTON 2 FOR MACHINES NOT SUPPLIED WITH INPUT CABLE 300 1 R RED 425 cs SWITCH EOR SINGLE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES W WHITE 16 J5 J16 CONNECT TERMINALS U amp W TO SUPPLY CIRCUIT Y YELLOW 5 L t 1 R11 EOR THREE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES 00000 OUTPUT CONTROL CONNECT TERMINALS U V amp W TO SUPPLY CIRCUIT ee eee SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING n 7 n THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM NOT SHOW THE EXACT CONNECTOR CAVITY NUMBERING SEQUENCE 812 COMPONENTS OR CIRCUITRY HAVING COMMON CODE NUMBER THERMAL N C WIRE FEEDERS REQUIRING 24VAC USE PINS N amp 1 VIEWED FROM COMEONEM SIDE OFBOARD OVERLOAD oe INDICATOR N D PLACE A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE ELECTRICAL SYMBOLS PER E1537 CONNECTION SHOWN IS FOR 440 460V OPERATION PIBIGALS OLS 53 V300 1 ONLY N E D1 THRU D5 OUTPUT DIODES 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 CONTROL
42. PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC o Lr 5 METER POLARITY SWITCH The wire feeder polarity switch is located at the rear of the machine The switch provides a work connection for wire feeder voltmeters Place the switch in the posi tion of the electrode polarity indicated by the decal The switch does not change the welding polarity EI OUTPUT REMOT Ge 3 O V 6 gs 2 v9 LINCOLN ELECTRIC INVERTEC V300 PRO OPERATION AUXILIARY POWER A24 VAC 1 amp supply is included for use with the LN 25 wire feeder 24 volts needed for K431 and K432 options This supply is protected by a self resetting current limiter A 42 VAC 5 5 amp supply is included for use with other wire feeders This supply is protected by a 6 amp breaker located on the rear of the machine A 110 115 VAC 2 amp supply is included for use with the LN 7 or LN 9 GMA wire feeders This supply is protected by a 2 5 amp breaker located on the rear of the machine It is NOT available on IEC units All three supplies are not to be loaded simultaneous ly CONSIANI VOLIAGE AND CONSIANI CURREN WELDING POWER SOURCE OUTPUT V300 PRO LI
43. R7 R7 faulty Return to Section TOC Return to Master TOC V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC Lr 5 31 TROUBLESHOOTING amp REPAIR OUTPUT DIODE TEST 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 cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will determine if the Output Diodes are defective MATERIALS NEEDED Volt Ohm Meter multi meter Wiring Diagram Section G V300 PRO LINCOLN F 31 Return to Section Return to Master TOC Return to Section TOC o 9 1 0 iz 212 515 ply Return to Section Return to Master TOC Return to Ma
44. Should the output cur rent exceed 340 to 360 amps an electronic protec tion circuit will reduce the current to approximately 150 amps Lincoln Electric refers to this current reduction as Fold Back The machine will continue to produce this low current until the protection circuit is reset by removing the load Another protection circuit is included to monitor the voltage across input filter capacitors 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 1 Capacitor conditioning is required Required if machine has been off for prolonged periods of time 2 Line surges over 500 VAC 3 Internal Component damage 4 Improper connections THEORY OPERATION ES THERMAL PROTECTION Thermostats protect the machine from excessive operating temperatures Excessive temperatures may be caused by a lack of cooling air or by operat ing the machine beyond it s duty cycle or output rat ing If excessive operating temperature should occur the thermostat will open and prevent output The meter will remain on during this time Thermostats will normally self reset once the machine cools suffi ciently If the thermal shutdown was caused by excessive output or duty cycle and the fan is operating normal ly the Power Switch may be left on and the reset should occur within a
45. TOC Return to Master TOC PRODUCT DESCRIPTION The Invertec V300 PRO is a 300 amp arc welding power source that utilizes single or three phase input power to produce either constant voltage or constant current outputs The V300 PRO is designed for 50 60 Hz supply systems The welding response of the Invertec has been optimized for GMAW SMAW TIG and FCAW processes It is designed to be used with the LN 25 and LN 7 semiautomatic wire feeders A WARNING ELECTRIC SHOCK can kill Have an electrician install and ser vice this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts LOCATION The Invertec has been designed with many features to protect it from harsh environments Even so it is important that simple preventative measures are fol lowed in order to assure long life and reliable opera tion The machine must be located where there is free cir culation 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 CAUTION NOT ATTEMPT POWER THIS UNIT FROM THE AUXILIARY POWER SUPPLY OF AN ENGIN
46. Y TRANSFORMERS 2 8 cb SWITCH i peret 1 BOARD 001 400 001 400 ala BOARD 2 1 ery 5 9 I J154 3 401 403 8 s R W1 8 5 1 2202 a Mel 111 BOTTOM 5 INSIDE I 55 1 046 gt Vv METER 220 FUNCTION SWITCH en x 0 q 214 m 1 wA i P No DRIVER 19 26 ppiMETER BOARD TUNE 27 ZING J9 INPUT RECONNECT 123456 1324 750 UNG J PER i 1 90 xk i 2 4 T olg 120 dh 7 12 T8 EIE 314 815 307 1809 CURRENT 215 CC SOFT 9B molom 12 7 6 808 1310 1 T cls TRANSFORMER 1 L 206 7 o 82 o9 i 2044 42 7 CC CRISP 9 2 SWITCH Slo 98 277777 D 04B 2 FCAW 7 4 5 P 5 5 47 9B i 213 cu 9 gt 402 i WoR Y Y 218 5 d 25 OUTSIDE 9 9 3 2w 001801 pies CW MAX SLOW i 25 2200 8 1 B1 EIE BLOW o RIGHT p 305 LEHE 412 276 Qe OUTPUT i INSIDE 001 400 23A qe 11 8 229 275C CONTROL o 9 p lt REMOTE 227 2 13 2 228 2758 OUTPUT 2 213 lt 12 p 207 275A CONTROL
47. and auxiliary power circuitry of the Invertec Mis ACCESSORIES iik K876 REMOTE CONTROL ADAPTER For operating an LN 25 wire feeder The adapter connects to the 14 pin receptacle of Invertec power sources and to the 6 pin connector of the LN 25 K432 remote control cable K900 1 DC TIG STARTER Solid state GTAW starting unit Rated 300 A 60 V300 PRO LINCOLN Return to Master TOC Return to Master TOC o 2 5 Return to Master TOC Section D 1 TABLE OF CONTENTS MAINTENANCE SECTION Section D 1 Section D Input Filter Capacitor Discharge D 2 Preventive 1 0 3 Overload Thermal Protection nennen nnns 0 3 Printed Circuit Board 0 3 V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC Lr 5 WARNING Failure to follow this capacitor discharge procedure can result in electric shock e INPUT FILTER CAPACI
48. and the specific welding procedure and application involved Worker expo sure level should be checked upon installation and periodi cally thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b AUG 06 Return to Master Return to Master TOC o 5 Return to Master WELDING SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraul
49. dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t
50. determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting Some test boards are available to Service Facilities through the Parts Department NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 1 0 iz 212 515 ply Return to Section Return to Master TOC ni TROUBLESHOOTING amp REPAIR
51. from breathing zone WELDING SPARKS can cause fire or E explosion Keep flammable material away Do not weld on closed containers ARC RAYS can burn eyes and skin Wear eye ear and body protection See additional warning information at front of this operator s manual DUTY CYCLE The Invertec is rated at 300 amps 60 duty cycle for 3 phase inputs based on a 10 minute cycle It is also rated at 250 amps 100 duty cycle CONTROL FUNCTION OPERATION POWER SWITCH Place the lever in the position to energize the machine When the power is on the digital meter will activate and the fan will operate OUTPUT CONTROL This controls the output voltage in the CV modes and output current in the CC modes Control is provided over the entire output range of the power source with 1 turn of the control knob This con trol may be adjusted while under load to change power source output OUTPUT 5 4 7 31 e 18 2 90 a 9 1 40 LOCAL REMOTE SWITCH Place in the LOCAL position to allow output adjustment at the machine Place in the REMOTE position to allow output adjust ment at the wire feeder or with a remote control option package REMOTE DIGITAL METER SWITCH Select either for amps or V for volts to display welding current or voltage on the meter When welding current is not present the meter will dis play the set current for
52. ohm D7 08 09 010 DZ1 DZ2 DZ3 DZ12 274 277 DIODE Zener 1W 10 5 1N4740A DIODE Zener 1W 15 5 1N4744A DIODE Zener 1W 6 2V 5 1N4735A R18 R29 R37 R42 R35 R36 R38 R39 R40 R41 RESISTOR MF RESISTOR MF RESISTOR MF 25W 1 475 ohm 25W 1 47 5 ohm 25W 1 39 2K ohm R1 R3 R5 R24 RESISTOR MF 25W 1 100 ohm 025 026 078 029 p Q1 Q2 010 TRANSISTOR NMF 4PDIP 1 100V NOTE Individual parts listed are not available from Lincoln Electric S 5 RFD110 5 D Q4 Q12 TRANSISTOR N T226 0 5A 40V 9 2N4401 9 Q5 Q7 Q8 Q9 011 TRANSISTOR P T226 0 5A 40V 5 234403 aag 5135 ply NOTE Lincoln Electric assumes no responsibility for resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN machine PRO Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 1 0 iz 212 515 ply Return to Section Return t
53. proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid in the relpacement of the Output Diodes Return to Section TOC Return to Master TOC MATERIALS NEEDED Misc Hand Tools Torque Wrench 60 Wiring Diagram Section G 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 9 1 0 iz 212 515 ply Return to Section Return to Master TOC V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 z Return to Section Return to Master TOC ke 5 60 TROUBLESHOOTING amp REPAIR F 60 OUTPUT DIODE REPLACEMENT PROCEDURE cont FIGURE F 31 RECTIFIER ASSEMBLY WITH PARALLELED DIODES PROCEDURE Paralleled IndividualDiodes 1 2 Turn main power OFF Perform Input Filter Capacitor Discharge dure detailed in Maintenance section Detach and remove both Switch Board assemblies and attached capacitors See Switch Board Removal Replaceme
54. proper operation and proper position for voltage applied Perform Capacitor Balance V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC Lr 5 43 TROUBLESHOOTING amp REPAIR THERMAL PROTECTION AC TRIGGER CIRCUIT 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 pre cautions detailed throughout this manual for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 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 Wiring Diagram Section G V300 PRO LINCOLN F 43 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC
55. replace Output Remote Control Device Test Local Remote Switch S3 with ohmmeter See Wiring Diagram in Section Check continuity of local remote circuit See schematic drawing in Section CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 V300 PRO LINCOLN 7 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ojo O O ci a gt 23 5 5 a Return to Section Return to Master TOC PROBLEMS SYMPTOMS No ouput Main fuses open indicat ing excessive current draw POSSIBLE AREAS OF MISADJUSTMENT S FEEDING PROBLEMS Inspect input leads for possible shorts or grounds or misconnec tions Install new fuses and reapply power If fuses open again go to next col umn of this Guide RECOMMENDED COURSE OF ACTION Inspect interior of machine for phys ical signs of electrical and heat dam age Replace any damaged compo nents after conducting the tests below S ee Input Rectifier test See Switch Board kest See Capacitor Balance tests See Snubber Resistor fest
56. test be rejected for any reason requiring the removal of any mechanical part that could affect the machine s electrical characteristics or if any electrical components are repaired or replaced the machine must be retested NOTE 50 Hz machines may be tested using 60 Hz power INPUT IDLE AMPS AND IDLE WATTS Single Phase Three Phase Volts Hertz Max Amps Max Watts Max Amps Max Watts 220 50 or 60 2 75 425 230 60 3 00 450 Return to Section TOC Return to Master TOC 440 50 or 60 460 60 380 50 or 60 575 60 at rated INPUT V300 PRO 300 1 60 75V MAXIMUM ACCEPTABLE OUTPUT AMPS AT MINIMUM OUTPUT SETTINGS Return to Section TOC Return to Master TOC Output Min Max acceptable all machines CC modes 12A 10V GTAW SOFT CRISP CV modes 20A 19V FCAW GMAW OUTPUT MINIMUM ACCEPTABLE VOLTS AT MAXIMUM OUTPUT SETTINGS WITH FULL LOAD Min Acceptable Max Modes 300 1 V300 PRO 1 phase 200A 220 440V 230 460V 575V 38V 38V 36V 3 phase 300A 36V 38V 36V 9 1 0 iz 212 515 ply AUXILIARY TRANSFORMER 50 Hz 60 Hz TEST POINTS RANGE 18 VAC winding to Power Board J7 pins 5 and 6 Welding 17 20 VAC terminals sw remote 24 VAC winding to Control Board J2 pin 4 to lead 212 23 26 5 VAC STANDARD CODES Test at Amphenol 24 VAC without load measure across pins C and D 22 25 VAC 42 VAC without load measure across pins
