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Lincoln Electric INVERTEC SVM199-A User's Manual

1. 5 5 5 2 gt 155 1 10VREF JER POWER SUPPLIES m c c 10VREF _ gt 4 x m 3 100 amp 133 s 5 5 alioa REMOTE POT INTERFACE 1ssPl lt 1 1551 div m 01W oc P 8 t up T 019 14 02 04 isle n ha sO 67 E 3074 T 4ov 400v 82 1 R138 R140 R136 man 35 a 200 200 200 J33 10 5 av 05 02 iW 1W lt 23 2700 bsa 01 50 400V Sov R66 R12 233159 77 OF REMOTE POTS t 1 TOK 5VREF 219 SPI POWER s g LLELLLLLLL 08 E CONNECTIONS 100K
2. Return to Section TOC Return to Master TOC eel ELECTRICAL DIAGRAMS G 21 PC BOARD ASSEMBLY LED SELECT PC BOARD M19875 C GZ86 LIN ENGINEERING CONTROLLED CHANGE DETAIL ADDED MAKE PER E1911 ROHS PART NUMBER DESCRIPTION MANUFACTURER No SEE BLANK INFO PC BOARD BLANK C1001498 E3165 25 75 20 REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW REFERENCES QTY NUMBER DESCRIPTION J60 519365 5 CONNECTOR PCB WW MALE RT L 5 PIN LED1 LED2 LED3 LED4 LED5 LED6 713657 13 LED T 1 3 4 RED HIGH INTENSITY OVAL P C BOARD BLANK INFORMATION R1 R2 S19400 7500 RESISTOR MF 1 4W 750 196 BUY COMPLETE AS M19875 C 2 LAYER BOARD PER E3281 51 T13381 16 SWITCH PUSHBUTTON SPST MAKES 63 BOARDS PER PANEL SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION Return to Section TOC Return to Master TOC RESISTANCE OHMS MANUFACTURE AS 19875 2 0 PART NO IDENTIFICATION CODE Return to Section TOC Return to Master TOC M19875 2 LED SELECT MAKE PER E1911 ROHS ENCAPSULATE WITH E1844 2 COATS BRUSH COAT ACCEPTABLE TEST PER E3964 ST NOTES N A DO NOT COAT WITH ENCAPSULATION MATERIAL N B INSERT ITEM 2 BETWEEN ROWS OF LED S ITEM 2 MUST BE FLUSH WITH LED BULB elo olg o c gt 3 55 Dio
3. 10 55 VOC OPERATION DC Input 452 505 5 15VOLTS 750 AMP xB 2 UCZB44AN 5 7815CDT Machi Shut Capacitor 19 15 GNI Return to Section TOC Return to Master TOC 30 55 VOC OPERATION OVERVOLTAGE SHUTDOWN i5VOLTS 250 AMP SPI 820pF 50V 78 05 GN 5VOLTS 100 AMP CAN 20 VOLTS 200 GATE DRIVE elo olg c gt
4. a Tct ar m gt 12 elo olg c gt 5 5 c usn THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY 8 0 OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC INVERTER WELDER ON 3 PLACE DECIMALS IS 002 DOCUMENT Ci TO AGREE 7 SCHEMATIC DIGITAL CONTROL VISION DO NOT SCALE THIS DRAWING NONE foare 10 26 2006 wuvec CRM22115 GA MANUFACTURING TOLERANCE PER E2056 EQUIPMENT TYPE ON 2 PLACE DECIMALS IS 02 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 2 ELECTRIC V450 PRO dd ELECTRICAL DIAGRAMS one SCHEMATIC DIGITAL POWER SUPPLY PC BOARD G5631 WER SUPPLY Return to Section TOC Return to Master TOC
5. VOLTAGE 200 208 200 208V VOLTAGE 440 460V 200 208V fm 220 230V 440 460V 550 575 220 230 440 460V t 550 575V VOLTAGE 550 5751 200 208V IN 440 460V 550 575V THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A NOTE Turn main input power to the machine OFF before performing connection procedure Failure to do 0 will result in damage to the machine INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and wire sizes Fuse the input circuit with the recommend ed super lag fuse or delay type breakers also called inverse time or thermal magnetic circuit breakers Choose an input and grounding wire size according to local or national electrical codes Using fuses or circuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if the machine is not being used at high currents INPUT VOLTAGE CHANGE OVER FOR MULTIPLE INPUT VOLTAGE MACHINES ONLY Welders are shipped connected for the highest input voltage listed on the rating plate To move this connec tion to a different input voltage see the d
6. LL RE D 1 Safety Preca tions ss iua osa NOE E Ru Seen eee RES D 2 Routine Maintenance Rh s RE RE Den Eo Dae e Odo eee Ee X X RUP a D 2 Major Component Location 2 D 3 V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i gt 5 2 Dllo amp c Return to Section TOC Return to Master TOC MAINTENANCE SAFETY PRECAUTIONS WARNING 6 ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves 2 EXPLODING PARTS can cause injury Failed parts explode or cause other parts to explode when power is applied Always wear a face shield and long sleeves when servicing See additional warning information throughout this Operator s Manual CAPACITOR DISCHARGE PROCEDURE 1 Obtain a power resistor 25 ohms 25 watts 2 Hold resistor body with electrically insulated glove DO NOT TOUCH TERMINALS Connect the resis tor terminals across the two studs in the position shown Hold in each position for 1 second Repeat for all three capacitors
7. gt ELECTRICAL DIAGRAMS LEFT SIDE OF MACHINE CONTROL BOARD SOLID DIGITAL POWER SUPPLY BOARD TN mmm 8 1 2 4 253 254 POWER BD RECTIFIER Stamp ioo 2400F 100 Sw TOP LOAD LINE TO CONTACTOR TO RECONNECT PANEL A o TO 444 TOAUX 1 MAIN CHOKE cm THERM P59 AUXILIARY TRANSFORMER 1 xs ov 51 pis x 24 v 42 V TO POWER BD RECTIFIER 224A j CHOKE AE THERM CURRENT TO SOLID STATE RELAY TO AUX 2 RECONNECT PANEL TO FAN RANSDUCER MAIN TRANSFORMER LEFT SIDE SWITCH BD 2 5001 200 190 MAIN TRANSFORMER HARMONIC 20 FILTER RECONNECT SWITCH Hia TQ AUX 2 SWITCH TO AUXGH THIS AREA VIEWED FROM REAR OF MACHINE N B N G NH SWITCH To SWITCH BD 1 NC Toswi NJ man E 2 220230 7 440 460V SWITCH BD 1 550 575 V FILTER TO RECONNECT SWITCH 19 INPUT INPUT BOARD RIGHT SIDE 5 lt 5 5 lt 5 5 TO CONTACTOR
8. Power Switch 24 42 10 Amp Wire Feeder Circuit Breaker 115V Auxiliary Power amp Wire Feeder Circuit Breaker 6 pin Remote Work Stud Electrode Stud 14 Pin Wire feeder Remote Auxiliary Output 110V or 220V STD Display Board Weld Terminal Remote ON Output Control Remote Local Wire Feeder Polarity Switch Control Knob Mode Panel or optional Advance Process Panel found underneath Front Panel Door Thermal Light CONTROL CLEVELAND SC NONE garsize_ SUBJECT MACHINE SCHEMATIC NUMBER REVISION for Pow oma PEE 64875 Case front Detail THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC EQUIPMENT TYPE INVERTEC V450 PRO PAGE 3 3 DOCUMENT DOCUMENT INVERTEC V450 PRO GG ELECTRICAL DIAGRAMS SCHEMATIC DIGITAL CONTROL PC BOARD G3789 SHEET 1 ENGINEERING CONTROLLED 032768459 MANUFACTURER Yes US Ou ys xm 1 1 1 T tu inus pu 2 I cwn 3 a Cle
9. A al 1 iE Wwe 4m al REDI pia eis ja nena Lie Ta IERI X Ha 8 apr 1 Xm Pa seat En E is for reference only It may not be accurate for all machines covered by this manual 5252 W gt i p HCPL ERB re n E EL TA wu pou MCi n4Bz xim d eH Sz Leti jar 16 H H P DELI T sm 5 L lam MUEZED HARE E WMEZETGREITI 1228 ot lay np og DUPI EA 85232 COMMUNICATION JNE BARRIER COMMUNICATION CIRCUITRY THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL 5 OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC MANUFACTURING TOLERANCE PER E2056 ON2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS IS 002 ON A
10. RESISTOR CAPACITOR TERMINALS RESISTOR 5 CAPACITOR TERMINALS 3 Use a DC voltmeter to check that voltage is not present across the terminals on three capacitors VISUAL INSPECTION Clean interior of machine with a low pressure air stream Make a thorough inspection of all compo nents Look for signs of overheating broken leads or other obvious problems Many problems can be uncovered with a good visual inspection ROUTINE MAINTENANCE 1 Every 6 months or so the machine should be cleaned with a low pressure airstream Keeping the machine clean will result in cooler operation and higher reliability Be sure to clean these areas All printed circuit boards Power switch Main transformer Input rectifier Auxiliary Transformer Reconnect Switch Area Fan Blow air through the rear louvers 2 Examine the sheet metal case for dents or breakage Repair the case as required Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained All external sheet metal screws must be in place to insure case strength and electrical ground continuity OVERLOAD PROTECTION The machine is electrically protected from producing high output currents Should the output current exceed 570A an electronic protection circuit will reduce the current to approximately 100A The machine will con ti