57. than None Continue 100 ohms Greater than Replace both Snubber Test 1K ohm Switch Boards 402 404 Less than None Continue 100 ohms Greater than Replace both Snubber Test 1K ohm Switch Boards 402 404 Greater than OK None Continue 1K ohm Less than Shorted Replace both Snubber Test 100 ohms Switch Boards V300 PRO LINCOLN F 28 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC o 5 29 TROUBLESHOOTING amp REPAIR SNUBBER RESISTOR TEST 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 pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will determine if the Snubber Resistors are defective MATERIALS NEEDED Volt Ohm Meter multi meter Misc Hand To
58. the CC modes or the set volt age for the CV modes This set reading is an indication of machine control setting For a more precise process reading read meter during actual welding 1 1 V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC o 9 1 0 iz 212 515 ply Return to Section TOC Return to Master TOC Return to Master TOC MODE SWITCH GTAW Optimized for both scratch start and Hi Freq kit use CC SOFT Best for EXX18 thru EXX28 stick elec trodes CC Crisp Use this mode for stick welding with EXX10 thru EXX14 electrodes Non welding applications such as resistive heating or output tests with resistive loads should be done in this mode with Arc Force Control set to minimum CV FCAW This setting has been optimized for Innershield and Outershield flux cored electrodes CV GMAW Short circuit glob and spray transfer solid wire and gas welding are done in this mode Low end procedures less than 16V may operate better in the FCAW mode SMAW OF SP FLAW SMAW SOFT oc GMAW GTAW OUTPUT TERMINALS SWITCH For processes and equipment that require energized machine terminals stick TIG air carbon arc cutting or hot tip LN 25 set the Output Terminals Switch to ON position Set to the REMOTE OFF position when using LN 25 with K431 K432 or K624 1 options or oth
59. the other terminal 4 Place the local remote switch in the remote posi tion 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 volt age 6 K608 1 adapter is required in LN 9 GMA for LN 9 type control K608 1 is installed in line with P10 See connection diagram S20607 7 K442 1 Pulse Power Filter Board is also required for GMAW but should beremoved for FCAW 8 If K596 is not available see connection diagram S20608 for modification of K196 LN 9 GMA input cable with K867 universal adapter plug These kits are no longer available GENERAL INSTRUCTIONS FOR CONNEC TION OF WIRE FEEDERS TO INVERTEC Wire feeders other than LN 7 and LN 25 may be used provided that the auxiliary power supply capacity of the Invertec is not exceeded K867 universal adapter plug is required See connection diagram 519406 and 519386 for more information Remote Control of Invertec Remote control K857 hand amptrol K963 and foot amptrol K870 require K864 remote control adapter See connection diagram 519309 K954 1 MIG PULSER The MIG Pulser is a hand held pendant type GMAW Pulsing option for the V300 PRO Power Source See the Mig Pulser s IM manual 555 for connection information A 5 K900 1 DC TIG STARTER CONNECTION This versatile new kit was made to mate with the Invertec A cont
60. 0 R128 RESISTOR MF 25W 196 301 C69 C70 C74 P1 plugs into J 1 PLUG HOUSING Molex 8 pin ius RESISTOR ME C4 C23 C75 CAPACITOR CEMO 150P P2 plugs into J 2 PLUG HOUSING Molex 4 pin mee Ee NM OMS OR 100 5 plugs into 3 PLUG HOUSING Molex 2 pin linear C5 CAPACITOR PEMF 0 33 plugs into 4 PLUG HOUSING Molex 12 R39 RESISTOR R131 RESISTOR MF 25W 1 68 1K 200V 10 P5 plugs into J 5 PLUG HOUSING Molex 14 pin R146 RESISTOR MF 25W 1 28 0K C10 C29 C33 CAPACITOR TAEL 1 8 20V 1096 Q1 Q2 TRANSISTOR N T226 0 5A 40V uso piss RARES RESISTORME 25W 19 263K cu CAPACITOR VALEL 20 50V TERMINALS 1 2 TERMINALS Molex mini 75 10 R2 R4 R8 R20 R23 RESISTOR MF 25W 1 10 0K P4 P5 12 CAPACITOR PFC 018 50V 2 Ros p Rs IAS 1 X11 QUAD gen purpose C13 C22 C25 CAPACITOR CEMO 330P R51 R57 R64 R68 R87 224 100V 5 R109 R125 R139 R141 x2 CONTROLLER IC PWM I mode C18 CAPACITOR CEMO 4700P R143 R151 3847 50V 10 R3 R10 R26 R42 R129 RESISTOR MF 25W 196 475K QUAD IC OP AMP high perf 1014 C19 C39 C42 C48 C65 CAPACITOR TAEL 4 7 35V 1096 Ba Re RES STOR NN qup 5 8 10 SWITCH 5 analog quad pus CAPACITOR 47P 300V R7 R30 7 R71 RESISTOR MF 25W 196 47 5K 5 dia Psion SIME 22W 207 X7 INVERTER IC CMOS Schmitt h C26 C41 C46 C59 C73 CAPACITOR CEMO 0 1 50V 10 2 RE
61. 2 143 amp 213 B W 50 mV AT 400 AMP LINEAR FEEDBACK 3 805 amp 2J1 229 275 OUTPUT FEEDBACK 13 VDC NO LOAD 4 7J1 amp 1J1 303 275D 8 VDC FULL LOAD 13 V DC amp 304 2750 8 V DC FULL LOAD 142 amp 32 N 4 2 81144 210 223 fie eave 21419 017504 1 02 2750 15V DC FULL LOAD 15V DC fasai H FULL LOAD a 268746 305 301 SW BOARDS R W lt 75 V DC NO LOAD 2 11 amp 4J11 CB2 HAMPAS oP 32A 9 0 32 4132 poms 212 lt 1 31 VAC 5 42 lt 42 42 212 4 ler4i 2238 4 Def 4 1 22 eu TRIGGER 212C Me 81 I Leg 21 He 21 GND GND WIRE FEEDER 285 21 229 502 503 503A V ue 56 WIRE FEEDER THERMAL WELDING OVERLOAD POLARITY INDICATOR SWITCH V300 ONLY It may not be accurate for all machines covered by this manual 2118 SPARE 75 lt RE REMOTE MIN OUTPUT 76 A Fed 76 1 CONTROL REMOTE CONTROL RECEPTACLE DAD 5 20 94 V300 PRO SCH G 10 PRO Return to Section Return to Master TOC Return to Section TOC ojo E gt 23 e 5 5 ply ajo Return to Section TOC Return to Master TOC Return to Master TOC G 11 ELECTRICAL DIAGRAMS G 11 SCHEMATIC DRIVER PC BOARD S20216 LINCOLN
62. 28 100 Duty Cycle 30 100 Duty Cycle 26 5 Return to Section TOC Return to Master TOC OUTPUT THREE PHASE SINGLE PHASE Welding Welding Constant Open Auxiliary Current Range Current Range Circuit Voltage Power 5 300 Amps 5 200 Amps 60 70 VDC 42 VAC 5 5 Amps 24 VAC 1 Amp 115 VAC 2 Amps Not on all codes Return to Section TOC Return to Master TOC 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 RECOMMENDED INPUT WIRE AND FUSE SIZES THREE PHASE SINGLE PHASE Type 75 C Type 75 C ojo E a 3 Ec 5 5 ply a Return to Section Return to Master TOC 208 60 230 60 460 60 575 60 Fuse Superlag or Breaker Size Input Ampere Rating on Nameplate Type 75 C Copper Wire in Conduit AWG IEC Sizes 6 16mm 8 10mm 10 6mm 10 6mm Copper Ground Wire in Conduit AWG IEC Input Voltage Frequency 208 60 230 60 460 60 Fuse Superlag or Breaker Size Input Ampere Rating on Nameplate Type 75 C Copper Wire in Conduit AWG IEC Sizes Copper Ground Wire in Conduit AWG IEC Sizes V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC e st olg iz 212 515 ply Return to Section Return to Master
63. B 223B 223A REMOTE l A S4 OUTPUT TERMINAL SWITCH ELECTRICAL DIAGRAMS S7 RECONNECT SWITCH 9B 80 12 Cu 9B olo 12A 2200 fe 25W 450V piat SLOW BLOW 1 311 2 39 275F 3 x 313 4 3 306 PROTECTION 1 32 314 BOARD 2 3 316 4 gt 315 5 3 6 35 317 Ti AUXILIARY TRANSFORMER 275A 2758 2750 276 228 204 2040 214 2758 225 226 227 275C 1 5 GND DPC DPT IN NIS FOCAL jn S3 OUTPUT LOCAL REMOTE CONTROL SWITCH NOTE This diagram is for reference only T2 MAIN TRANSFORMER 4 10 F OUTSIDE 6 F CURRENT TRANSFORME 1 0 0 00180 1 yen 1 215 213 218 204B 204A 20611 15 GMAW CC Ee CV FCAW F V A CC CRISP 55 52 FUNCTION SWITCH SWITCH 42 J8 49 410 412 J11 J14 J18 J15 J16 J1 J7 0000000 ooooooo gt CONNECTOR CAVITY NUMBERING SEQUENCE VIEWED FROM COMPONENT SIDE OF BOARD ELECTRICAL SYMBOLS PER E1537 ARC FAN CHOKE THERMOSTAT THERMOSTAT 212C 212A 42 COLOR CODE B BLACK R RED G GREEN W WHITE YELLOW SOLDERED CONNECTION O QUICK CONNECTION _ SINGLE LINE MULTI LINES zu 5 va WIRE T LOCATION NUMBERS VOLTAGE R11 175 176 0 4 5VDC 0 V AT 0 AMP
64. CAL CODES W WHITE OUTPUT CONTROL CONNECT TERMINALS U amp W TO SUPPLY CIRCUIT Y YELLOW FOR THREE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES CONNECTOR CAVITY NUMBERING SEQUENCE B1 CONNECT TERMINALS U V amp W TO SUPPLY CIRCUIT VIEWED FROM COMPONENT SIDE OF BOARD THERMAL ARC FORCE INDUCTANCE N B SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING CONTROL THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER ELECTRICAL SYMBOLS PER E1537 300 ONLY WIRE FEEDERS REQUIRING 24VAC USE PINS amp I 01 THRU D5 OUTPUT DIODES ARE A MATCHED SET D7 THRU 011 OUTPUT DIODES ARE A MATCHED SET CONTROL PANEL 61 62 C14 C15 CAPACITORS ARE A MATCHED SET LAYOUT CLEVELAND OHIO U S A 9301 NOTE This diagram is for reference only may not be accurate for machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN ELECTRIC V300 PRO e ELECTRICAL DIAGRAMS bul WIRING DIAGRAM ENTIRE MACHINE CODE 10130 L9567 o 9 o o 2 a Return to Master TOC olo Olo 217 E 3 pm 1 Tres 1 1
65. E WELDER Special protection circuits may operate causing loss of output The supply from engine welders often has exces sive voltage peaks because the voltage waveform is usually triangular shaped instead of sinusoidal If voltage peaks from the engine welder are too high 380 230v setting the input circuits of this machine protecting the filter capacitors FETS and other components from damage will not be ener gized INSTALLATION pe ELECTRICAL INSTALLATION 1 The Invertec should be connected only by a quali fied electrician Installation should be made in accordance with the U S National Electrical Code all local codes and the information detailed below 2 When received from the factory multiple voltage 208 230 460 machines are internally connected for 460 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 Open the access panel on the right side of the machine b For 208 or 230 Position the large switch to 200 230 For 460 Position the large switch to 380 460 c Move the lead to the appropriate terminal CAUTION DO NOT CHANGE SWITCH POSITION WITH INPUT POWER APPLIED MAJOR DAMAGE WILL RESULT INPUT VOLTAGE SETUP RECONNECT PROCEDURE WARNING Disconn
66. ENERAL INFDRMATIDN ELECTRICAL 5 5 PER E1537 CAPACITORS MFD 1 022 50 UNLESS OTHERA SE SPECIFIEDI RESISTORS Dhms 1 48 UNLESS DIHERW SE SPECIFIED LABELS DIODES 4001 UNLESS OTHERWISE SPECIFIED Single Phase SUPPLY VOLTAGE NET PER SUPPLY SOURCE POINT 48 gt gt NOTES SINCE COMPONENTS OR CIRCUITRY A PRINTED CIRCUIT BOARD NAY CHANGE 5 CONNECTION WITHOUT AFFECTING THE INTERCHANGEABILITY OF A CDMPLETE BOARD THIS DIAGRAM NAY FRAME CONECTION NOT SHON THE EXACT COMPONENTS DR CIRCUCTRY DF CONTROLS HAVING A CODE TH T NUMBER EARTH GROUND CONNECTION V300 PROTECTION 12 10 93 16097 Return to Section Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 PRO Return to Section Return to Section TOC Return to Master TOC o ma 2 2 Return to Section Return to Master TOC Return to Master TOC o 2 0 5 23 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY PROTECTION L7915 2 PROTECTION 33
67. HASE INPUT CONNEC GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE OUTPUT TERMINAL SWITCH WRAP RED LEAD WITH TAPE TO PROVIDE 600V INSULATION 3 METER FUNCTION FOR THREE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE 42 48 J9 J10 J12 LOCAL REMOTE SWITCH PED CONNECT BLACK amp WHITE LEADS TO SUPPLY CIRCUIT J Jit J14 418 415 416 J4 J7 2 FOR MACHINES NOT SUPPLIED WITH INPUT CABLE V300 1 1 12 1 3 1 4 R11 EOR SINGLE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES CONNECT TERMINALS U amp W SUPPLY CIRCUIT OUTPUT CONTROL FOR THREE PHASE INPUT ACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES VALE s r ECT TE UPPLY CIRCUIT J4 J5 R12 N B SINCE COMPONE ITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING 1 8 1 1 7 FORCE INDUCTANCE THE INTERCHANGEABIL PLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT 990000 0000000 OVERLOAD CONTROL COMPONENTS OR CIRCU NG A COMMON CODE NUMBER INDICATOR WIRE FEEDERS REQUIRING SE PINS N amp I COLOR CODE n 7 p v300 1 ONLY D1 THRU 05 OUTPUT DIOD E A MATCHED SET B RSEN CONNECTOR CAVITY NUMBERING SEQUENCE 07 THRU 011 OUTPUT DIODES ARE A MATCHED SET R RED VIEWED FROM COMPONENT SIDE OF BOARD C1 62 63 C4 CAPACITORS ARE A MATCHED SET W WHITE CONTROL PANEL Y YELLOW ELECTRICAL SYMBOLS PER E1537 LAYOUT 18841 Y CLEVE
68. LAND OHIO U S A NOTE This diagram is for reference only may not be accurate for machines covered by this manual wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN je ELECTRIC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 ra Return to Section TOC Return to Master TOC o Lr 5 4 4 G ELECTRICAL DIAGRAMS WIRING DIAGRAM ENTIRE MACHINE CODE 10034 L9299 311 756 313 I IY o 4 ARC FS PT Ge 12 3 4 14 53 53 TRANSFORMER IPROTECTION 271 314 T BOARD 2 OUTSIDE 7 ARC 153 9 316 S 4 1 3 1 BOTTOM Loc INSIDE 204 E INPUT 220 FUNCTION S1 RECTIFIER 1 SWITCH 013 214 5 FF ON 275B GND 1 z 225 1789 I 226 4 ppiMETER 1 THERMOSTAT 227 IN E INPUT Jr P sete per EJ I I ER TER 2750 JUN N A j I 8 0 Y 203 T3 g 8 CURRENT i EE a CC SOFT T TRANSFORMER 2011 2252 CCCRISP MODE 2 2048 6 4 SWITCH 218 4 2 BOTTOM 218 5 CV GMAW OUTSIDE 77B i 276 10 OUTPUT INSIDE no
69. LEFT SWITCH BOARD O o 5 E FIGURE E 2 INPUT CIRCUITS 2 2 PIU o olg amp 0 9 POWER SWITCH 9 SECTIONS MAIN 20 2 TRANSFORMER CHOKE o FET MODULES 1 DIODE lt FET MODULES CURRENT TRANSFORMER 10 OR DETETCTION 5 PRE CHARGE LINE INPUT 1 SWITCH RECTIFIER 154 I CONTROL 1 5 DIODES ee X 1 1 1 or ore 1 PROTECTION 5 2 oto Ac2 N BOARD WFEEDBACK 1 3 oto N a Ln ICR2 E o EE c O o cri ALEAD LJ 1 Ln E PRE CHARGE og t5 8 RIGHT SWITCH BOARD 9 3 8 TRANSFORMER 2ND STEP PWM EES 5 DIODES o 4 dl 9 9 POWERBOARD T EA c 14 PIN SIUS FET MODULES 4 mi Ld lt o CHOKE TO CHOKE ojo WIREFEEDER f MODE ro rr VOLTAGE FEEDBACK 1 1ST STEP PWM VOLTAGE CURRENT FEEDBACK PROTECTION 15VDC CONTROL BOARD FUNCTION VOLTAGE 24VAC THER
70. MOSTATS GUN TRIGGERING INPUT LINE VOLTAGE amp AUXILIARY TRANSFORMER The V300 PRO can be connected for a variety of three o e st 9 1 0 iz 212 515 ply Return to Section TOC Return to Master TOC phase or single phase input voltages Power is applied through the Line Switch to the Input Rectifier and the Auxiliary Transformer The Reconnect Panel has switches to select high or low operating voltage The A lead must then be set for the proper input voltage It is important to set the switches and A lead to the proper positions before applying input power Changing the switch position with the power applied will result in major damage to the machine The auxiliary transformer provides 18v a c and 24v a c supplies to the Control and Power Boards It also provides 115v a c 42v a c and 24v a c supplies to the wirefeeder amphenol CE machines do not have 115v a c supply The Power Board provides a 15v d c supply to the Control Board and a 24v d c supply to the Driver Board to operate the Pre charge Relays NOTE Unshaded areas of block logic diagram are the subject of discussion V300 PRO LINCOLN THEORY OPERATION oe LEFT SWITCH BOARD FET MODULES ojo O o 5 FIGURE E 3 PRECHARGE amp PROTECTION CIRCUITS 2 2 ols 9 2 POWER SWITCH SECTIONS 2 8 20 2
71. Misc Hand Tools Small jumper or clip lead Wiring Diagram Section G NOTE BOTH SWITCH BOARDS IN A MACHINE MUST HAVE IDENTICAL PART NUMBERS THEY SHOULD ALWAYS BE CHANGED IN PAIRS EXCEPT FOR L10958 BOARDS WHICH MAY BE REPLACED INDIVIDUALLY O10 O10 E 2 2 818 e 5 5 ply ajo Return to Section TOC Return to Master TOC V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC o ke 5 58 TROUBLESHOOTING amp REPAIR F 58 TEST AFTER SWITCH BOARD OR CAPACITOR REPLACEMENT cont TEST PROCEDURE 1 2 5 Turn main power OFF Perform Input Filter Capacitor Dis charge proce dure detailed in Mainten ance section Connect a shorting conductor across terminals 14 and 53 of Protection Board Set an ohmmeter to X1000 range and place probes on terminals 9 and 12 of one Switch Board The meter will show the Capacitors charging up and may take a minute or so to stabilize The final meter reading should not exceed 8600 ohms 8 6 on the scale Test the other Switch Board the same way NOTE Repeat the Input Filter Capacitor Dis charge procedure 6 T Remove the shorting conductor set up in step 3 Install 5 amp fuses in the i
72. NCOLN Section 1 TABLE OF CONTENTS Section C 1 ACCESSORIES SECTION sioan a AAA souudcauusaaweuausesacsuadseadadbacsasecuusdsussavesuaus Section Return to Master TOC amp 8 aaa 2 Return to Master o 2 5 Return to Master V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 1 0 iz 212 515 ply Return to Section Return to Master TOC OPTIONS ACCESSORIES CABLE PLUGS Cable Plug Kit for 1 0 2 0 cable K852 70 attaches to welding cable to provide quick disconnect from machine Cable Plug Kit for 2 0 3 0 cable K852 95 NOTE Two K852 70 plugs are included with the V300 I K864 REMOTE CONTROL ADAPTER Plugs into the 14 pin receptacle on the rear panel of the Invertec Adapter splits remote control circuitry to a 6 pin receptacle and to a 14 pin receptacle Adapter per mits remote output control of Invertec by means of K857 Remote Control K812 Hand Amptrol K870 Foot Amptrol Allows remote while using LN 7 K480 7 control cable K867 UNIVERSAL ADAPTER PLUG Consisting of a 14 pin plug connected to labeled wires the adapter allows user connection of any suitable accessory or wire feeder to the remote control contac tor
73. OOTING amp REPAIR read PROTECTION BOARD OUTPUT TEST cont FIGURE F 6 INSERTING PROBES L7915 PROTECTION Return to Section TOC Return to Master TOC olo 55 5 8 8 818 306 tr ca 275F 311 TEST PROCEDURE 12 Open S4 and Turn Power OFF olo o 9 1 0 iz 212 515 ply 13 Move probes to test between leads 306 275 See Figure F 6 14 Turn Power ON and close S4 If voltage is less than 1 VDC Protection Board is OK If voltage is greater than 14 VDC Protection Board may be defective See Trigger Circuit Step11 Return to Section TOC Return to Master TOC V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC o 5 21 TROUBLESHOOTING amp REPAIR F 21 CAPACITOR BALANCE TEST 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 pre cautions detaile
74. OVIDE 600 INSULATION Bi 5 FOR THREE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE CONNECT BEACK RED amp WHITE LEADS TO SUPPLY CIRCUIT J2 J8 J9 J10 J12 LOCAL REMOTE SWITCH METER FUNG HON SWITOH 2 FOR MACHINES NOT SUPPLIED WITH INPUT CABLE 300 1 J3 411 J14 J13 415 416 Jt J7 12 1 3 1 2 4 QR SINGLE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES M 22 4 FOR THREE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES CONNECT TERMINALS U1 amp W TO SUPPLY CIRCUIT Ta 455 Te SINCE COMPONENTS OR CIRCUITRY A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING 46 J4 J5 INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT THERMAL ARG EORCE INDUGTANCE CONTROL COMPONENTS OR CIRCUITRY HAVING COMMON CODE NUMBER 000000 000000 OVERLOAD e WIRE FEEDERS REQUIRING 24VAC USE PINS N amp I 329229 2009900 N D PLACE A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE e 1 l V300 cjs CONNECTION SHOWN IS FOR 440 460V OPERATION COLOR CODE CONNECTOR CAVITY NUMBERING SEQUENCE Olo D1 THRU 05 OUTPUT DIODES MATCHED SET B BLACK VIEWED FROM COMPONENT SIDE OF BOARD 5 D7 THRU 011 OUTPUT DIODES ARE A MATCHED SET G GREEN 25 N F R1 R9 BLEEDER RESISTORS ARE A MATCHED SET ELECTRICAL
75. PANEL CONNECTION SHOWN IS FOR 380 460V OPERATION LAYOUT 12 2 93L CLEVELAND OHIO U S A 19299 NOTE This diagram is for reference only It may not be accurate for machines covered this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN je ELECTRIC V300 PRO Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E E iz 212 5 o Return to Section Return to Master TOC G 5 G 5 ELECTRICAL DIAGRAMS WIRING DIAGRAM ENTIRE MACHINE CODE 10035 L9301 1 ARC T2 IPROTECTION MAIN BOARD TRANSFORMER 95 204C 55 V METER 4 220 gt FUNCTION INPUT SWITCH RECTIFIER S 214 5 1 275 GND 225 4 DPC 226 4 227 IN 2750 THERMOSTAT 224 5 G0 208 g CURRENT CC SOFT FORME 206 52 PANSFORNERH 204A 3 2 Ir CC CRISP 3 SWITCH oo 204 4 2 BOTTOM 5 220 213 CV GMAW 2044 44 10 218 76 4 5 EM ow es T INSIDE 2114 46 12 2 OUTPUT I 2234 4 11 8 29 229 CONTROL Jp T It 227 k 2 13 228 212 4 9 12 207 214 6 7 208 225 a
76. Q CONTROL 8 8 38 275 275 1 LOCAL 83 OUTPUT 2259 REMOTE LOCAL REMOTE CONTROL 2048 FAN 8047 SWITCH 76 gt gt 76 MOTOR 77 E gt 77B CB2 4 207 CW MAX 110 115 f 31 9 43 212 4 2 807 8 1 power 2 Joos 5 ARC FORCE VAC A 309 03 Boarn LE 9 4 208 W INDUCTANCE AEEA g Ie 2 5 505 801 4 5 CONTROL 42 Faia 212 4 2 N D 310 4 0 3 303 302 TES 1 VAC 142 K gt of CB1 501 5 8 304 6 46 305 4 3 212 COUR 903 ya 4 ON TRIGGER 4 4 2238 Ei i caps 804 8 2 5 275 L OUTPUT e mimi 223 21 REMOTE z 9 9 2128 CONTROL 223A SWITCH 81 M p 10 39p 2 12D BOARD ER He 2 86 AUXILIARY 52 4 21 TRANSFORMER THERMAL GND gt B gt GND 9 WIRE FEEDER de VS cc OVERLOAD gt N 211B 285 WELDING Y INDICATOR POLARITY V300 1 ONLY 229 SWITCH 503 WIRE REMOTE 508A FEEDER CONTROL A RECEPTACLE NOTES 54 1 FOR MACHINES SUPPLIED WITH INPUT CABLE V300 PRO OUTPUT TERMINAL FOR SINGLE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE 12 48 J9 J10 J12 SWITCH CONNECT BLACK amp WHITE LEADS TO SUPPLY CIRCUIT J3 J11 J14 J18 J15 J1 J7 WRAP RED LEAD WITH TAPE TO PROVIDE 600V INSULATION COLOR CODE 12 1 3 83 EOR THREE PHASE INPUT CONNECT GREEN LEAD TO GROUND
77. R16 R23 19400 2212 22 1K 1 4W gle m 998 fes R18 R29 R37 R42 4 519400 4750 475 1 4W 8 R35 R36 819400 47 5 47 5 1 4W O R38 R39 R40 R41 4 S19400 3922 39 2 1 4W 1 CJ 1 9 1 3 1 8 Bla 2 15 amp 10958 1 SWITCH La EIS 0 mes 11 01 2002 0 8 50 L10958 1 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN machine ELECTRIC V300 PRO on ELECTRICAL DIAGRAMS oY SCHEMATIC CONTROL PC BOARD G2525 TRIGGER Return to Section TOC Return to Master TOC OPEN CIRCUIT DETECTOR PRIMARY CURRENT CONTROL AMPLIFIER DRIVER BOARD Return to Section TOC Retu
78. RE F 28 LOOSENING THE CLAMP RING SET SCREW O o 5 5 PEN gt elg e 5 2 Return to Section Return to Master TOC V300 PRO LINCOLN TROUBLESHOOTING amp REPAIR F1 CAPACITOR REMOVAL AND REPLACEMENT cont FIGURE F 29 COMPLETE SWITCH BOARD ASSEMBLY READY FOR INSTALLATION Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC NOTE Proper capacitor polarity must be noted when attaching the capacitor to the Switch Board assembly 6 Install the new Capacitor and tighten the two bolts to a torque of 55 inch pounds 6 Nm Hand tight en first then tighten the bolts in increments of 10 inch pounds alternating between the two See Figure 27 7 Tighten the set screw of the clamping ring 8 Perform the Test After Repair of Switch Boards and or Capacitors O o 5 5 9 9 gt 212 gt 5 2 oO Return to Section Return to Master TOC V300 PRO LINCOLN peus TROUBLESHOOTING amp REPAIR Pon SWITCH BOARD REMOVAL AND REPLACEMENT PROCEDURE Return to Section TOC Return to Master TOC 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 sa
79. RETURN TO MAIN MENU SVM105 B April 2007 INVERTEC V300 PRO For use with machines having Code Number 9825 THRU 10450 Return to Master TOC View Safety Info SUTRA Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ i 2 ING THIS MANUAL AND THE E 11 ES DATUR SAFETY PRECAUTIONS CON BSS pos TAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info 9 gt 2 2 gt O O i o 9 gt SERVICE MANUAL NCOLN Copyright 2007 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com View Safety Info Return to Master TOC SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS A 9 Diesel engine exhaust and some of its constituents The engine exhaust from this product contains gt known to the State of California to cause can chemicals known to the State of California to cause 9 cer birth defect
80. S GLOVES V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC o Fle PEN 815 5 43 Return to Section Return to Master TOC Return to Master TOC PREVENTIVE MAINTENANCE 1 Perform the following preventive maintenance procedures at least once every six months It is good practice to keep a preventive maintenance record a record tag attached to the machine works best 2 Remove the machine wrap around cover and per form the input filter capacitor discharge procedure detail at the beginning of this chapter 3 Clean the inside of the machine with a low pres sure airstream Be sure to clean the following components thoroughly Figure D 2 for loca tion of these components Power Switch Driver Protection and Control printed circuit boards Power Switch Main Transformer Input Rectifier Heat Sink Fins Input Filter Capacitors Output Terminals 4 Examine capacitors for leakage or oozing Replace if needed 5 Examine wrap around cover for dents or break age Repair as needed Cover must be kept in good condition to assure high voltage parts are protected and correct spacings are maintained 6 Check electrical ground continuity Using an ohm meter measure resistance between either output stud and an unpainted surface of the machine case See Figure D 2 for locations Mete
81. S TOR ea haze is ex 4584 RA O oiii R13 R34 R40 R48 R50 RESISTOR MF 25W 196 100K 31 40 CAPACITOR TAEL 0 33 50V 10 NOTE Individual parts listed are not available from Lincoln Electric C34 C37 CAPACITOR CEMO 2700P oO ae R14 TRIMMER ST 50W 10 5K linear 4288 CAPACITOR TAGE 2 Sav 10 R15 R100 R103 R104 THERMISTOR PT 56 ohms 9 oma CAPACITOR TAEL 39 20V 10 R16 R19 R28 R41 R113 RESISTOR MF 25W 1 332K ce CAPACITOR TAEL 10 R17 THERMISTOR PTC 08 0 19 ohms D1 D2 D3 D7 DIODE AXLDS 1A 400V FR 1 85A 1N4936 R18 RESISTOR CC 2W 5 680 D4 D5 D8 D9 D10 D11 DIODE AXLDS 1A 400V R21 R73 R102 R119 RESISTOR MF 25W 196 2 67K D12 D13 D14 D15 R144 D17 D18 D20 D21 R22 R70 R126 R132 RESISTOR MF 25W 1 26 7K D22 D25 D26 D27 D28 R137 R140 D29 D30 D31 D33 D34 R24 R130 RESISTOR MF 25W 1 56 2K D35 D36 D37 D38 D39 R27 R37 R53 R55 RESISTOR MF 25W 1 33 2K D40 D41 D42 D45 D46 R58 R92 R115 R136 247 048 050 051 052 R29 RESISTOR MF 25W 1 392K D16 D19 D24 DIODE AXLDS 0 15A 75V 1N914 R31 R79 R88 R90 R93 RESISTOR MF 25W 1 4 75K D23 DIODE AXLDS 1A 30V Schottky R97 99 R121 R135 21 073 078 DIODE Zener 0 5W 3 0 5 R33 RESISTOR MF 25W 1 3 32K DZ2 DZ7 DIODE Zener 1W 10V 5 RESISTOR CC INY R36 R66 R85 R91 R110 RESISTOR MF 25W 1 150K R39 R52 R72 R86 RESISTOR MF