11. elo olg o c gt 5 5 cio T LEFT DISPLAY BLOCK H a b c d e f g h GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 HC3680 MFD 022 50V UNLESS RESIS Ohms 1 4W UNLESS DIODES 1A 4 00V UNLESS OTHERWISE SPECIFIED MC14489DW Vss 77 FRAME CONNECTION e EARTH GROUND CONNECTION THIS ENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLI PROPRIETARY amp CONFIDENTIAL OTHER PARTI USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GL SINCE COMPONENTS OR CIRCUITRY PRINTED CIRCUIT BOARD MAY CHANGE PESIGN INFORMATION REFERENCE EQUIPMENT UNIFIED SPI PANELS WITHOUT AFFECTING THE INTERCHANGE DRAV ML ABILITY OF A COMPLETE BOARD THIS SUBJECT SCHEMATIC DISPLAY PCB REVISION DIAGRAM MAY NOT SHOW THE EXACT ENGINEER MLD COMPONENTS OR CIRCUITRY OF CONTROLS SCALE THIS MATERIAL APPROVAL PROJECT 2 HAVING A COMMON CODE NUMBER ___ APPROVED DRAWING oispostrion NA pare 04 19 2006 CRM38136 11108 4E0 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be
12. J ENABLE BANK DATA IN xc 1 CLOCK 8 HC14AD MC14489DW HC14AD LEDs en THERMAL LEUS LEFT DISPLAY RIGHT DISPLAY AT Q1 1220 LED3 Leo gt THERMAL LEDS 00 BANKI TO CONVERT TU TEST FIXTURE DISPLAY BOARD 2 CONNECT SPDT SWITCH AS FOLLOWS REMOVE R22 AND R23 BANS VIA 2 CONNECT A NORMALLY OPEN PUSHBUTTON PM AS FOLLO ENABLE BANK 12 DATA IN yg 5 O 4 CLOCK Rx Return to Master TOC Return to Section TOC MC14489DW THE LOCATIONS OF VIA 1 THRU VIA 5 ARE SILKSCREENED ON THE BOARD VIA 1 POSITION TO TESTS CS7 DISPLAY BOARDS POSITION A TO TESTS ALL OTHER CHIP SELECT BOARDS RIGHT DISPLAY BLOCK DATA QUT BANKI 7 LOGIC TABLE BOARD 10 x0000010 BANK INPUTS OUTPUTS ENABLE BANK X2 Y ves ces les d EN X3 Pin 11 DATALIN ys CS3 CS2 CS1 ssp x7 ZEN _ MISO CLOCK 2 28 Rx i MC14489DW E 502 X L
13. POWER SOURCE CONTACTOR SWITCH MUST BE IN THE fi MAGNUM GUN ON POSITION OR USE A was AND CABLE Je K848 JUMPER PLUG KIT qm ASSEMBLY um WIRE FEEDER e _ K1870 1 ELECTRODE CABLE eio 091 ms 3 5 5 gt amp WORK CLAMP CONROL CABLE MODEL V450 PRO Zi 5 1819 10 SEMIAUTOMATIC Qu K1871 1 MODEL la INVERTEC V450 PRO LINCOLN B MAGNUM GUN AND CABLE ASSEMBLY ELECTRODE CABLE Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f gt 5 5 Dllo amp Return to Section TOC Return to Master TOC Bet INSTALLATION Aet LN 742 Connection Instructions Turn the Invertec power switch off A K1819 1 Input cable assembly is required to con nect the LN 742 to the Invertec Connect the control cable from the LN 742 to the 14 pin MS style connector Connect the electrode cable to the output terminal of the polarity required by electrode Connect the work lead to the other terminal Set the meter polarity switch on the front of the Invertec to coincide with wire feeder polarity used The wire feeder will now display the welding volt ag
14. ui aoe ta oe DE UE AE i EAE B 1 Safety PreCautiOns wesc soe eere aber eis B 2 General Description i e ee ala B 2 Case Front 6 2 Hidden Middle Control Panel 1 1 4 B 3 TIG GTAW nre nv B 4 CV Inne rshieldi Ex RR EERE B 4 Weld Mode Select orescence itd deck e brace need B 5 Memory Selections cock d Secs EE A bu RE E Eus B 6 Weld Mode DetallS ise eR Re PODER RU Meee DEDE EIS P ERROR YS B 7 Pulse Programs rp RC EE Eam bu ux IX eb ER d aeu a B 8 Remote Control Selection B 9 Limitations eects EE E eR e E NE V B 10 V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 091 o gt 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC B2 OPERATION B2 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Do not touch electri
15. 69 2 Return to Section TOC Return to Master TOC 5 o gt 2 r OPERATION ES LN 10 DH 10 Wire Feeder Compatibility Note The LN 10 and DH 10 feeders can be used to pulse weld and in the power mode with the panel The displays on the LN 10 amp DH 10 do not show the wire feed speed or power 9 SERIAL PORT FOR SOFTWARE UPDATES 10 HOT START and ARC CONTROL features have different functions depending on the welding Mode that is active Each feature is described under the welding mode heading See Item 8jor BA for specified Mode Operations See Figure 1 2 LOWER CASE PANEL See Figure B 1 The output studs Meter Polarity switch and remote connector are located on the lower case front 11 Both Output terminals are STUD connectors 12 The METER POLARITY switch is located above the out put connectors The switch provides a work connection for wire feeder voltmeters Place the switch in the position of the electrode polarity indicated by the decal The switch does not change the welding polarity 13 6 pin MS style connector for remote control 14 14 PIN MS style connector for wire and remote control 15 AUXILIARY POWER 115VAC 42VAC and 24VAC power is available from the 14 pin MS style connector 42 supply is rated at 10 amps 24 supply is rated at 10 amps 115VAC outlet rated at 15 amps Earlier models us
16. V450 PRO LINCOLN B THEORY OF OPERATION ENT FIGURE 4 CONTROL BOARD amp MODE SELECTION BOARD CURRENT MAIN TRANSFORMER re zl SENSOR OUTPUT TERMINAL INPUT INPUT CONTACTOR RECTIFIER Return to Section TOC Return to Master TOC CAPACITOR VOLTAGE FEEDBACK SWITCH BOARD OUTPUT TERMINAL THERMOSTATS CURRENT FEEDBACK CONTROL BOARD VOLTAGE FEEDBACK POWER BOARD MODE BOARD OR ADVANCED MODH BOARD Return to Section TOC Return to Master TOC WIRE FEEDER 85232 VOLTAGE THERMAL RECEPTACLE CONN SENSI LIGHT RECEPTACLE CONTROL BOARD amp MODE SELECTION The control board performs the primary interfacing The control board also monitors the thermostats main functions to establish and maintain output control of the transformer primary current and capacitor voltage INVERTEC V450 PRO Refer to Figure E 4 The activates either the thermal light and or the status control board sends and receives digital command light Dependent upon the fault situation the control information through the wire feeder receptacle and or will either disable or reduce machine output or the RS232 connector The software that is contained de energize the main input contactor within the control board processes and compares these commands with the voltage and current feed back information it receives from the current sensor and voltage sensing lea
17. e og gt 5 5 cio Return to Section TOC Return to Master TOC Return to Master TOC G 5 ELECTRICAL DIAGRAMS SCHEMATIC COMPLETE MACHINE G4875 SHEET 3 LINCOLN amp ELECTRIC 18 9 ENGINEERING CONTROLLED CHANGE DETAIL CB2 AND FUSE REVISED AMPS MANUFACTURER No REVISED NOTE N B CONTROL BOARD STD DISPLAY PC BOARD ASSEMBLY SPI ASSEMBLY REMOTE PC BOARD ASSEMBLY LED SELECT PC BOARD ASSEMBLY G 5 Error codes for the Invertec V450 PRO The following is a list of possible error codes that the Power Wave can output via the status light FACTORY MODE PANEL ASSEMBLY Error Code Indication S 1 S1 is not used Unprogrammed Weld Mode Contact the Service Department for instructions on reloading the Welding Software Empty Weld Table Contact the Service Department for instructions on reloading the Welding Software Weld Table checksum error Contact the Service Department for instructions on reloading the Welding Software Primary overcurrent error Excessive Primary current present May be related to switch board or output rectifier failure 32 Capacitor A under voltage Left side facing machine 33 Capacitor B under voltage Right side facing machine Low voltage on the main capacitors May