82. SISTOR UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED LESS OTHERWISE SPECIFIED 40V 2N4403 Ohms y 402 104 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS RESISTORS 4 TRANSFORMER Or PRIMARY Return to Section TOC Return to Master TOC 2 BYT30P600 INPUT T FILTER T CAPACITOR 0 06 1 4936 0 600 Qt 600mA 40V 2N4403 8 TRANSFORMER PRIMARY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM 2N4403 09 600 40V Di 02 03 04 05 di N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE O10 O10 E a 23 e 5 5 ply ajo SNUBBER RESISTOR BYT12P600 NEGATIVE INPUT Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 300 PRO G 16 ELECTRICAL DIAGRAMS G 16 PC BOARD ASSEMBLY SWITCH L8441 B10 B7 B5 Be B2 Bl Return to Master TOC o 5 5 2 E E 011 CN
83. SYMBOLS E1537 CONTROL PANEL o N G C1 C2 CAPACITORS ARE A MATCHED SET E Y YELLOW LAYOUT els N H PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE cle CONNECTION SHOWN IS FOR 380 460V OPERATION 9 11 02 gt 815 5 9 18657 NOTE This diagram is for reference only It may not be accurate for machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine PRO LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 512 212 5 ply oO Return to Section Return to Master TOC WIRING DIAGRAM ENTIRE MACHINE CODE 9934 L8841 3112756813306 3E tu 7 _ T2 IPROTECTION MAIN BOARD TRANSFORMERQS J15 001 400 faux 001 400 oursioe 3 ys S I 2 alc 5 85 i 1 S 2040 i 220 FUNCTION i SWITCH 9D CR1 NO 214 1 9A CR2 NO 1 128 4 tio de ono DRIVER 210 i CHOKE 226 4 pp1METER n 1 227 IN INPUT a FER 1 7 i T3 4 GTAW CURRENT i CC SOFT TRANSFORMER MODE 5 s il CV FCAW SWITCH F 220 BOTTOM
84. T S COURSE OF ACTION FEEDING PROBLEMS Meter reads low voltage 1 2 VDC Local Remote Switch must be in 1 See Output Diodes jest and output is extremely low or no LOCAL position unless Remote output Control device is attached to remote 2 See Capacitor Balance tests receptacle See Switch Board test See Power Board test See Control Board test Return to Section TOC Return to Master TOC Poor welding weld settings drift or Check welding procedures and weld 1 CheckMode Switch S2 fordam output power is low cable connections age and continuity Check with machine on local con trol Check for continuity between Mode Switch S2 and Control Check input voltages and input volt Board See Wiring Diagram in age reconnect procedures See Section G installation section pf this manual Check for loose or faulty con nections in heavy current carry ing leads ie choke shunt output bridge and output studs See wiring diagram in Section G Overcurrent Protection urrent Trigger Circuit See Control Board test Return to Section TOC Return to Master TOC O10 O10 a gt 3 5 5 a Welding hot Actual weld Check condition of the shunt See Step 7 of the rent is considerably higher than dis leads to the Control Board Protection Current Trigger test play indicates If shunt and leads check OK possi ble defective Contr
85. TOR DISCHARGE PROCEDURE 1 Turn off input power or disconnect input power lines 2 Remove 14 5 16 hex head screws from side and top of machine 6 screws on each side and 2 Screws on top and remove wrap around machine cover 3 Be careful not to make contact with the capacitor terminals that are located in the center of the Switch Boards 4 Obtain a high resistance and high wattage resis tor 25 1000 ohms and 25 watts minimum This resistor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCE DURE MAINTENANCE ais Locate the two capacitor terminals large hex head capscrews shown in Figure D 1 Use electrically insulated gloves and insulated pli ers 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 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 Check voltage across terminals of all capacitors with a DC voltmeter Polarity of capacitor termi nals is marked on PC board above terminals Voltage should be zero If any voltage remains repeat this capacitor discharge procedure FIGURE D 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS CAPACITOR TERMINALS SWITCH BOARD POWER RESISTOR INSULATED PLIER
86. TOR MF 25W 1 1 82K ohm RESISTOR MF 25W 1 150K ohm RESISTOR MF 25W 1 56 2K ohm POTENTIOMETER Cermet trmr 25W 1 5K ohm RESISTOR MF 25W 1 100K ohm RESISTOR MF 25W 1 475 ohm RESISTOR MF 25W 1 10K ohm RESISTOR MF 25W 1 3 32K ohm RESISTOR MF 25W 1 15K ohm RESISTOR MF 25W 1 332K ohm RESISTOR MF 25W 1 276K ohm RESISTOR MF 25W 1 332 ohm TERMINALS Molex mini QUAD OP AMP VOLTAGE REGULATOR linear 7805 5VDC 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 pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine LINCOLN PRO Return to Section Return to Master TOC Return to Section TOC Return to Master TOC G 24 ELECTRICAL DIAGRAMS SCHEMATIC POWER PC BOARD M16018 GND TS C442 FIA N 5 B f n 18 FROM AUXILIARY TRANSFORMER S 414
87. Turn the Input Power Switch ON described in the Maintenance Section 3 Remove the four screws that hold the Control Panel to the frame 4 Move the Control Panel forward and to the left so that there is access to the Control PC Board Be careful not to stress any of the connections to the Control Panel FIGURE F 2 REMOVING CONTROL PANEL CONTROL j Imm BOARD CONTROL PANEL 300 LINCOLN Eus TROUBLESHOOTING amp REPAIR OUTPUT PILOT CIRCUIT TEST cont FIGURE F 3 CONTROL BOARD TEST POINTS Return to Section TOC Return to Master TOC ojo 513 dE 210 223A 15 2 302 ala ec CONTROL 41 J2 J4 J3 2750 S 7 Measure voltage from Lead 210 J2 Pin 4 to 8 Measure voltage from lead 302 J1 Pin 6 to Lead Lead 223A J4 Pin 11 2750 41 Pin1 2 5 i a If voltage is 24v a c thermostats transfor a If voltage is 15v d c Transformer T1 and 15 9 2 mer 1 and switch 54 are on to volt supply are OK Go to Protection Board B Step 8 Output test 5 5 b voltage is Ov a c test the following com b If voltage is Ov d c check Transformer T1 uc ponents individually and then go to Power Board est Auxiliary Transformer T1 Fan Thermostat Choke Thermostat Output Termi
88. UU om aM xcu dui andi PE prid ni T HIWI x an i ENT gd 2t Ib 17 Lan Wo ates a UN Qe 14725 NI 5 2 p Pac 1 AM E 2 Th 1 5 uix gue TRIGGER dM elke Id t a TP I7 bau EL x usos s HAM MT ye 5 SIH u pe 2 AC CHIL oe Fzkuch NN NEL Mur She sr o Ce REID 148 IIET cmn ss ion Eu 2 1 2 Ha L ER WAS Uhia wT E YII MA ts 1990 H LEE 2244107 GREEN LESS TS 23042 MAIJAA JELY TzRhlna za we T EJSPLY aA NE ni 4 2 WIS E h a 0 5291 as EET anon _ TN LEA IE YI 01 RA EO LLS EIS S592 ASR a 1 za M 2 11 2 Tis riro ES 552 ma Ha rink 3 3 E WIT 742070 a EFE 4 uz 5 d OE LGA 2008 mE Mr HD ea c 1 n A SEE IRCNET msg b 5 DH 40147 PARE FES 42 ELECTO aL CCC ER 5 EN i RAS C Tuna Ho
89. WER SWITCH SECTIONS 20KHZ TRANSFORMER choke RECTIFIER HEATSINK LEFT SWITCH BOARD FET MODULES 4 65 5 5 6 6 5 e 1 1DIODE Return to Section Return to Master TOC FET MODULES 1 OR 3 DETETCTION H5 Von ic PRE CHARGE BN LINE INPUT DRIVER 1 E SWITCH RECTIFIER BOARD E CONTROL BDIODES Ej nis lt ent e BOARD H 1 T re PROTECTION H 2 0 170 4 1 AC2 H N BOARD YY FEEDBACK 3 02 N 3 H 3A 1222 i S ALEAD 1 een 1 1 1 i 24VDC 1 rir eqs RIGHT SWITCH BOARD 1 i i 2 gt TRANSFORMER 2ND STEP PWM 5 DIODES FET MODULES 1 v 4 i 916 i 8 gt POWERBOARD 5 p MO olo FET MODULES we E E WIREFEEDER d o LOCAL POT VOLTAGE FEEDBACK a REMore METER 1ST STEP PWM VOLTAGE CURRENT FEEDBACK PROTECTION 15VDC CONTROL BOARD FUNCTION VOLTAGE
90. YNAMIC CAPACITOR TEST 3 Record VDC measured for each Switch Board and TEST PROCEDURE determine the difference in VDC 1 Move Output Terminal Switch S4 to ON position NOTE The following measurements should result based on VAC input Adjust the output control to the minimum setting Place the mode control at the SMAW soft position o Im 2 5 2 3 8 Return to Master TABLE F 1 EXPECTED VOLTAGE READINGS the Switch Boards then capacior balance is OK a If less than 15 VDC difference is measured This indicates that Capacitors C1 and C2 between the Switch Boards test is OK Resistors R1 and R9 are OK VDC at Switch 2 Test VDC across terminals 9 and 12 of one Switch Board Terminals Board see Fig F 7 Repeat the test for the other should be Switch Board See Table F 1 for expected voltages If VAC Input is approximately 575VAC 407 VDC NOTE For 575 VAC ONLY compare voltage S 460 VAC 325 VDC across 9A and 13 and 13 and 12A then 9B and 15 Fie 440 VAC 311 VDC and 15 and 12B 5 5 415 293 9 E 380 VAC 269 VDC 3 Record VDC measured for each Switch Board and p 9 a If less than 25 VDC difference is measured between determine the difference in VDC See Table F1 2 2 eic b If more than 15 VDC difference is measured 575 only machines Capacitors C1 between the Switch Boards the Power Board C2 C14 and C15 Resistors R1 a
91. amp REPAIR OUTPUT PILOT CIRCUIT TEST 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 pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 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 Wiring Diagram Section G V300 PRO LINCOLN F 13 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 3 Return to Section Return to Master TOC Q Lr 5 TROUBLESHOOTING amp REPAIR OUTPUT PILOT CIRCUIT TEST cont TEST PROCEDURE 1 Turn Input Power Switch OFF 5 Set the Output Terminals Switch to the ON position 2 Perform Input Capacitor Discharge test as 6
92. cated in the center of the Switch Boards 4 Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resis tor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE Locate the two capacitor terminals large hex head capscrews shown in Figure F 1 Use electrically insulated gloves and insulated pli ers 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 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 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 FIGURE F I LOCATION OF INPUT FILTER CAPACITOR TERMINALS CAPACITOR TERMINALS SWITCH BOARD POWER RESISTOR INSULATED PLIERS GLOVES V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC o 5 13 TROUBLESHOOTING
93. chines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN 8 V300 PRO Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o HE 315 0 12 gle 5 Return to Section Return to Master TOC ELECTRICAL DIAGRAMS eT WIRING DIAGRAM ENTIRE MACHINE CODE 10131 L9569 1 5 5 m L2 5 Pun 1 4 116 4 1345 Tod pie H 11 1 3 TEF BU T 5 Ic T OI oat Du os 99 EE I i wi 405 E 3 E k thee t 5 912 127 1 PITE E cd Cee eth Ed eds E i i i 4590 5 4 E 1 5 T Tt Ha t 1 i us Ps pe nr vi GRH l la cB iT Hr 2 dE c AtS ums Ej FEDTE EL Tar EF m Boos 75 M 1 unn FAH 52 Hz Tm 8 Teen 10 _ 8 1 352 zh ila 1 51 COM lll P oo 00 5 m fee dE oe ati
94. ctiferif readings are not as indi cated NOTE When installing a new Input Rectifier torque mounting nuts in a cross tightening pattern to 6 inch pounds 7 Nm Torque terminals to 26 inch pounds 3 Nm ALWAYS GO TO STEP 6 TO CHECK RELATED COMPONENTS 7 Test Capacitors C1 and C2 and replace both Capacitors if either is faulty NOTE Faulty Capacitors could be the reason for a defective Input Rectifier Visually inspect Capacitors for leakage damage etc and use appropriate test equipment to determine com ponent integrity also check test Switch Boards for damage TABLE F 5 Test Points Probe Acceptable Meter Reading 9 A B C D E F G H 4 L Greater than 1K ohms Greater than 1K ohms Greater than 1K ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Greater than 1K ohms Greater than 1K ohms Greater than 1K ohms V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC Lr 5 35 TROUBLESHOOTING amp REPAIR OVERCURRENT PROTECTION CURRENT TRIGGER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on
95. ctor to provide strain relief for the input power cord It is designed for a cord diameter of 310 1 070 7 9 27 2mm The jacketed portion of the cord must go through the connector before tightening the connector Screws Recommended Fuse Sizes Based On The U S National Electrical Code And Maximum Machine Outputs Fuse Size in Amps Input Volts Time Delay Fuses 3 phase 50 60 Hz 1 phase 50 60 Hz Input voltage must be within 10 of rated value INSTALLATION a CONNECTION OF WIRE FEEDERS TO THE INVERTEC LN 25 Connection Instructions 1 Turn the Invertec power switch off 2 Connect the electrode cable to the output terminal of polarity required by electrode Connect the work lead to the other terminal 3 LN 25 with remote control options K431 432 Use K876 adapter with K432 cable or modify K432 cable with K867 universal adapter plug See con nection diagram 519899 and 519309 519405 Operator s Mamual 4 Place the local remote switch in the remote posi tion if output control is desired at the wire feeder rather than the Invertec LN 25 must have K431 and K432 options for remote output control opera tion LN 7 Connection Instructions not applicable to IEC machines with only 42V Aux 1 Turn the Invertec power switch off 2 Connect the K480 or K1818 10 control cable from the LN 7 to the Invertec control cable connector The control cable connector is l
96. ctric 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 NOTE Fig F 19 shows the Overvoltage Protection DC trigger Circuit V300 PRO LINCOLN F 38 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o E 5 5 9 9 gt 212 5 2 o Return to Section Return to Master TOC F 39 TROUBLESHOOTING amp REPAIR F 39 OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST cont FIGURE F 16 PC BOARDS REMOVED TEST PROCEDURE 1 2 Turn main power OFF Perform Input Filter Capacitor Discharge proce dure detailed in Maintenance section 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 Control Board e Protection Board e Power Board NOTE Do not disconnect any wires The machine must be functional to perform tests PROTECTION CONTROL BOARD 4 Arrange the PC boards and wiring so you can easi ly perform the tests NOTE Do not allow live connections to touch each other Turn main power
97. cycle The top drawing above shows the minimum output signal possible over a 50 microsecond time period The positive portion of the signal represents one FET group conducting for 1 microsecond The negative portion is the other FET group The dwell time off time is 48 microseconds both FET groups off 1 An FET group consists of the sets of FET modules grouped onto one switch board Since only 2 microseconds of the 50 microsecond time period is devoted to conducting the output power is minimized 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 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC e E 9 1 0 iz 212 515 ply Return to Section Return to Master TOC Return to Master TOC PROTECTIVE CIRCUITS Protective circuits are designed into the Invertec machine to sense trouble and shut down the machine before the trouble damages the internal machine components Both overload and thermal protection circuits are included OVERLOAD PROTECTION The machine is electronically protected from produc ing excessive output current
98. d throughout this manual for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 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 NOTE This procedure should only be done with the reconnect switches and jumper set for 380 460 Volt operation and the proper input voltage applied V300 PRO LINCOLN TROUBLESHOOTING amp REPAIR Fue CAPACITOR BALANCE TEST cont STATIC CAPACITOR TEST TEST PROCEDURE 1 With Output Terminal Switch S4 in REMOTE OFF b 2l position turn Power Switch ON etween the Switch Boards test each of the fol lowing components Return to Section TOC Return to Master TOC 2 Test VDC across terminals 9 and 12 of one Switch Board see Fig F 7 Repeat the test for the other f C2 and Resistors Switch Board See Table 1 this procedure for expected voltage readings g 575 VAC only machines Capacitors C1 C2 C14 and C15 and Resistors R1 and NOTE For 575 VAC only machines compare volt R9 age across 9A and 13 and 13 and 12A then 9B and D
99. dual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine NOTE DOL 0 DOL uonoeg oj LINCOLN E Return to Section Return to Master TOC Return to Section TOC Return to Master TOC st 512 e 2 5 Return to Section Return to Master TOC G 21 ELECTRICAL DIAGRAMS Identification Identification Item Identification C1 C2 C8 C14 CAPACITOR CEMO 022 50V 20 1 RECEPTACLE Molex mini 8 R61 R147 R148 RESISTOR MF 25W 1 10 0 C15 C16 C17 C20 C24 12 RECEPTACLE Molex mini 4 R62 RESISTOR MF 25W 1 8 25K C27 C30 C32 C35 C36 13 RECEPTACLE Molex mini 2 pin R63 RESISTOR MF 25W 1 1 00K C38 C44 C45 C47 C49 14 RECEPTACLE Molex mini 12 R65 R77 RESISTOR MF 25W 1 475 C50 C51 C52 C53 C54 15 RECEPTACLE Molex mini 14 R69 RESISTOR MF 25W 1 18 2K C55 C56 C57 C58 C60 OPTOCOUPLER Photo 70V R74 RESISTOR MF 25W 1 24 3K C61 C63 C64 C66 C67 GNE R82 R12
100. e leads may eliminate that 143 and 233 to the shunt See Figure F 14 problem a zero ohms resistance continuity is shown If tests for steps 5 7 are OK and the machine contin test is OK ues to experience the problem the Control Board should be replaced b If resistance of any value is shown check wire and connections FIGURE F 15 OVERCURRENT PROTECTION CURRENT TRIGGER CIRCUIT 302 6 1 1 1 CONTROL BOARD 1J3 233 WHITE L3 400 AMP OUTPUT CHOKE SHUNT TERMINAL V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC Lr 5 38 TROUBLESHOOTING amp REPAIR OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST 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 pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Ele
101. ect input power before 1 BESURE POWER SWITCH IS OFF inspecting or servicing machine 2 CONNECT LEAD A TO DESIRED INPUT VOLTAGE RANGE 440 460V 380 415v 220 230 gt 200 208V Do not operate with wraparound removed ELECTRIC Do not touch electrically live parts SHOCK Only qualified persons should install EI use or service this equipment IF MACHINE CEASES TO OPERATE NO METER NO FAN AND THERE IS NO OTHER KNOWN FAILURE CHECK FUSE REPLACE WITH A 3 AMP SLOW BLOW ONLY 3 POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE Tomei jones THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A 9 11 92 520324 300 LINCOLN Return to Section Return to Master TOC Return to Section TOC 9 1 0 iz 212 515 ply o Return to Section TOC Return to Master TOC Return to Master TOC POWER INPUT CONNECTION Connect terminal marked to earth ground per existing local or national electrical codes Single Phase Input Connect the supply lines to the upper and lower termi nals of the line switch Torque to 27 5in Ibs 3 0 Nm Do not use center terminal of the line switch Three Phase Input Connect the supply lines to the line switch Torque to 27 5in lbs 3 0 Nm Install in accordance with all local and national electric codes The V300 PRO is supplied with one cord conne
102. ection TOC Return to Master TOC EA THEORY OF OPERATION Ed FIGURE E 4 SWITCH CIRCUITS amp TRANSFORMER POWER SWITCH SECTIONS 20KHZ LEFT SWITCH BOARD MAIN TRANSFORMER CHOKE RECTIFIER HEATSINK FET MODULES E 1DIODE FET MODULES 10 OR DETETCTION 5 TRANSFORMER PRE CHARGE INPUT DRIVER RECTIFIER SWITCH e I i CONTROL 1 5 DIODES eros BOARD 1 o el e 1 PROTECTION lt 2 0 AC2 N BOARD FEEDBACK 3 02 N be 1 T cc i 134 1 24VDC E PORTS RIGHT SWITCH BOARD 8 DIODES TRANSFORMER ae 2ND STEP PWM FET MODULES 2 14 42 9019 5 2 x ZW POWERBOARD i FET MODULES 1DIODE CHOKE CHOKE TO WIREFEEDER 1 LOCAL REMOTE 1ST STEP PWM VOLTAGE METER MODE VOLTAGE FEEDBACK CURRENT FEEDBACK PROTECTION 15VDC CONTROL BOARD FUNCTION VOLTAGE SHUNT
103. er b 1 15 VDC is not present the Power Board may ly be faulty Check for 18 VAC input voltage at lead 501 and 504 47 b If 15 VDC is present go to Thermal Protection AC Trigger Circuit Test If 18 VAC is present the Power Board is faulty and must be replaced 9 Test for 0 1 VDC DC trigger circuit between leads 305 and 275D on Power Board a 1 0 1 VDC is present DC trigger circuit is oper ating properly b If 15 VDC is present go to step 10 V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 5 Return to Section Return to Master TOC Q Lr 5 TROUBLESHOOTING amp REPAIR pede OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST cont FIG 19 OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT THESE LEADS ARE USED FOR MONITORING CAPACITOR VOLTAGES 15 VDC SEE TABLE 1 PROTECTION BELOW BOARD OPTOCOUPLER DEPENDENT ON PROTECTION BOARD TABLE 1 INPUT VOLTS FOR 460 VOLTS AC IF AC TRIGGER oe CIRCUIT IS GOOD 52 53 325 VDC 301 LEAD 51 53 325 VDC on 1 15 VDC 14 53 14 15 VDC 2 CONTROL BOARD 14 52 315 VDC If 15 VDC is present at step 7 test Capacitor volt ages using leads shown in Figure F 19 If voltage does not match table check reconnect switches for
104. er wirefeeders which allow the gun trigger to energize the welding ter minals ON OUT UT TERMINALS bn OPERATION FORCE INDUCTANCE CONTROL This control functions in all modes except GTAW For CC modes this control acts as an Arc Force adjust ment The arc is soft at the minimum settings and more forceful or driving at the maximum settings Higher spatter levels may be present at the maximum set tings For CV modes this control will set the degree of pinch effect which predominantly affects short circuit trans fer In FCAW the maximum setting is generally pre ferred With GMAW the upper half of the range is pre ferred with or high content CO mixed gas The lower half is for inert gas mixes 2 gt Uz RECOMMENDED SETTINGS FOR SELECTED APPLICATIONS Full Range Is 1 10 1 Is Very Soft 10 Is Very Crisp Recommended Adjustment Range Nominal Process Setting EXX18 thru EXX28 stick EXX10 thru 6 14 stick Air Carbon Arc 1 Cutting 1 1 gentle may stick to 9 forceful more spatter CV FCAW Innershield or Outershield Air Carbon Arc Cutting GMAW 25 7 5 or similar gas mixes 98 Ar 2 90 He 7 5 Ar 2 5 and other predominantly inert gases 1 Lowest pinch highest inductance and least spatter 10 Highest pinch lowest inductance and most spatter V300
105. ergize but there is still a ation of the control relays suspicion that the Power Board is faulty go on to Test B 3 Turn main power ON olo eile 5 FIGURE 22 REMOVING CONTROLPANEL a 9 2 Sa olo CONTROL BOARD CONTROL ala PANEL o 55 o o 0 2 2 5 Pc Test B 4 Detach Control Panel by removing the four mount ing screws Move the panel to the left to gain 1 Turn main power OFF access to the Power Board O10 e 2 2 Remove wrap around cover 5 Turn main power ON 8 2 dure 9 2 2 3 B V300 PRO LINCOLN TROUBLESHOOTING amp REPAIR bas POWER BOARD TEST cont FIGURE F 23 POWER BOARD TEST POINTS Return to Section TOC Return to Master TOC o 2 5 2 3 8 Return to Master 6 Test for 18 VAC input from Auxiliary Transformer 9 Test for 24VDCfrom lead 309 to lead 313 between leads 504 and 501 J7 pin 5 amp pin 6 on 47 2 to 414 pin 2 Power Board If 24VDC is not present but 24VAC step 8 is cor If 18 VAC is not correct check the 3 amp fuse the rect the Power Board is defective o o 9 Auxiliary Transformer and associated wires c 5 10 Test for 24 from lead 309 to lead 310 47 8 to 7 Testfor 15 VDC output between leads 275D and pin 2 to J7 pin 4
106. ew to collapse copper tube The SS screw must apply pressure against welding cable 27 The top of the set screw will be well below the sur face of the brass plug after tightening BRASS PLUG 6 Slide the rubber boot over the brass plug The rub ber boot must be positioned to completely cover all COPPER TUBE electrical surfaces after the plug is locked into the receptacle V300 PRO LINCOLN Return to Master TOC Return to Master TOC o 2 5 Return to Master TOC Section B 1 TABLE OF CONTENTS Section B 1 OPERATION SECTION OD Cr ATION IRE WA Section Operating 411816 eiecit ntn kn 2 Controls and eene nennen B 2 B 4 POWO Em 4 V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC o 5 OPERATION ads OPERATING INSTRUCTIONS WARNING ELECTRIC SHOCK kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work 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
107. f 204A e 10 i 1 16 de 203 4 3 77B sh F 71 206 mm 104 R11 gop 2118 86 12 2 502 278 OUTPUT AUX 001 400 223 4 lt 11 8 229 275 CONTROL 8 1 0 227 46 2 13 228 2758 A 213 9 12 49 207 275 MM D6 214 4 6 7 208 Li 225 46 8 LOCAL T OUTPUT 228 REMOTE LOCAL REMOTE J 77A 9040 SWITCH 1 EN 52 gt 0 gt 75 275 4 amp 2 ue 207 5 GW R12 5 8 3 3 5 b ARC FORCE 76 F 76 2808 94 8 7 2 901 2150 46 1 9 208 510 INDUCTANCE 77 gt gt 77 309 6 p 802 301 4 5 I cc 2W 110 115 31 J gt 212 220 2 382 903 302 46 6 9 pia Y VAC 501 5 5 8 gt 304 305 4 lt 4 212A 32 5 A gt 32 504 4 6 1 48 2750 124 3 42 4 212 2 1 4 D 211A 303 6 7 4 210 2128 54 gt 2 304 46 8 2 275 OUTPUT VAC 429K gt 42 3 UL 223B TERMINAL 2 212 5 CONTROL SWITCH 2120 or as me iE or BOARD pens TRIGGER 2238 2 212D FAN mom 14 502 THERMOSTAT THERMAL 4 2 0101 OVERLOAD INDICATOR 56 AUXILIARY 300 1 ONLY 21 GND B gt GND o f WIRE FEEDER SPARE N 2118 mh 285 WELDING x POLARITY a ae 229 SWITCH WIRE REMOTE FEEDER CONTROL s2 RECEPTACLE MODE SWITCH 1 FOR MACHINES SUPPLIED WITH INPUT CABLE V300 PRO S4 FOR SINGLE P