18. G 18 PC Board Assembly LED Potentiometer PC Board 19874 G 19 Schematic LED Select PC Board 525259 2 24 G 20 PC Board Assembly LED Select PC Board 19875 G 21 NOTE Many PC Board Assemblies are now totally encapsulated surface mounted and or multi lay ered and are therefore considered to be unserviceable Assembly drawings of these boards are no longer provided V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC elo c gt 3 512 cio Return to Section TOC Return to Master TOC G 2 WIRING DIAGRAM COMPLETE MACHINE G4923 INVERTEC V450 PRO WIRING DIAGRAM SPIFLEX CIRCUIT TERMINALS LED SELECT LED SELECT WIRE FEEDER REMOTE REAR VIEW NOTE IF ADVANCED PROCESS PANEL IS INSTALLED THERREMOTEISP CABLE PLUGS INTO THE ADVANCED PROCESS PANEL ADVANCED PROCESS PANEL SPI CABLE CONNECTS TO THE SPI EXTENSION CABLE FRONT OF MACHINE 54 N G 15 RECEPTACLE S4 SPI EXTENSION CIRCUIT 53 2207 352A RECEPTACLE Y sacircurr BREAKER eo mars Xr TOWORK TOELECTRODE 202A RI son a5 d ELECTRODE zoea TRL
19. 8 211 212 213 123 4 918 gt els ele 5 6 7 8 216 CURRENT TRANSDUCER TEST PROCEDURE 1 Remove input power to the V 450 PRO 2 Using the 3 8 nut driver remove the case 7 ELECTRIC SHOCK can kill top and the control box cover WARNING eio OJO f i olg gt 5 5 amp High voltage is present when 3 Locate the current transducer leads at input power is applied to the Control Board plug J8 See Figure 10 machine 4 Carefully apply input power to the V 450 PRO Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B Return to Section Return to Master TOC Return to Section TOC eio OJO 091 gt 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 45 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST continued 5 Turn on the V 450 PRO Check for the correct DC supply voltage to the current transducer at plug J8 See Figure 10 A Pin 2 lead 212 to pin 6 lead 216 should read 15 VDC B Pin 3 lead 213 to 6 lead 216 should read 15 VDC If the DC supply voltages are not present the control board may be faulty If both of the supply voltages are low or missing check the associated leads between plug J8 and current transducer plug P91 and th
20. S FIGURE F 3 INPUT RECTIFIER 8 5 c c INPUT RECTIFIER cc Return to Master TOC e 69 E o 8 ps PROCEDURE 15 1 Remove input power to the INVERTEC NOTE Some RTV sealant may have to be alz V450 PRO removed from the input rectifier terminals gt The RTV should be replaced when test is 2 Using the 3 8 nut driver remove the case top complete T 5 E Perform the Capacitor Discharge Procedure 5 with the Phillips head screwdriver remove the 4 Locate the Input Rectifier and lead locations positive and negative leads from the rectifier Refer to Figure F 3 Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B Return to Section Return to Master TOC Return to Section TOC eio OJO E f i 091 3 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR nee INPUT RECTIFIER TEST PROCEDURE continued 6 Use the analog ohmmeter to perform the tests 9 If the input rectifier is good be sure to recon detailed in Table F 1 nect the positive and negative leads to the cor rect terminals and torque to 31 in Ibs See the 7 If the input rectifier does not meet the accept Wiring Diagram able readings outlined in the table the compo nent may
21. eget pad E E A 3 Lifting Stacking amp Machine Grounding A 3 High Frequency A 3 put Connection lt lt denn nd ia eS A 3 Input Fuse and Supply Wire Considerations A 4 Negative Electrode Polarity A 5 Connections of Wire 0 A 6 Parallel Operation 04 404 bere ______ eg A 7 INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 2 Return to Section TOC Return to Master TOC 5 o E 2 tc INSTALLATION TECHNICAL SPECIFICATIONS V450 PRO INPUT AT RATED OUTPUT THREE PHASE ONLY INPUT VOLTS OUTPUT INPUT IDLE POWER FACTOR EFFICIENCY FREQUENCY CONDITIONS CURRENT POWER 0 RATEDOUTPUT RATED AMPS VOLTS DUTY CYCLE AMPS OUTPUT 208 230 460 575 450 38 100 58 53 25 22 570 60 82 78 37 31 400 Watts 95 MIN 88 400 36 100 49 45 2318 200 220 440 575 SOHZ 5ooA 40V 60 67 61 31 25
22. 5 5 c 6 78 05 09 GND 50V dide 180 09 600v 20 VOLTS 200 DRIVE Dy SE SPECIFIED SPECIFIED FIED INFORMATION ISE L 10 EQUIPMENT MISCELLANEOUS eee HEM DIGITAL POWER SUPPLY PCB A ENGINEER 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 TE INVERTEC V450 PRO G 11 SCHEMATIC INPUT PC BOARD M19528 ELECTRICAL DIAGRAMS G 11 PRE CHARGE CONNECTIONS CONTACTOR 00 Return to Section TOC Return to Master TOC CONTACTOR COIL CONNECT CONTACTOR CONTROL 13V FROM CONTROL BOARD Return to Section TOC Return to Master TOC PRE CHARGE CONTROL 5 CNY17 3V 1 4 SINGLE PHASE DETECT elo og o c gt 5 5 cio GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 25 0 1 CAPACITORS 22 5 V UNLESS OTHERWIS
23. DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 71 TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER NO 1 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of auxiliary trans former No 1 MATERIALS NEEDED 3 8 Nut Driver Wire Cutters Wire Splicer and Soldering Equipment INVERTEC V450 PRO LINCOLN B F 71 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e 69 2
24. 6 The left display will change to ICAL to indicate 15 that current calibration is in progress The right display will scroll the following mes sage Adj oCP SorEAL cur 300A Adjust the Output Control knob until the actual output current reading on the test ammeter is 300amps 2A Wait for the machine s output to be automatically turned off and then back on Adjust the Output Control knob again if nec essary to make the actual output current read ing on the test ammeter 300 amps 2 Wait for the machine s output to be automati cally turned off and then back on Repeat the above two steps if necessary Press and release the Mode SELECT MEM ORY button to save the calibration The left display will scroll the message IcAL SAVEd The machine will reset to normal operation INVERTEC V450 PRO LINCOLN B F 17 18 NOTES INVERTEC V450 PRO LINCOLN F 18 DOL 19159 01 DOL 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC F 19 TROUBLESHOOTING AND REPAIR WARNING Service and repair should o
25. LED BANK 2 lt 3 SWITCH 4 RAL IN MATION LAST NO USED R 2 LED 6 ECTRICAL SYMBOLS PER E153 1 APACITORS MFD 022 50V UNLESS OTHERWISE SPECIFI ESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED DIODES 1A4 400V UNLESS OTHERWISE SPECIFIED elo o c 3 5 Dio cio THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NO L COMMUNICATED PROPRIETARY amp CONFIDENTIAL TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LI E SINCE COMPONENTS OR CIRCUITRY PRINT D CIRCUIT BOARD M GN INFORMATION REFERENCE EQUIPMENT V 350 E 01 OF 01 WITHOUT AFFECTING THE I ANCE WN BY DOCUMENTI ABILITY OF A COMPLETE B SUBJECT SCHEMATIC LED S NUMBER REVISION DIAGRAM MAY NOT SHOW NEER CFH COMPONENTS OR CIRCUITRY L MATERIAL APPROVAL PROJECT HAVING COMMON CODE APPROVED DISPOSITION NA DATE 8 9 2006 CRM38150 A 5 25252 200 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp INVERTEC V450 PRO
26. doa 2 S oO 16 0 1W gt 155 1 2 153 15 130 SL 20 0K fa x 6 DG201A0Y 7 EIS 0 T 07A 3 WT Tolo cas 14 PIN SENSE 01 01 01 01 01 5 sov sov sov T sov T sov 5 E took 3 2o 2 CONNECTED gt sse UNCONNECTED isse asri V 155 1 L n n d 3 35 C37 5 X8 X8 M ox OL ul x A y ots xT Sov 7 GND 100 0 33074 ADT 33074A0T 33074ADT DG201ADY 1 8 e V DGZ0LADY DG201ADY it 11 it 4 R22 ERN 1 ITE A 155 Visser Vest Pe USE NS GENERAL INFORMATION R137 R139 R135 BIN ELECTRICAL SYMBOLS PER E1537 ea 200 200 200 Jii NA THESE PINS SHOULD NEVER USED BECAUSE THEY x75 15 NA CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED E 06 1w 4 gt 75 OF REMOTE POTS EE THE DUO Bii RESISTORS Ohms 1 44 UNLESS OTHERWISE SPECIFIED LABELS 2790 F bsa n ar x35 gt NA DIODES 1A 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET i 4338 POWER SUPPLY SOURCE POINT Tk REMOTE 57 COMMON CONNECTION 17 FRAME CONNECTION 077 100 2 EARTH GROUND CONNECTION 5 TAS M E THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OW BY LINCOLN GLOBAL IN