108. fety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid in the relpacement of the Switch Boards MATERIALS NEEDED Misc Hand Tools Torque Wrench 60 Wiring Diagram Section G Return to Section TOC Return to Master TOC NOTE BOTH SWITCH BOARDS IN A MACHINE MUST HAVE IDENTICAL PART NUMBERS THEY SHOULD ALWAYS BE CHANGED IN PAIRS EXCEPT FOR L10958 BOARDS WHICH MAY BE REPLACED INDIVIDUALLY O10 E 2 2 818 e 5 5 ply ajo Return to Section TOC Return to Master TOC V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC 5 56 TROUBLESHOOTING amp REPAIR F 56 SWITCH BOARD REPLACEMENT cont NOTE If a test indicates that a Switch Board is defec 7 Apply thin layer 002 of Dow 340 or Penetrox tive unless their part number is L10958 both Switch A13 Heat Sink Compound to the mounting sur
109. h Boards 3 Fold the leads up so they do not interfere with the exposed PC board terminals See Figure 8 4 Using an ohmmeter perform the Resistance Tests detailed in Table F 2 and Table F 3 If any test fails replace both Switch Boards See Switch Board replacement procedure 5 If the Switch Boards appear to be burned or over heated or if the machine was supplied by a 380 VAC or higher voltage supply when the failure occurred replace the Capacitors and the Switch Boards FIGURE F 8 SWITCH BOARD RESISTANCE TEST C Em 2 aw A V300 IPRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC 5 dici TROUBLESHOOTING amp REPAIR SWITCH BOARD TEST CONT TABLE F 2 SWITCH BOARD RESISTANCE CHECKS Apply Positive Apply Negative Test Probe to Test Probe to Terminal Terminal Test Result Conclusion Repair Action Next Procedure Notes 1 8 12 Greater than OK None Continue 1K ohm Less than Shorted Replace both Snubber Test 100 ohms Switch Boards Less than OK None Continue 100 ohms Greater than Replace both Snubber Test 1K ohm Switch Boards Greater than OK None Continue 1K ohm Le
110. ic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard 249 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Wo
111. ine screws 14 Reconnect all the leads to the PC board Double 5 Remove the Switch Board from the heat sink check that each lead is connected to the correct terminal Failure to reconnect the leads correctly 6 Clean the heat sink surfaces thoroughly to remove can result in machine damage when the power is all the heat sink compound During machine oper applied ation this compound helps conduct heat from the PC board to the heat sinks 15 Perform the Test After Repair of Switch Boards V300 PRO LINCOLN TROUBLESHOOTING amp REPAIR Pa TEST AFTER SWITCH BOARD OR CAPACITOR REPLACEMENT Return to Section TOC Return to Master TOC 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 pre cautions 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 Return to Section TOC Return to Master TOC DESCRIPTION This test MUST be performed after replacement of either the Switch Boards or Input Filter Capacitors MATERIALS NEEDED
112. l strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con 1 888 935 3877 V300 PRO LINCOLN F 2 tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call Return to Section Return to Master TOC Return to Section TOC 9 1 0 512 212 515 ply o aja Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill Have 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 Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected
113. le phase or three phase and pass that information to the Control Board The maximum output of the machine will be limited to approximately 250 amps with single phase input and 360 amps with 3 phase input The DC voltage from the Input Rectifier is applied to the Driver Board to begin charging the Switch Board capacitors at a slow rate When the pre charge level is achieved the input relays close applying the full DC voltage to the capacitors Depending on the Code Number of the machine there will be either two or four relays and they may or may not be mounted on the Driver Board OJO E a 23 e 515 ply ajo The Driver Board is also responsible for gating the Field Effect Transistors FETs on the Switch Boards as directed by the pulse width modulated PWM signal from the Control Board The Protection Board monitors the capacitors for prop er balance and voltage level If an imbalance or over voltage condition is detected the Protection Circuit will de energize the relays removing the power from the switch circuits The machine output will also be dis abled NOTE Unshaded areas of block logic diagram are the subject of discussion Return to Section TOC Return to Master TOC V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo o E a gt 2 2 5 5 ply ajo Return to S
114. lee 3 276 5 6 218 Pele Er 226 7 2 4 LOCAL REMOTE SWITCH J13 m J12 z 215 75 G gt 75 n 275 2 10 36 18 3 5 306 ARG FORCE 76 gt F gt 76 1 2150 4 1 INDUCTANCE amp 201 46 5 5 x CONTROL J 110015 2301 302 4 6 1 Y 305 4 3 5 Y 32 gt 32 303 7 254 210 54 42 41 1 212 4 304 8 OUTPUT VAC 442 3 K gt 42 TERMINAL 2 212 CONTROL SWITCH 2120 BOARD TRIGGER 4 3 D 3 23B FAN THERMAL 81 Me sea EOR REESE OVERLOAD 82 INDICATOR 1 86 AUXILIARY V300 1 ONLY 21 H gt 21 TRANSFORMER N C _GND gt GND WIRE FEEDER SPARE 2118 5 e UN Y N SWITCH WIRE REMOTE FEEDER CONTROL RECEPTACL NOTES 42 8 J9 J10 J12 S4 111 414 018 J15 J1 J7 OUTPUT TERMINAL MODE SWITCH 1 FOR MACHINES SUPPLIED WITH INPUT CABLE V300 PRO 3 SWITCH FOR SINGLE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE CONNECT BLACK amp WHITE LEADS TO SUPPLY CIRCUIT 9000 83 S WRAP RED LEAD WITH TAPE TO PROVIDE 600V INSULATION COLOR CODE sa LOCAL REMOTE METER FUNCTION FOR THREE PHASE INPUT CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE B BLACK J5 J16 SWITCH SWITCH CONNECT BLACK RED amp WHITE LEADS TO SUPPLY CIRCUIT G GREEN 2 FOR MACHINES NOT SUPPLIED WITH INPUT CABLE V300 1 R RED R11 FOR SINGLE PHASE INPUT GROUND MACHINE PER NATIONAL AND LOCAL ELECTRI
115. les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Si on utilise la machine souder comme une source de 11 Pour obtenir de plus amples renseignements sur la s ret voir courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie du corps LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel donc TRANSFORMATEUR ET REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou 1 quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage
116. nal Switch S4 Return to Section TOC Return to Master TOC V300 PRO LINCOLN 16 5 V300 PRO LINCOLN F 16 901 4 1 0 uunjeHd 901 491590 0 uunjeH 901 1 01 UuunjeH 901 J91Se N 01 uunjeH DOL uonoes 0 DOL uonoes DOL uonoes 0 DOL uonoes oj Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC o 5 17 TROUBLESHOOTING amp REPAIR PROTECTION BOARD OUTPUT TEST 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 pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 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
117. nd R9 are or Switch Board is damaged See SWITCH OK BOARD test POWER BOARD test Go to Dynamic Capacitor Balance Test Return to Section TOC Return to Master TOC V300 PRO LINCOLN 23 V300 PRO TROUBLESHOOTING amp REPAIR CAPACITOR BALANCE TEST cont LL 40 737 Y 33 F 23 901 Je1Se A 0 uunjeHd 901 Je1Se A 0 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes 0 DOL uonoes 0 DOL uonoes DOL uonoes 0 24 5 V300 PRO LINCOLN F 24 901 4 1 0 uunjeHd 901 491590 0 uunjeH 901 1 01 UuunjeH 901 J91Se N 01 uunjeH DOL uonoes 0 DOL uonoes DOL uonoes 0 DOL uonoes oj Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC Lr 5 25 TROUBLESHOOTING amp REPAIR F 25 SWITCH BOARD TEST 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 safet
118. nnections Check input voltage and reconnec tion procedures See Switch Board test Snubber Resistor test See Output Diode Test CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 V300 PRO LINCOLN 10 5 V300 PRO LINCOLN F 10 901 4 1 0 uunjeHd 901 491590 0 uunjeH 901 1 01 UuunjeH 901 J91Se N 01 uunjeH DOL uonoes 0 DOL uonoes DOL uonoes 0 DOL uonoes oj Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC o 5 11 TROUBLESHOOTING amp REPAIR F 11 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 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 pre cautions detailed throughout this manual for any reason you do not understand the
119. nput supply fuse holders NOTE These fuses should be installed to protect against excessive current flow caused by a short circuit during the procedure Turn on the machine With the output free of a load check the open cir cuit voltages of the output Connect the machine for 440 or 575 volt opera tion With the output free of a load check open circuit voltages of the output Voltage should be 70 VDC Remove the 5 amp fuse from the input supply fuse holders Install 20 amp fuses and test under load NOTE A resistive type grid load bank is recom mended Perform Retest After Repair FIGURE F 30 PLACEMENT SHORTING JUMPER JUMPER BETWEEN TERMINALS 14 AND 53 B300 PRO LINCOLN 59 TROUBLESHOOTING amp REPAIR ae OUTPUT DIODE REPLACEMENT PROCEDURE Return to Section TOC Return to Master TOC 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 pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you
120. nt procedure Detach the fan shroud to gain access to the diode heat sink and mounting bracket When the fan shroud is lifted the tabs securing the heat sink mounting bracket will release Move the diode heat sink and mounting bracket away from the Case Back Unsolder the leads from each of the diodes to be replaced 7 Remove the nut that secures each diode to the heat sink and mounting bracket 8 Mount the replacement diodes to the heat sink IMPORTANT The replacement diodes will come with an instruction sheet that addresses surface preparation and torque values Failure to follow these instructions may result in subsequent break down 9 Carefully resolder the leads to the new diodes 10 Reassemble the unit being careful to use all of the insulating materials Also make certain to replace all disconnected leads in their proper location Failure to do so may result in machine damage when the power is applied 11 Perform the Test After Switch Board or Capacitor Replacement V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC OJO Fle 9 Sm 5 4353 o Return to Section Return to Master TOC Return to Master TOC F 61 TROUBLESHOOTING amp REPAIR F 61 OUTPUT DIODE REPLACEMENT PROCEDURE cont FIGURE F 32 RECTIFIER ASSEMBLY WITH DIODE MODULES PROCEDURE Diode Mod
121. o Master TOC 6 17 ELECTRICAL DIAGRAMS 6 17 SCHEMATIC SWITCH PC BOARD L10956 04 1N493E wo 144336 POSITIVE o9 INPUT Ci SNUBBER ha RESISTOR 05 402 144936 484 T 1 50K 341 1200 22 4 TRANSFORMER 5 PRIMARY 2 BYT3BPEBQ o4 m T JN4935 FILTER par 39 2 39 2 C2 0 600 AZ 51 TRANSFORMER 8 PRIMARY cs 1700 214 403 08 K SNUBBER 144926 2 2 RESISTOR RO 2 NEGATIVE INPUT 6 5 98 L 18956 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp 300 PRO Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o FE S PEN gt g 2 e 5 2 Return to Section Return to Master TOC G 18 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY SWITCH L10958 1
122. ocated at the rear of the Invertec 3 Connect the electrode cable to the output terminal of polarity required by electrode Connect the work lead to the other terminal 4 Place the local remote switch in the local position to allow output control at the Invertec K864 remote control adapter and K857 remote control are required for remote output control See con nection diagram 519901 5 Set the meter polarity switch on the rear of the Invertec to coincide with wire feeder polarity used The wire feeder will now display the welding volt age 6 If a K480 or K1818 10 is not available see con nection diagram 519404 for modification of K291 or K404 LN 7 input cable with K867 universal adapter plug V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC o P 5 no INSTALLATION LN 9 GMA Connection Instructions Not applicable to machines with only 42V Aux 1 Turn the Invertec power switch off 2 Connect the K596 or K1820 10 control cable assembly from the LN 9 GMA to the Invertec control cable connector The control cable connector is located at the rear of the Invertec 3 Connect the electrode cable to the output terminal of polarity required by electrode Connect the work lead to
123. od xr meg ZH d SIM UE ESI YXELSIS J4 CURCLITAY 37 4 DXIETFO 51617 MINE SR RETIET ILTE3 wXHEESBD TT GF 4 101 HAY C SHEN 4E ESITT ss 73 28 cavi rrt H WIET i cuytie Won fe X ow ME 2 ACE 4a pewar DERE URS OR D GA DEDPORTRT STE ANI OI We RLE CA LESI I OATIEDERGATE mM SORTE Tk 5HOAh I3 45 4527 reges duh 22121 RIGS fle 7l 12 33 4 7 xl BLEEDS 927 4 5 XX v CL A SET L gaz E FOES TOR ad Pari SEP SH 17 F3 34 0 2 2 1 I FARDE ELECTRIC teva NOTE This diagram is for reference only may not be accurate for machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN V300 PRO aa ELECTRICAL DIAGRAMS nds WIRING DIAGRAM ENTIRE MACHINE CODE 10257 L10191 ojo 8 5 gt PEN 9 gt olg Bop eje celE J AR Biz 21 gt M FH