27. Carefully apply the correct input power and check for 115 VAC at plug P51 pins 1 and 4 If 115 VAC is present the Auxiliary Transformer No 2 is good 8 TRANSFORMER 2 If 115 VAC is not present between pins 1 and 4 check the associated leads and plugs for loose or faulty connections A WARNING High voltage is present at plug P50 9 Carefully test for the correct AC input voltage applied to the primary windings at H6 and H1 P50 Pins 1 and 5 Normal is 550 575 VAC See wiring diagram 10 If the correct AC input voltage is applied to the primary of the Auxiliary Transformer No 2 and the secondary voltage is NOT correct the transformer may be faulty Replace Install the left and right case sides using the 3 8 in nut driver INVERTEC V450 PRO LINCOLN B F 34 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC F 35 TROUBLESHOOTING AND REPAIR WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throu
28. The resistance reading pin to corresponding pin should be zero ohms or very low resis tance f the resistance reading is high or open check the plug connections to the SPI network PC boards If the connections are OK and the resistance is high or open the SPI cable may be faulty Reconnect the plug into the control board With plug J33 reinstalled in the control board carefully apply the correct input power to V450 PRO 15 16 Turn on the machine Carefully check for the presence of 15VDC from plug J33 pin 1 to plug J33 pin 10 at the display board receptacle Carefully check for the presence of 5VDC from plug J33 pin 2 to plug J33 pin 10 at the display board receptacle If either of these voltages are low or not pre sent the control board may be faulty Replace Also Perform the Power Board Test Remove the input power to the V450 PRO machine Replace any cable ties previously removed Replace the case front FIGURE 15 Plug J33 PLUG J33 INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 59 TROUBLESHOOTING AND REPAIR CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should
29. G 14 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY SWITCH PC BOARD 63734 VELeD ENGINEERING CONTROLLED CHANGE DETAIL ADDED 6 AND NOTE ITEM USED WITH PART NUMBER DESCRIPTION MANUFACTURER No REVISED MANUFACTURED AS IDENTIFICATION CODE AND SCHEMATIC REFERENCE PART NUMBERS 7 BOARD BLANK BOARD BLANK REFERENCE INFORMATION N D 2 B11 B19 B20 19147 11 CONNECTOR EYELET POWER FEMALE 524869 2 PC BOARD SHIELD fme BUY COMPLETE AS G3734 E 4 LAYER BOARD PER E3281 ESI EPOXY ENGAPSULATING REST N A CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC 1 524869 1 PC BOARD SHIELD 1oz E2861 SEALANT ELECTRICITY SEE E2454 BEFORE HANDLING SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION N D FEMALE EYELET TO BE AGAINST THE COPPER SIDE AS SHOWN D EYELET MUST NOT SPIN AFTER CLINCHING REFERENCES QTY NUMBER DESCRIPTION N E SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET AND N A N J N R AT AZ 21214 2 ELECTRONIC MODULE 5 112704 84 IGBTS B11 B19 B20 T9147 15 CONNECTOR EYELET POWER MALE ALL AROUND EYELET ON COPPER SIDE ONLY NO ICICLES OR GE 13 524866 BRACKET POWER HOLDER SOLDER BLOBS PERMITTED MUST BE SMOOTH AND EVEN WITHIN 020 OVER SURFACE S 523006 CONNECTOR TERMINAL POWER N H MOLEX CAVITIES AND AREA AROUND LOCKING TAB TO BE FREE OF ENCAPSULATION MATERIAL 045 520500 14 022 100 8 0 5 MASK PER A
30. Hertz per voit T 206 325 Volts 2600 Hertz X Return to Section TOC Return to Master TOC HARMONIC M frequency FILTER 7 240 3 IGBT DRIVE 27 440 6 IGBT DRIVE A Located m Tont side CURRENT SWITC H BOARD 2 c TRANSDUCER 125 1 Located right of Work stud _ TO 14 PIN AMPHENOL See Page 2 11385 NB Located on right side of machine Located on rear Located behind horizontal baffle me reconnect panel Located bottom left side Located Behind Work Stud UNA INPUT LINE FILTER 8 Hertz per Volt 325 Volts 2600 Hertz 5 frequency 20 3504 Ma 15 RE 1603 GBT DRIVE 4506 IGBT DRIVE 48 4605 Located on rear Toroid from horizontal panel main harness Return to Section TOC Return to Master TOC Located behind INPUT BOARD pid reconnect panel Schematic M19528 _ Not recommended for Located in reconnect single phase operation cavity in rear of machine 13V gt 4605 238 U INGLE PHASE DETECT LOW 1 PHASE 5 6 231 1 2 2 2200 224 29 OUTPUT RECTIFIER CHOKE THERM THERM Bolted Connected with 206 Connection epoxy 414 418 514 Fe
31. RECEPTACLE A BAND LEADS A B AND C ARE CONNECTED TO THE INPUT EQUIPMENT TYPE INVERTEC V450 PRO 4 W Vice GONE TRG PE ake Located on the right side of Located on the left side of 115V RECTIFIER TERMINALS RATHER THAN CRI EPRINTED SUBJECT MACHINE SCHEMATIC Harmonic Filler Harmonic Filter RECEPTACLE on case font ITH PUBLSHED STANDARDS 2 TNT REFERENCE Located on case font DO NOT SCALE THIS DRAWING INCH wingers CRM36847 _ 4421 04875 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 amp ur V450 PRO of ELECTRICAL DIAGRAMS G 4 SCHEMATIC COMPLETE MACHINE G4875 SHEET 2 61879 ENGINEERING CONTROLLED CHANGE DETAIL CB2 AND FUSE REVISED AMPS MANUFACTURER No REVISED NOTE N B NOTES N E THE REMOTE UI PCB ALWAYS RESPONDS AS A REMOTE SPI BOARD CONNECTING PINS 1 amp 2 OF J333 TOGETHER WILL ENABLE THE REMOTE UI PCB TO RESPOND AS A STATUS SPI CONNECTING PINS 11 amp 14 OF J332 TOGETHER WILL ENABLE THE REMOTE UI PCB TO RESPOND AS A MODE PCB 253 254 Return to Section TOC Return to Master TOC LEDS 10 TOTAL DIP SWITCH 1 BANK OF 8 SEE PAGE 3 FOR DETAILS gt 2 3 gt TRANSMIT gt 2 4 2 gt J2 1
32. RIGHT SIDE OF MACHINE TO MAIN TRANSFORMER NE HEr 54 HOA P ima m aas 1 5 AUXILIARY TRANSFORMER 2 TOSW1 NOTES N A PIN NEAREST THE FLAT EDGE OF LED LENS CATHODE ALIGNS WITH BLACK LEAD OF LED SOCKET PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR 440 575V OPERATION N C PLACE A LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE CONNECTION SHOWN IS FOR 550 575V OPERATION N D PIN NEAREST THE FLAT EDGE OF LED LENS ANODE ALIGNS WITH WHITE LEAD OF LED SOCKET N E LEAD 34 IS PRESENT IN MODELS WITH 115V RECEPTACLE ON THE CASE FRONT LEAD 352A IS PRESENT ONLY IN MODELS WITH 220V RECEPTACLE ON THE CASE FRONT N F ONLY PRESENT ON CE MODELS N G ONLY PRESENT ON NON CE MODELS EARLIER MODELS USED 10A CIRCUIT BREAKER CE MODELS DO NOT HAVE A RECONNECT SWITCH POS LEAD CONNECTS DIRECTLY TO OF C4 LEAD C CONNECTS OF C4 TO C5 AND NEG LEAD CONNECTS TO OF C5 N J THE CE MODELS DO NOT HAVE A RECONNECT PANEL INSTEAD LEAD H4B CONNECTS H4 TO SW1 N K ON CE MODELS LEADS T1 T2 AND T3 ARE REPLACED BY LEADS A B AND C LEADS A B AND C ARE CONNECTED TO THE INPUT RECTIFIER TERMINALS RATHER THAN 1 RECTIFIER E ANIHOVW CRI E TOAUX T is n 1 w v U TO SUPPLY LINES SYSTEM GROUN
33. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC F 39 POWER BOARD TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the power board is receiving the correct voltages as well as if the power board is regulating and producing the correct DC voltages MATERIALS NEEDED 3 8 in Nut Driver Volt Ohmmeter Wiring Diagram INVERTEC V450 PRO LINCOLN B F 39 TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 3 c gt 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 40