124. ol Board CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC o Lr D 5 PROBLEMS SYMPTOMS Poor stick electrode performance Arc pops out pa TROUBLESHOOTING amp REPAIR E TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FEEDING PROBLEMS Check output welding cables Is electrode DRY Try welding with another electrode from a different container Make sure you have the correct electrode for your application RECOMMENDED COURSE OF ACTION 1 Check for loose or burned con nections at choke shunt and output studs See wiring dia gram in Section Test and inspect D6 D12 L1 and L2 See Wiring Daigram in Machine makes squealing noise while under load when welding Output power is low less than 20 VDC on meter 100 amps Input voltage 230 VAC or lower Check input lines and co
125. ols Wiring Diagram Section G V300 PRO LINCOLN F 29 pen TROUBLESHOOTING amp REPAIR SNUBBER RESISTOR TEST cont Fie 918 910 FIGURE F 9 SNUBBER RESISTOR TEST POINTS gt gje oflo oflo alz W 401 1 9 12 44 402 RW o 9 403 8 5 404 olo 55 1 olg gt 8 8 5 SWITCH 2 1 Turn main Power off a If 25 ohms is measured Resistor R4 is OK 2 Perform Input Filter Capacitor Discharge proce b If 30 ohms or more is measured Resistor R4 is dure faulty and must be replaced 3 Remove leads 401 402 403 amp 404 from theSwitch c 20 ohms or less is measured Resistor R4 is Boards faulty and must be replaced 4 Test for 25 ohms resistance from lead 401 to termi 5 Repeat same procedures to test R5 R6 and R7 per nal 12 on Switch Board Table F 4 TABLE F 4 SNUBBER RESISTORS TEST Q 5 Test Result Conclusion Next Test Step Repair Action Lead 401 to OK Continue Terminal 12 R4 open Replace R4 R4 faulty Lead 402 to OK Continue Terminal 9 R5 open Replace R5 R5 faulty o 2 2 G 3 Lead 403 to OK Continue Terminal 12 R6 open Replace R6 R6 faulty Lead 404 to OK Continue Terminal 9 R7 open Replace
126. oltage for 24 VAC between leads 503 and 2120 See Figure F 21 a If 24 VAC is present transformer is OK Go to step 7 b VAC is present test input voltage to Auxiliary Transformer c If input voltage to Auxiliary Transfor mer is cor rect replace Auxiliary Transformer d If input voltage to Auxiliary Transfor mer is not correct check Line Switch S12 and connecting leads 224 pe NORMALLY CLOSED NOTE WHEN THERMOSTATS TRIP THE CIRCUIT WILL BE OPENED CONTROL 55 BOARD 4 2 Check that Output Terminal Switch 54 is in the position closed Test for 24 VAC between leads 223A and 210 a If 24 VAC is present then AC Trigger Circuit is functioning normally b If O VAC is present check Choke Thermostat and Fan Thermostat V300 PRO LINCOLN 46 5 V300 PRO LINCOLN F 46 901 4 1 0 uunjeHd 901 491590 0 uunjeH 901 1 01 UuunjeH 901 J91Se N 01 uunjeH DOL uonoes 0 DOL uonoes DOL uonoes 0 DOL uonoes oj Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC Lr 5 47 TROUBLESHOOTING amp REPAIR POWER BOARD TEST WARNING Service and repair should be performed b
127. or input voltage being used Output Terminal Switch or Remote Trigger MUST be in ON position Local Remote Switch must be LOCAL position unless remote con trol device is attached to remote receptacle If machine has not been used for a long time and is connected for 380 VAC or higher Capacitors need conditioning See Filter Capacitor Conditioning this section Check continuity of 3 amp slow blow fuse located on reconnect panel 1 Check Power Switch S1 2 Look for loose or broken wires between Power Switch and Input Rectifier component D13 Check for broken leads to pri mary of Auxiliary Transformer T1 Possible open primary coil of Auxiliary Transformer T1 See Output Pilot Circuil test SeelThermal Protection AC Trigger Circuit test See Overvoltage Protection DC Trigger Circuit test 4 See Capacitor Balance test 5 See Switch PC Board test 6 See Power Board fest Look for broken or loose con nections on high current carry ing 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 con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Ret
128. otect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 5 5 5 be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment
129. output current In CV modes set the pots to iden tical positions Then switch the machine meters to read amps and adjust one of the output control pots for current balance Check the voltage and if read justment is necessary repeat the current balancing step Pinch settings should also be kept identical on the machines V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC ojo O10 a gt 818 e 5 5 ply Return to Section Return to Master TOC Return to Master TOC iid INSTALLATION A6 OUTPUT CABLES Select the output cable size based upon the following chart Cable sizes for Combined Length of Electrode and Work Cable Copper 75 rated Duty Length Up 61 76m Cycle Current 61m 200 ft 200 250 ft 100 1 0 60 1 0 QUICK DISCONNECT PLUGS 852 7 A quick disconnect system is used for the welding cable connections The welding plug included with the machine is designed to accept a welding cable size of 1 0 to 2 0 1 Remove 1 inch 25mm of welding cable insulation WELDING CABLE 2 Slide rubber boot on to the cable end The boot ple end be trimmed to match the cable diameter N Soap or other lubricant will help to slide the boot EHE TRIW over the cable peg 9 3 Slide the copper tube into the brass plug se gp e 4 Insert the cable into the copper tube 5 Tighten set scr
130. p the engine and allow it to cool before refuel 2 a Electric current flowing through any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts Bes Exposure to EMF fields in welding may have other health when starting operating or repairing equipment effects which are now not known Lr 0 52 5 All welders should use the following procedures order to In some cases it may be necessary to remove safety uet 4 Me minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 1 Route the electrode and work cables together Secure Always use the greatest care when working near moving them with tape when possible
131. p you locate and repair possible machine malfunctions Simply follow the three step pro cedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into categories of typical problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points components termina
132. parts 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or 2 4 3 Do not place your body between the electrode and idler by pushing on the throttle control rods work cables If the electrode cable is on your right while the engine is running side the work cable should also be on your right side Connect the work cable to the workpiece as close possible to the area being welded To prevent accidentally starting gasoline engines while d 5 Do not work next to welding power source turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Return to Master TOC LINCOLN 8 Return to Master Return to Master TOC Q He 2 0 52 5 Return to Master SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 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 In addition to the normal safety precautions if welding must be performed under electrically hazardo
133. pressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations 8 c Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 Return to Master Return to Master TOC Q He 2 0 52 5 Return to Master PRECAUTIONS DE SURETE i SAFETY zones l on pique le laitier Pour votre propre protection lire et observer toutes les instructions 6 Eloigner les mat riaux inflammables ou les recouvrir afin de et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude
134. r read ing should be 500 000 ohms or more If meter reading is less than 500 000 ohms check for electrical components that are not properly insu lated from the case Correct insulation if needed 7 Replace machine cover and screws D 3 MAINTENANCE pa OVERLOAD PROTECTION The machine is electrically protected from producing high output currents Should the output current exceed 340 360A an electronic protection circuit will reduce the current Fold Back to approximately 150A The machine will continue to produce this low current until the protection circuit is reset Reset occurs when the output load is removed THERMAL PROTECTION Thermostats protect the machine from excessive operating temperatures Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rat ing excessive operating temperature should occur the thermostat will prevent output voltage or current The meter will remain energized during this time PC BOARD REPLACEMENT 1 Handle PC Boards by edges only 2 Store PC Boards only in the bags that disperse static charges 3 Inspect PC Board for burned conductors or com ponents If damage is visible inspect the machine wiring for grounds or shorts to avoid damaging a new PC Board 4 f 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 rein
135. rk 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 LINCOLN CYLINDER may explode if damaged 7 a Use only compressed cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Com
136. rn to Master TOC VOLTAGE CONTROL MODE SWITCH CRISP 4 TIG Cut out for Std ojo O10 E gt 8 8 5 5 o ajo ARC FORCE PINCH N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER GENERAL INFORMATION more notes ELECTRICAL SYMBOLS PER E 1537 CAPACITORS 0 UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED UNLESS OTHERWISE SPECIFIED test points SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT PRESET TO COMMON CONNECTION METER FRAME CONNECTION EARTH GROUND CONNECTION Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 300 PRO G 20 ELECTRICAL DIAGRAMS G 20
137. rol cable assembly is supplied with the kit to connect the kit to an Invertec The cable can be con nected either end at the DC TIG Starter kit and at the Invertec by attaching to the 14 pin Amphenols on the backs of each unit See diagram 520405 A negative output cable assembly is also supplied with the DC TIG Starter kit to connect the kit with the Invertec s negative output terminal All Magnum one and two piece water cooled torches with 7 8 left hand threads and gas cooled torches with 7 8 and 5 16 right hand threads can be connected to the starter kit To secure the DC TIG Starter kit to the bottom of the Invertec and for more detailed instructions see the K900 1 1 465 manual 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 run ning in a CC mode adjust output and arc force to maintain current sharing while establishing the prop er
138. rts listed are not available from Lincoln Electric D1 D2 D3 D4 D5 D8 D9 1N4004 R9 1150K 1 4W D10 D11 D12 D13 R21 2 21 1 4W C6 1 8 20 R3 243 1 AW 4 7 35 R7 R8 R24 267 1 4W C5 39uF 20VDC R2 2 67K 1 AW 3300 50 R18 26 7 1 4W OCI1 OPTO ISOLATOR R20 267K 1 AW X2 X3 8 PIN I C SS R13 R15 R16 R17 33 2K 1 4W C8 C9 C12 C13 1 50 R23 4 75K Olo J6 HEADER R12 475K 1 AW p 10 500 50 R25 5 11K 1 4W cla 071 1 4744 4 LM224 9159 072 073 1 4746 14 HEADER 2 Q1 Q3 3A 60V TRANSISTOR Q40 2N4401 9 gt 02 04 60V PNP TRANSISTOR R42 R43 100 1 AW olo Q5 3 5A 60V MOSFET SS 074 075 1 4742 D6 D7 1N5822 SCHOTTKY BARRIER DIODE R28 R29 10 1 4W 5 5 R1 0 5W RESISTOR D14 1N4936 t o ojo NOTE PRO
139. s and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines oc 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 copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society 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 2 1 h To avoid scalding do not remove the 55 radiator pressure cap when the engine is powered equipment oo 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 X 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors Return to Master TOC ELECTRIC AND MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld S may be dangerous ing arc or when the engine is running Sto
140. s on the bracket Protection Board V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC o Lr 2 0 5 19 TROUBLESHOOTING amp REPAIR F 19 PROTECTION BOARD OUTPUT TEST cont TEST PROCEDURE 8 With power OFF disconnect J8 and attach voltage probes into back of wire harness lead junction block J8 See Figure F 5 Insert probes into back of the connection cavities for leads 313 and 311 of Protection Board Make sure contact is made with conductor materi al NOTE Right angle thin gauge probes are best for this test With probes attached plug the J8 block into the PC board 9 Turn main power ON 10 Move Output Terminal Switch S4 to ON position on 11 Control Panel Test for less than 1 VDC between leads 313 and 311 a If less than 1 VDC is measured test is OK and Protection Board is functioning properly b If more than 5 VDC is measured go to Static Capacitor Balance Test NOTE During voltage test be cautious when positioning loose components to avoid shorts and damage to equipment FIGURE F 5 INSERTING PROBES L7915 PROTECTION 306 275F 311 V300 PRO LINCOLN vee TROUBLESH
141. s these inputs sets up the proper weld information and sends the set para meter information to the meter NOTE Unshaded areas of block logic diagram are the subject of discussion Return to Section TOC Return to Master TOC V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC ojo E gt 818 e 5 5 ply Return to Section Return to Master TOC Return to Master TOC THEORY OF OPERATION Ee FIELD EFFECT TRANSISTOR OPERATION GATE TERMINAL 0 VOLTS SOURCE TERMINAL SOURCE N SUBSTRATE P DRAIN TERMINAL DRAIN N N CHANNEL A PASSIVE GATE TERMINAL 6 VOLTS SOURCE N g g 9 g 6 g S9 aL 0 5 9 4 0 5 DRAIN N ELECTRONS B ACTIVE An FET is a type of transistor FETs are semiconduc tors well suited for high frequency switching because they are capable of going from full off to full on much more quicklfy than other types of semi conductors 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
142. ss than Shorted Replace both Snubber Test 100 ohms Switch Boards Less than OK None Continue 100 ohms Greater than Replace both Snubber Test 1K ohm Switch Boards Less than None Continue 100 ohms Greater than Replace both Snubber Test 1K ohm Switch Boards Greater than OK None Continue 1K ohm Less than Shorted Replace both Snubber Test 100 ohms Switch Boards Less than None Continue 100 ohms Greater than Replace both Snubber Test 1K ohm Switch Boards Greater than OK None Continue 1K ohm Less than Shorted Replace both Snubber Test 100 ohms Switch Boards NOTE K ohm ohm reading multiplied by 1000 NOTE Always make sure that Switch Boards are changed in matched pairs Never mix an old style different part number Switch Board with a newer style V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC Lr 5 TROUBLESHOOTING amp REPAIR SWITCH BOARD TEST CONT TABLE F 3 SWITCH BOARD RESISTANCE CHECKS Apply Positive Apply Negative Test Prove to Test Probe to Terminal Terminal Test Result Conclusion Repair Action Next Procedure Notes 401 403 Greater than OK None Continue 1K ohm Less than Shorted Replace both Snubber Test 100 ohms Switch Boards 401 403 Less
143. stall the old board and see if the problem reoccurs If the problem does not reoccur check the wiring harness and plugs for loose connec tions V300 PRO LINCOLN 0 4 MAINTENANCE FIGURE D 2 LOCATION OF MAINTENANCE COMPONENTS D 4 KO YK 207 be lt lt p 5 7 AN V300 PRO COMPONENT PC BOARDS 901 Je1Se A 0 901 Je1Se A 0 SOL uonoeg 0 901 J91Se N 01 UuunjeH DOL uonoes 0 DOL uonoes 0 CONTROL DRIVER PROTECTION MAIN TRANSFORMER INPUT FILTER CAPACITORS INPUT RECTIFIER POWER SWITCH OUTPUT STUDS HEAT SINK FINS 901 J91Se N 01 UuunjeH DOL uonoeg 0 LINCOLN E Section E 1 TABLE OF CONTENTS Section E 1 THEORY OF OPERATION SECTION O 5 9 gt INIM Section 5 Power Supply Operation a Pre Charge and Protection Circuitry Switch Board and Main E 4 Control and Output Circuitry 1 eee E 5 Field Effect Transistor FET E 6 Pulse Width 9 E 7 Proteclive Cirio E 8 Q p 2 0 9 E 5 FIGURE E 1 V300 PRO BLOCK LOGIC DIAGRAM
144. ster TOC pu TROUBLESHOOTING amp REPAIR OUTPUT DIODE TEST cont TEST PROCEDURE 1 Locate the Output Terminals on front panel 2 Remove any cables from Output Terminals 3 Test for more than 200 ohms resistance between positive and negative Output Terminals positive meter lead to the positive terminal negative meter lead to the negative terminal NOTE Polarity of test leads is important a reading is more than 200 ohms Output Diodes are OK b If reading is less than 100 ohms or more Output Diode is shorted Test all Output Diodes D 1 thru D 12 or diode modules individually NOTE On codes prior to 10200 the diodes should also be tested individually to check for Open diodes An open diode may cause an imbalance condition when output is activated sure to per form the Input Filter Capicitor Discharge as detailed in this section FIGURE F 10 TESTING OUTPUT DIODES V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC Lr 5 33 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on
145. t is OK Go to step 6 Board b If 15 VDC is not present check Power Board 3 Arrange wires so there is ample room to work on and leads 302 and 275D for continuity and wire the board breakage FIGURE F 13 CONTROL BOARD TEST POINTS 302 75D V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o E 2 2 Return to Section Return to Master TOC o ke 5 TROUBLESHOOTING amp REPAIR per OVERCURRENT PROTECTION CURRENT TRIGGER TEST cont FIGURE F 14 CONTROL BOARD TEST POINTS 2J3 White J3 Idd Pa 51512210 allig PN 2 2 EL gt gt 143 Black 6 Turn main power OFF 7 Perform Input Filter Capacitor Discharge NOTE On earlier codes the terminals on the shunt Procedure detailed in this section leads were crimped but not soldered Corrosion may cause inaccurate current readings Cleaning and sol Test resistance of the Black and White leads from dering the terminals to th
146. test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 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 Misc Hand Tools V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC Lr 5 TROUBLESHOOTING amp REPAIR pale INPUT FILTER CAPACITOR DISCHARGE PROCEDURE cont A WARNING Failure to follow this capacitor discharge procedure can result in electric shock e INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 1 Turn off lines input power or disconnect input power 2 Remove 14 5 16 hex head screws from side and top of machine 6 screws on each side and 2 Screws on top and remove wrap around machine cover 3 Be careful not to make contact with the capacitor terminals that are lo
147. 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 cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will determine if the Input Rectifier is defective MATERIALS NEEDED ANALOG Volt Ohm Meter multi meter Misc Hand Tools Wiring Diagram Section G V300 PRO LINCOLN F 33 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC Lr 5 34 TROUBLESHOOTING amp REPAIR F 34 INPUT RECTIFIER TEST FIGURE F 11 INPUT RECTIFIER LOCATION INPUT RECTIFIER TEST PROCEDURE 1 Perform Input Filter Capacitor Discharge 6 Inspect Main Power Switch 51 and replace if faulty as detailed in this section Go to step 7 2 Locate Input Rectifier Component D 13 3 Locate leads needed to perform tests shown in Figure F 11 4 Use ohmmeter to perform tests shown in Table F 5 Replace the Inpit Re
148. 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 cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 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 Wiring Diagram Section G V300 PRO LINCOLN F 35 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 9 1 0 iz 212 515 ply Return to Section Return to Master TOC 59b TROUBLESHOOTING amp REPAIR is OVERCURRENT PROTECTION CURRENT TRIGGER TEST cont FIGURE F 12 GETTING ACCESS TO CONTROL BOARD CONTROL BOARD CONTROL PANEL TEST PROCEDURE 4 Turn main power ON 1 Perform Input Filter Capacitor Discharge detailed in this section 5 Test for 15 VDC between leads 302 and 275D 2 Remove front panel from machine to access Control a 15 VDC is present tes
149. ules 1 2 Turn main power OFF Perform Input Filter Capacitor Discharge proce dure detailed in Maintenance section Detach and remove both Switch Board assemblies and attached capacitors See Switch Board Removal Replacement procedure Detach the fan shroud to gain access to the diode heat sink and mounting bracket When the fan shroud is lifted the tabs securing the heat sink mounting bracket will release SPRING WASHER HEX NUT CAP SCREW I LOCK WASHER HEX NUT CAP SCREW DIODE MODULE PLAIN WASHER HH P DIODE MODULE MOUNTING DETAIL 7 Mount the new module and re connect the leads IMPORTANT The replacement module will come with an instruction sheet that addresses surface preparation torque values and hardware changes Failure to follow these instructions may result in subsequent breakdown 8 Reassemble the unit being careful to use all of the insulating materials Also make certain to replace all disconnected leads in their proper location Failure to do so may result in machine damage when the power is applied 9 Perform the Test After Switch Board or Capacitor Move the diode heat sink and mounting bracket away from the Case Back Disconnect the leads from the defective Module and remove the module from the heat sink V300 PRO LINCOLN eee TROUBLESHOOTING amp REPAIR pee RETEST AFTER REPAIR Should a machine under
150. urn to Master TOC o 2 2 Return to Section Return to Master TOC ke D 5 PROBLEMS SYMPTOMS No output or reduced output the first time power is applied to machine dii TROUBLESHOOTING amp REPAIR i TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FEEDING PROBLEMS Check input voltages fuses and input voltage reconnect procedures See Installation section If high input 380 VAC or higher voltage is applied Capacitors may need conditioning Output turns on momentarily then switches off and repeats cycle Check input voltages and recon nection procedures See Instal lation section Check output terminal switch S4 and or Remote Trigger Options i e wire feeders guns cables etc RECOMMENDED COURSE OF ACTION Check continuity of 3 amp slow blow fuse located on reconnect panel See Input Filter Capacitor in this section 1 See Thermal Protection Trigger Circuit test See Overvoltage Protection DC Trigger Circuit test See Capacitor Balance test NOTE This test is necessary only if machine is connected for 380 VAC or higher See Switch PC Boarditest See Snubber Resistor lest Remote output control not function ing Machine performs well on LOCAL control Test or
151. us conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items and 8 LINCOLN ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to pr
152. where Diode Modules are used in place of individual diodes both modules on a heat sink assembly should be replaced if one fails Capacitor Bleeder Resistors R1 amp R9 Capacitors C1 amp C2 Capacitors C1 C2 C14 amp C15 on 575 v a c units Switch Boards proir to L10598 V300 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 2 Return to Section Return to Master TOC o Lr D 5 PROBLEMS SYMPTOMS Major physical or electrical dam age is observed when cover wrap around is removed F3 TROUBLESHOOTING amp REPAIR b TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FEEDING PROBLEMS Contact Lincoln Electric Service Department 1 888 935 3877 RECOMMENDED COURSE OF ACTION Machine is dead no output no fan no display No output but fan operates and the meter display is on Power Switch must be in ON posi tion Check input voltage If machine is set for single phase operation inspect to assure that WHITE and BLACK leads of the Power Cord are connected properly and RED lead is not connected and is insulated Check that input voltage set up switch and jumper A the reconnect auxiliary jumper are in proper posi tion f
153. y and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will determine if the Switch Boards are working properly This resis tance 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 PRO LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 o 8 3 Return to Section Return to Master TOC o ke 5 26 TROUBLESHOOTING amp REPAIR F 26 SWITCH BOARD TEST cont TEST PROCEDURE 1 Disconnect power to the machine and perform Input Filter Capacitor Discharge Procedure 5 described in Section F 2 Disconnect all wiring harness leads 401 403 1 8 9 12 4 5 402 404 from the Switc
154. y 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 pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will help to determine if the Power Board or associated circuitry is defective MATERIALS NEEDED Volt ohm Meter multimeter Misc Hand Tools Wiring Diagram Section G V300 PRO LINCOLN F 47 TROUBLESHOOTING amp REPAIR POWER BOARD TEST cont olo E cla 4 Listen for control relays to operate audible click of 8 2 TEST PROCEDURE contacts closing after about a 5 second delay i NOTE Perform Test before disassembling the unit a If audible click of control relay contacts closing is heard Power Board is probably z 5 Test cc b If audible click of control relay contacts closing 1 Turn main power OFF is not heard Power Board could be faulty Go to Test B 2 Position yourself at Switch Board area of the machine near Case Back so as to hear the oper NOTE f the relays en

Lincoln Electric V300-PRO User's Manual

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