34. This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into the following categories output problems and welding problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem 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
35. 2 Return to Section Return to Master TOC o 5 o gt 2 r dia TROUBLESHOOTING AND REPAIR iue AUXILIARY TRANSFORMER NO 1 REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 20 DOOR REMOVAL 3 8 MOUNTING SCREWS 2 TRANSFORMER 1 REMOVAL PROCEDURE 1 Remove input power to the V450 PRO 5 Remove leads 41B and unplug P59 Figure F 20 2 Using the 3 8 nut driver remove the case top and input access panel 6 Label and cut or remove all primary and sec ondary leads from transformer 1 See Wiring 3 Perform the Capacitor Discharge Procedure Diagram 4 Using the 3 8 nut driver remove the case back 7 Disconnect plug P59 See Figure F 20 INVERTEC V450 PRO LINCOLN B TROUBLESHOOTING AND REPAIR Pads AUXILIARY TRANSFORMER NO 1 REMOVAL AND REPLACEMENT PROCEDURE continued 8 Cut any necessary cable ties and clear the leads 9 Using the 3 8 nut driver remove the two mounting screws that hold the transformer to the fan baffle and the machine base Return to Section TOC Return to Master TOC 10 Carefully remove the transformer from the V450 PRO REPLACEMENT PROCEDURE 1 Carefully place the transformer into the V450 PRO 2 Install the two mounting screws that hold the transformer to the fan baffle and the machine base using the 3 8 nut driver Reconnect plug P59 and lead 41B Reconnect all
36. 2 0 67 mm 3 0 85 mm 3 0 85 mm 400 Amps 500 Amps 600 Amps NOTE K1796 coaxial welding cable is recommended to reduce the cable inductance in long cable lengths This is especially important when Pulse welding up to 350 amps CAUTION When using inverter type power sources like the V450 PRO use the largest welding electrode and work cables that are practical At least 2 0 67 mm copper wire even if the average output cur rent would not normally require it When pulsing the pulse current can reach very high levels Voltage drops can become excessive leading to poor welding characteristics if undersized welding cables are used INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f gt gt 5 5 Dllo amp c Return to Section TOC Return to Master TOC RS INSTALLATION Aon CABLE INDUCTANCE AND ITS EFFECTS ON PULSE WELDING For Pulse Welding processes cable inductance will cause the welding performance to degrade For the total welding loop length less than 50 ft 15 24m tradi tional welding cables may be used without any effects on welding performance For the total welding loop length greater than 50 ft 15 24m the K1796 Coaxial Welding Cables are recommended The welding loop length is defined as the total of electrode cable length A work cable le
37. 40 ON COMPONENT AND NON COMPONENT SIDES OF BOARD 6 PLACES DO NOT COAT WITH ENCAPSULATION MATERIAL APPLY ITEM 2 AS SHOWN ALL EXPOSED LEADS MUST BE COVERED MATERI MUST BE APPLIED PRIOR TO ENCAPSULATION APPLY ITEM 2 ON NON COMPONENT SIDE OF BOARD PRIOR TO ENCAPSULATION ALL EXPOSED PINS MUST BE COVERED 6 00 04 olg o c gt 3 55 Dio cio MAKE PER E1911 ROHS ENCAPSULATE WITH E1844 MANUFACTURED AS TEST PER E3647 SCHEMATIC REFERENCE 19528 280 111396 2 0 IDENTIFICATION CODE olo ALL COMPONENTS AND MATERIALS USED IN THIS ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 5 8 3 PROPRIETARY amp CONFIDENTIAL CONTAINS ONE GV INCUN ING OT E er rri INVERTER WELDERS ONAL ANGLES I OF ADEGREE ASE SUBJECT INPUT P C BOARD ASSEMBLY NUMBER aera WITH PUBLISHED STANDARDS UNITS DONOT SCALE THis DRAWING Now UF c 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
38. 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 67 TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER NO 2 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of auxiliary trans former No 2 MATERIALS NEEDED 3 8 Nut Driver Wire Cutters INVERTEC V450 PRO LINCOLN B F 67 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f gt gt 5 5 amp c Return to Section TOC Return to Master TOC Pee TROUBLESHOOTING AND REPAIR oe AUXILIARY TRANSFORMER NO 2 REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 19 TRANSFORMER AND PLUG LOCATIONS 3 8 MOUNTING SCREWS 2 REMO
39. A Do not attempt to override the governor or 2 d 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 lt 2 4 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 2 d 5 Do not work next to welding power source INVERTEC V450 PRO LINCOLN B Return to Master Return to Master TOC o 5 o gt 2 tc Return to Master TOC 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 hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped
40. B 5 Gouge Mode The gouging mode is specifically designed for car bon arc gouging with electrodes up to 3 8 Pulsed Modes In Pulse Modes The work point will be in the Amps window and should be set close to the wire feed speed of the wire feeder in inches per minute The Volts window will have SPd displayed indicating Wire Feed Speed Once current starts flowing and during the 5 second Hold feature the displays will show amps and volts Pulse Mode features that are displayed while selecting a Welding pulse mode are listed below Steel 030 035 045 052 1 16 Argon Blends Stainless Steel 030 035 045 Argon Blends amp Helium Argon Blends Aluminum 035 3 64 1 16 4043 amp 5356 Metal Core 045 052 1 16 Argon Blends Nickel 035 045 Argon Helium blends FIGURE B 2 n x T n f S 5 BEBA E OUTPUT KNOB CONTROL WELD TERMINALS an e Ei ON e SELECT SELECT LLY TOT MEMORY BUTTON M1 THRU M8 SELECT KNOB SCOLLS WELDING PROCESSES 0 THRU 10 HOT START 10 THRU 0 AND 0 THRU 10 ARC CONTROL SELECT BUTTON HOT START OR ARC CONTROL ADVANCE PROCESS PANEL MIDDLE SECTION OF WELDER OPTIONAL INVERTEC V450 PRO LINCOLN B Return
41. FOR ADDITIONAL INFORMATION R1 R2 519366 1 POT SINGLE TURN 0 5W 10K 1096 LINEAR R3 R4 R5 R6 R7 519400 2211 RESISTOR MF 1 4W 2 21K 196 51 1 113381 17 SWITCH PUSHBUTTON SPST GREEN W BLACK EXTENDER RESISTANCE OHMS LED POT MANUFACTURE AS gt 19874 2 0 IDENTIFICATION CODE ENCAPSULATE WITH E1844 2 COATS BRUSH COAT ACCEPTABLE MAKE PER E1911 ROHS TEST PER E3964 MS NOTES N A DO NOT COAT WITH ENCAPSULATION MATERIAL N B THERE MUST NOT BE MORE THAN A 010 GAP BETWEEN SPACER amp LED OR BETWEEN SPACER amp P C BOARD LEDS MUST BE PERPENDICULAR WITH P C BOARD AFTER ALL OPERATIONS ARE COMPLETE N C ENCAPSULATE AROUND BASE OF COMPONENT N D COAT EXTERNAL PINS WITH ENCAPSULATION MATERIAL N E ENCAPSULATE P C BOARD SPACER AND LOWER HALF OF LED SCHEMATIC REFERENCE S25258 2C0 ALL COMPONENTS AND MATERIALS USED IN THIS ENLARGED DETAIL ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED LED ORIENTATION PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC TESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER 2056 DESIGN INFORMATION REFERENCE EQUIPMENT INVERTER WELDERS PAGE 1 or 1 ON 3 PLACE DECIMALS IS e 002 DRAWNBY M19874 1 oC E s DOC
42. IGBT DRIVE gt 46 6 503 6110 RELAY w SWITCH 5 8 E 4 403 506 6 7 406 15 J10A gt 6 1 gt J6 E gt J10B 1 gt 4V 500AMPS CURRENT FEEDBACK 15 15V CONTROL BOARD COMMON ELECTRODE VOLTAGE SENSE ELECTRODE VOLTAGE SENSE LEAD FILTER Located right jpm 61 8 lt of Contactor 5 604 604 61 p 225 Ku 12 15 4 10 CONTROL BOARD COMMON 504 THERMOSTAT THERMOSTAT IGBT DRIVE 2 IGBT DRIVE IGBT DRIVE CT CURRENT gt J10A CT CURRENT J10B CT CURRENT CT CURRENT NORMALLY CLOSED MAIN CONTACTOR CONTROL VE o Switch Board 2 505 8 Hertz per Volt CONTROL BOARD s T 60 232 405 C Switch Board 1 325 Volts 2600 Hertz Schematic 63789 LEDS 10 TOTAL Additional outputs are 404 Kuete VIF Located on left side of control box DIP Switch 1 Bank of 8 pese Tes T am pee Single phase is 570A Max Output See pog for deta illustrated on schematic page 2 limited to 325amps Fold Back 100A 231 T SINGLE PHASE DETECT LOW 1 PHASE Remove Loadio reset Max Output 325A AUX _ 604 lt 2 PRECHARGE CONTROL Max i
43. MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Thermal light is ON The 1 The welding application may 1 One of the thermostats may machine regularly overheats be exceeding the be faulty Also check recommended duty cycle associated wiring for loose or and or limits of the machine faulty connections See the Wiring Diagram or the Dirt and dust may have Machine Diagram in Section clogged the cooling channels There are a total of 2 inside the machine Refer to thermostats in the system the Maintenance Section this manual Temporarily jumper out the aM thermostat circuit at the Air intake and exhaust louvers Control Board See the may be blocked due to inadequate clearance around the machine Check the upper section of the machine and Return to Section TOC Return to Master TOC Machine Diagram in this manual to jump this circuit function for test only If the Jj machine does not reset the AC DC switch lower section Control Board is defective If intakes it does reset perform the Make sure the fan is Thermostat Test functioning correctly Machines are equipped with F A N fan as needed circuitry The fans Return to Section TOC Return to Master TOC Temporarily jump around the fan relay contacts to test fan relay function See the run whenever the output is Machine Diagram in Section enabled and will continue test the fan relay running for a period of time approximately
44. THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC UFACTURNG TOLERANCE PER E2058 DESIGNNFORMATON REFERENCE EQUIPMENT TYPE INVERTER WELDER PAGE 1 or 4 2 PLACE DECIMALS IS 02 3 PLACE DECIMALS IS 002 wmv BY 63789 1E2 7 ON ALL ANGLES IS 5 OF A DEGREE H MATERIAL TOLERANCE t TO AGREE ENGINEER SCALI SUBJECT SCHEMATIC DIGITAL CONTROL WITH PUBLISHED STANDARDS DO NOT SCALE THIS DRAWING NONE MATERIAL APPROVAL PROJECT ATER 1026 2006 _ CRM22115 GA G3789 2FO 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 amp pube INVERTEC V450 PRO ad ELECTRICAL DIAGRAMS G SCHEMATIC DIGITAL CONTROL PC BOARD G3789 SHEET 2 Return to Section TOC Return to Master TOC Return to Section TOC olg o c gt 5 5 cio Return to Section TOC Return to Master TOC Return to Master TOC ENGINEERING CONTROLLED 03268159 MANUFACTURER Yes ni 1 12 As TL te Nenana A DEOS Wr POINT NOTE This diagram
45. WEES Return to Section TOC Return to Master TOC 915 HREM 95 iz 10 EN NMEZSTM Ane wart Tae pia 1 per a ELE 1 B m 4 nm Return to Master Return to Section TOC TEER mei Rut see PEE FB PSE 1 eg are CCMTRCLLEE HIE 1 1545 z rene ns a RS 7 TORIS EB esr 9150 1 86 eT races pruce HICH rige Lape olg c gt 5 5 Dio d c wie aee s i Rara E 5 MAPS ESL muss MP Ds m 1 a ODPIRA MOT Te E E E ds 3 n a 2 t n b 75 amaga ieza Taw E
46. c 96 L V1 ENGINEERING CONTROLLED CHANGE DETAIL REVISED NOTE N B REFERENCES MANUFACTURER No Ci CR2 o lt 3 a DESCRIPTION 516668 5 022 50 514293 18 DPST RELAY T12199 1 1N4004 T12705 58 DIODE 1 0A 1500V 524020 8 HEADER VERTICAL 524020 10 HEADER VERTICAL 515000 22 ISOLATOR 524376 3 100 10W 519400 2673 267K 1 4W 19400 4750 475 1 4W 19400 3011 3 01K 1 4W Return to Section TOC Return to Master TOC R1 R2 R6 R7 R8 R9 R10 R4 P C BOARD BLANK INFORMATION R5 BUY COMPLETE AS L11396 B RIZ R18 R S R17 R18 R19 R20 R21 R22 2 LAYER BOARD PER E3281 R23 R24 R25 MAKES 8 BOARDS PER PANEL SEE ELECTRONIC FILE TET I04 T13640 23 MOV 2504 660V a FOR ADDITIONAL INFORMATION 4 50 04 ITEM REQ D PART NO IDENTIFICATION SEE BLANK INFO P C BD BLANK 1002 EALANT 2 LASTIC EXPANSION NUT Return to Section TOC Return to Master TOC CAPACITORS MFD VOLTS RESISTORS OHMS WATTS NOTES NA THIS AREA TO BE COVERED ON BOTH SIDES OF BOARD WITH ITEM 2 PRIOR TO ENCAPSULATION MATERIAL MUST BE APPLIED THRU SLOTS FROM BOTTOM SIDE TO COMPLETELY FILL TO UNDERSIDE OF DEVICE ON COMPONENT SIDE P C BOARD HOLES TO BE FREE OF ENCAPSULATION MATERIAL AND RTV FOR A DIAMETER OF
47. cio CATHODE SQUARE N C ENCAPSULATE PC BOARD AND LOWER HALF OF LED N D ENCAPSULATE AROUND BASE OF COMPONENT ANODE N E COAT EXTERNAL PINS WITH ENCAPSULATION MATERIAL ROUND SCHEMATIC REFERENCE 525259 2 0 ALL COMPONENTS AND MATERIALS USED IN THIS ENLARGED DETAIL ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED LED ORI ENTATION PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC UNLESS OTHERWISE SPECIFIED TOLERANCE DESIGN INFORMATION REFERENCE re MN RIER PAGE OF eT 5 2 DOCUMENT MTS SCALE SUBJECT LED SELECT PC BOARD ASSEMBLY NUMBER pm MATERIAL APPROVAL PROJECT 2 DO NOT SCALE THIS DRAWING ROVED 11 pisposition UF pare 3 16 2007 NUMBER 34409 19875 2 Return to Section 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
48. electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct voltage is being applied to the primary of Auxiliary Transformer No 2 as well as if the correct voltage is being induced on the secondary winding of the transformer MATERIALS NEEDED Volt Ohmmeter Multimeter 3 8 in Nut Driver Wiring Diagram INVERTEC V450 PRO LINCOLN B F 33 AUXILIARY TRANSFORMER NO 2 TEST Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 3 c gt 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 34 TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER 2 TEST continued FIGURE F 7 PLUGS P52 AND P54 3 8 MOUNTING SCREWS 2 PROCEDURE 1 Remove the main input supply power to the INVERTEC V 450 PRO Remove any load that may be connected to the 115 VAC receptacle Using the 3 8 in nut driver remove the left and right case sides Perform the Capacitor Discharge Procedure Locate plugs P50 and P51 at the Auxiliary Transformer No 2 See Figure F 7
49. gt 5 5 Dllo amp c Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 66 TROUBLESHOOTING AND REPAIR 66 INPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 18 INPUT CONTACTOR LOCATION REMOVAL PROCEDURE 3 Perform the Capacitor Discharge Procedure Remove input power to the V450 PRO Using the 3 8 nut driver remove the case top and input access panel 4 Locate the input contactor Label leads and using the slot head screwdriver carefully remove the leads from the input contactor ter minals Note placement for reassembly See Figure F 18 With the 5 16 nut driver remove the three mounting screws Carefully remove the input contactor CONTACTOR REPLACEMENT PROCEDURE 1 Mount the contactor and tighten the mounting Screws 2 Assemble the previously removed leads to the correct terminals See wiring diagram 3 Install the case top sides and input access panel using the 3 8 nut driver INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5
50. left POS sv J COM gt 43 10 COM gt J43 12 5V COM 15V 45V SPI LEDS 2 TOTAL See page 3 for detail TO 14 PIN 459 4 24 located on lower AMPHENOL center case POWER DOWN INTERUPT FRAME GROUND Ht 169 2 51 EAR 10A E GROUND Located on the right side of 459 1 41A 51 pu Harmonic Filter 4 COMPONENT VALUE UNITS FUSE 10A 5 M19 TO Located on 650 575 i CAPACITOR MFD VOLTS reconnect area _ iv a ED Ce i center case front 352 5 9 351 CONNECTOR PIN NUMBERS AUXILIARY EX 12 PIN CONNECTOR TRANSFORMER T2 34451 4 right rear on base 5A A 31 NOTES 12 6 n N A CE MACHINE ONLY located 5124514 0090000 i B THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED o 5 9 95 reconnect J54 N B NON CE MACHINE ONLY EARLIER MODELS USED 10A CIRCUIT BREAKERS TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC 35A 220v NC ONCE MODELS LEADS T1 T2 AND T3 ARE REPLACED BY LEADS 5 hE TOR NS LEN gt J54
51. 0 005 in thick per surface 3 Mount the module to the heat sink and evenly torque the mounting screws with washers to 44 in lIbs 4 Assemble the leads to the correct module ter minals and torque to 26 in Ibs See Figure F 17 5 Apply RTV sealant to the rectifier connection terminals 6 Install the case top sides and input access panel using the 3 8 nut driver INVERTEC V450 PRO LINCOLN B TROUBLESHOOTING AND REPAIR uis INPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the input con tactor MATERIALS NEEDED 3 8 Nut Driver 5 16 Nut Driver Slot Head Screwdriver Return to Section TOC Return to Master TOC eio OJO E f i 091 3 c
52. 100K rz IS JS fs fs A A J J A 4 6 10VREF 0225W 4 7 08 RT CT mE fala ela 100K 014 E TE sa ajalises RI33 Go74ADT u asse Vise ROL VB R 10 son LU comp 337 NX 5VREF 220 100K 01W les 2843801 Le i 01 S 10 0K t 01 cst E 05 R63 50 1 H g H 8 3 tsb san 20 C51 mm E 130K 6 45VREF 4700pF X 100 csi 015 al 50 100k g 8 02 E 8i X6 3 O 5 433 lt 36221 tar 2 d 10 gt Lr 200K Suse 025 7 sel 1w 01 071 12 3 4 co m gt 6 PIN POT um o 01 Delect 6 PIN 50 ra 023 IN S 0022 05 gt zh 01 50 9 X 5 E 155 1 1 Hr ii GE 200K E 1W DG201ADY 75K 5 010 4 DV co en cz 8 6 PIN SENSE 01 01 01 01 01 01 T v Tov E 5 332 10 0K 2 00K 12V 15SPI 2 02 L CONNECTED 652 INCONNECTED J33h 155 Y GSPINZ gt GAS AUS rn x SOLENOID 600V en 38 _ am 5 10 9 55 ao SOLENOID 100v 200K 02 OIW 475K u 012 gt 14 PIN POT sov Detect 14 O LO NX 9 _ 05 E 0022 H 50V 5 o
53. 70 VDC 460 60 115 123 VAC 111 119 VAC 575 60 INVERTEC V450 PRO LINCOLN B Return to Master Return to Master TOC o 5 o gt 2 Return to Master TOC idi TABLE OF CONTENTS DIAGRAM SECTION e Electrical Diagrams 2 2 1 Wiring Diagram Complete Machine G4923 G 2 Schematic Complete Machine 84875 G 3 G 5 Schematic Digital Control PC Board 63789 G 6 G 9 Schematic Digital Power Supply PC Board 65631 G 10 Schematic Input PC Board 19528 G 11 PC Board Assembly Input PC Board 11396 G 12 Schematic Switch PC Board 111385 G 13 PC Board Assembly Switch PC Board 03734 G 14 Schematic SPI Remote Control PC Board 94017 G 15 Schematic Display PC Board 111108 G 16 PC Board Assembly Display PC Board 111130 G 17 Schematic LED Potentiometer PC Board 825258
54. 8 PULSE PROGRAMS IPM COMMENTS 030 Steel 75 800 The V450 pulse programs are non synergic and allow independent 035 Steel 50 800 control of the wire feed speed and the arc length The Output 045 Steel 60 800 Control Knob on the V450 adjusts an SPD value Similar to trim 052 Steel 60 750 the SPD value indicates the relative arc length setting The value 1 16 Steel 60 600 of SPD is meant to be a starting point at which to set the arc 045 Metal Core 60 700 length relative to the wire feed speed Depending on the applica 052 Metal Core 60 500 tion the SPD value can be adjusted to obtain the desired arc 1 16 Metal Core 60 500 length 030 Stainless Ar Blends 100 800 030 Stainless He Ar CO 100 800 The SPD value displayed on the V450 may not match the 035 Stainless Ar Blends 70 800 actual wire feed speed 035 Stainless He Ar CO 70 700 7045 Stainless Ar Blends 50 700 The operation of the Arc Control knob on the V450 is similar to the 1045 Stainless Ar 60 700 Power Wave series As Arc Control is increased the frequency is 035 Aluminum 4043 125 700 increased and the background reduced Decreasing Arc Control will 035 Aluminum 5356 130 750 reduce frequency and increase background current Arc Control 3 64 Aluminum 4043 85 600 acts to fine tune the arc plasma to the specific application 3 64 Aluminum 5356 85 700 Preferred gas selections 1 16 Aluminum 4043 55 300 zii 1 16 Aluminum 5
55. ANSI 287 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 FUMES AND GASES can 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 within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ven tilation In confined spaces or in some circumstances outdoors a respirator may be required Additional pre cautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker expo sure level should be checked upon installation and periodi call
56. E ACCeSSOFLI S ocn Rmus eem EE Eee LL LE C 1 5 5 2x feb ber RUE E mere Qaa Robe E E qur ek d don C 2 Return to Master TOC Return to Master TOC o 5 o gt 2 t Return to Master TOC INVERTEC V450 PRO LINCOLN B du ACCESSORIES ce NOTE All of the above remote controls connect direct ly to the 6 pin MS style connector with either a K864 or K876 adapter and connect it to the 14 pin wire feed er MS style connector See Diagram in Operator 2 OPTIONS ACCESSORIES 5 K857 Remote Output Control D 814 Arc Start Switch 812 Hand Operated Amptrol K870 Foot Operated Amptrol 2 5 Manual K930 TIG Module 428 K446 K449 LN 25 K617 1 or 2 K618 1 or 2 LN 742 K2327 LF 72 K2426 LF 74 K1559 1 K1564 1 LN 10 K1499 1 K1521 1 DH 10 K1587 1 Cobramatic Not recommended for pulse welding FIELD INSTALLED OPTION ALL vERSIONS Return to Section TOC Return to Master TOC K1763 1 Advanced Process Panel eio OJO f i fom eo cre 5 5 Dllo amp c Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B Return to Master Return to Master TOC o 5 o gt 2 t Return to Master TOC e TABLE OF CONTENTS MAINTENANCE SECTION Maintenance
57. M19612 CURRENT TRANSDUCER 125 TURN 6 00 04 1 13552 3 IC CONVERTER V F 654 515128 10 VOLTAGE REF ADJ 5 4311 Return to Section TOC Return to Master TOC u u a Im N NE NM N S N Q 3 PLACES elo olg o c gt 5 5 cio 12 12 138 a N T N U N V 2 00 12 11 15 04 MAKE PER E1911 ROHS POT PER E1911 E ROHS TEST PER E3901 SW NON COMPONENT SCHEMATIC REFERENCE L11385 3E1 SIDE ENCAPSULATION MANUFACTURED AS ALL COMPONENTS AND MATERIALS USED IN THIS G3734 3E1 ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 IDENTIFICATION CODE FOR PARTS ORDERS OR SUBSIDIARY ORDERS INCLUDE ONE G3010PRINT ONE M19661PRINT COMPONENT SIDE ENCAPSULATION ONE S25254PRINT AND ONE T12837 1 TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSIO
58. Steel 035 Arc lt 3 SPd is displayed in the upper right Volts window The left Amps window matches the desired wire feed speed that is set on the wire feeder Adjust the OUTPUT knob until desired number is displayed 4 Start welding If the arc length is too short turn the Output knob up If the arc length is too long turn the Output knob down The Arc Control which is displayed in the right digi tal window can be used to fine tune the arc length and characteristics After all adjustments have been made press and hold the MEMORY button until the display changes The right and the left window will display a memory position for example M1 or turn knob to select memory of your choice To store in M1 push the MEMORY button again to save the Pulse Mig mode to memory M1 9 The display in the digital windows read as follows M1 Pulse MIG Argon Blends Steel 035 Arc 1 2 7 To save a second welding mode to a memory posi tion of your choice turn the SELECT knob until the desired welding process mode is displayed in right digital window Then follow steps 2 thru 6 8 Adjust the output control to the correct wire feed set ting and the V450 PRO is ready to weld again NOTE The wire feed speed setting is not stored in memory and will need to be reset Adjust the Arc Control and note that the M1 goes away indicating that the V450 PRO settings no longer match what is stored in memory G
59. TOC Return to Section TOC eio OJO 3 c 9 1 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 41 CHECK POINT LOCATION POWER BOARD CONNECTOR PLUG J41 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J42 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CONNECTOR PLUG J43 POWER BOARD CONNECTOR PLUG J43 VDC SUPPLY FROM RS 232 SUPPLY FROM POWER BOARD SPI SUPPLY FROM SPI SUPPLY FROM CHECK 20 VDC STT TROUBLESHOOTING AND REPAIR F 41 POWER BOARD TEST continued TABLE F 4 POWER BOARD VOLTAGE CHECKS TEST CONNECTOR DESCRIPTION PLUG PIN NO LEAD NO OR IDENTITY NORMAL ACCEPTABLE VOLTAGE READING 477 4 38 42 475 225 15 VDC 222 221 5 VDC 222 i CHECK 40 VDC INPUT FROM DC BUS BOARD CHECK 15 POWER BOARD CHECK 5 VDC SUPPLY FROM POWER BOARD CHECK 15 VDC SUPPLY FROM POWER BOARD CHECK 5 VDC CHECK 15 VDC POWER BOARD CHECK 5 VDC POWER BOARD SUPPLY FROM POWER BOARD INVERTEC V450 PRO LINCOLN 42 NOTES INVERTEC V450 PRO LINCOLN F 42 DOL 19159 01 DOL 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DO
60. Y LED 6 LED 2 y R4 221K YY 5 15V LED3 161 5 03 1 R5 iq 212 10VREF 8 _ 221K Y 5 6 HLOVREF 2 15 VDC P ED O L pd 161 NX LED_4 6 R6 J6 221K Yy ele POT SUPPLY VDC 14 4 CW z 2 6 E _2 13 LEDS 16 10K LED 5 7 R7 GND 12 271 ono o GENERAL INFORMATION HELL A s Te J61 R 7 LED 5 6 lt 8 lt ELECTRICAL SYMBOLS PER E1537 e 5 o 61 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED 4 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 2 10 DIODES 1A 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE 5 5 lt C POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION L EARTH GROUND CONNECTION DDhDD THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED OPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC SINCE COMPONENTS OR CIRCUITRY Ja E PRINT D CIRCUIT BOARD MAY CHANGE DESIGN INFORMATION REFERENCE EQUIPMENT V350 LED POI PAGE 01 OF 1 WITHOUT AFFECTING THE INTERCHANGE DRAWN BY MAB DOCUMEN DOCUMENT ABILITY OF A COMPLETE BOARD THIS DO NOT SUB JECT ELE CB SCHEMA TIC NUMBER RE
61. above The displays blink indicat ing that the machine is in the Hold period 3 VOLT METER Prior to CV operation current flow the meter dis plays desired preset voltage value 5V Prior to STICK or TIG operation the meter displays the Open Circuit Voltage of the Power Source or four dashes if the output has not been turned on e During welding this meter displays actual average volts After welding the meter holds the actual voltage value for 5 seconds The displays blink indicating that the machine is in the Hold period Output adjustment while in the hold period results in the prior to operation characteristics stated above 4 OUTPUT CONTROL Output control is conducted via a single turn poten tiometer Adjustment is indicated by the meters as stated above When in TIG modes this control sets the maximum welding current Full depression of a foot or hand Amptrol results in the preset level of current 5 WELD TERMINALS REMOTE ON Two status lights indicate the location of trigger con trol as determined by the WELD TERMINALS push button If trigger control is local weld terminals on the ON display will be lit trigger control is remote weld terminals remotely controlled the REMOTE display will be lit unit will power up in pre determined preferred trigger modes STICK CV z REMOTE TIG REMOTE if remote output controls are attached to th
62. accurate for all machines covered by this manual LINCOL INVERTEC V450 PRO 17 PC BOARD ASSEMBLY DISPLAY PC BOARD 11130 ENGINEERING CONTROLLED CHANGE DETAIL REVISED NOTE N D 95 0811 MANUFACTURER No ELECTRICAL DIAGRAMS G 17 ITEM REFERENCE DESIGNATORS PART NUMBER DESCRIPTION L11757 F P C BOARD BLANK T15176 2 LED SPACER 0 140 HIGH E3539 ELECTRICAL INSULATING COMPOUND L11166 2 FLEX CIRCUIT T15067 2 LABEL FOR ITEMS BELOW REFER LECTRONIC COMPONENTS DATABASE FOR COMPONET SPECIFICATIONS 525024 75 5 11 47 20 10 57343 525020 35 CAPACITOR SMD CERAMIC 0 1MF 50V 10 X7R S0805 517395 9 LED DISPLAY 7 SEGMENT CC 4 DIGIT 18248 10 CONNECTOR MOLEX MINI PCB 10 PIN T13657 6 LED T 1 RED HLMP K101 T13657 14 LED T 1 3 4 AMBER HIGH INTENSITY 525000 15015 RESISTOR SMD METAL FILM 1 10W 1 50K 1 S0805 525000 12125 RESISTOR SMD METAL FILM 1 10W 12 1K 1 S0805 525000 26705 RESISTOR SMD METAL FILM 1 10W 267OHMS 1 S0805 525000 10015 RESISTOR SMD METAL FILM 1 10W 1 00K 1 S0805 25000 10ROSMT RESISTOR SMD METAL FILM 1 10W 10 00 5 1 50805 525000 47515 RESISTOR SMD METAL FILM 1 10W 4 75K 196 80805 525000 47525 RESISTOR SMD METAL FILM 1 10W 47 5K 196 80805 517900 85 IC SMD CMOS INVERTER SCHMITT HEX HC14A SS 517900 265 IC CMOS SMD MUX DAT 8 INPUT HC151 SS 517900 285 I
63. amp Return to Section TOC Return to Master TOC Return to Master TOC Fen TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST continued TEST PROCEDURE machine 2 Using the 3 8 nut driver remove the case top and control box cover FIGURE F 12 3R lt FAN CONTROL 15VDC comes on when lus lt FAN CONTROL output is enable X3A SOLID STATE Located in Rear of R E LAY PowerSource 444 4 Carefully apply the correct input power to the FAN CONTROL TEST PROCEDURE machine 5 Carefully check for 115VAC at X3A and 444 See Figure 12 1 Locate plug J7 on the control board Do not remove the plug from the control board See WARNING HIGH VOLTAGE IS PRESENT AT Figure F 12 THE RELAY TERMINALS 2 Energize the weld output terminals Select 6 Ifthe 115VAC is low or not present perform the Weld Terminals ON and carefully check for Check circuit 15VDC at plug J7 pins 15 amp 16 on the control breaker CB2 and associated leads for loose or PC board If the 15VDC is present and the fan faulty connections See Wiring Diagram is not running then the relay or fan may be faulty If the 15VDC is not present when the 7 Energize the weld output terminals Select weld terminals are energized then the control Weld Terminals ON and carefully check for board may be faulty 115VAC at the fan motor leads If the 115VAC is present and the fan is no
64. and check for the cor rect secondary voltages per Table F 3 3 8 MOUNTING SCREWS 2 NOTE The secondary voltages will vary if the 8 input line volage varies If the secondary voltages are present the T1 auxiliary transformer is functioning properly If any of the secondary voltages are missing or low check to make certain the primary is con figured correctly for the input voltage applied See Wiring Diagram If the correct voltage is applied to the primary and the secondary voltage s are not correct the T2 transformer may be faulty 10 Install the case sides and top using the 3 8 nut driver INVERTEC V450 PRO LINCOLN B F 36 TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER NO 1 TEST continued TABLE F 3 NORMAL EXPECTED LEAD IDENTIFICATION VOLTAGE Return to Section TOC Return to Master TOC X8 to 41B 28 VAC X3 to X5 115 VAC X3 to X4 24 VAC X6 to X7 24 VAC X6 to X9 42 VAC Return to Section TOC Return to Master TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B NOTES ps INVERTEC V450 PRO LINCOLN F 38 DOL 19159 01 DOL 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5
65. approximation of the laws of the Member States relating to electromagnetic compatibility 2004 108 EC It was manufactured in conformity with a national standard that implements a harmonized standard EN 60974 10 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases i
66. at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 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 Work cables connected to the building framework or other locations away from the welding area increase the
67. be faulty Replace 10 Replace any RTV sealant previously removed NOTE Before replacing the input rectifier perform 11 Install the case top the Switch Board Test and the Input Contactor Test 8 When installing a new input rectifier see Input Rectifier Removal and Replacement dure TABLE F 1 INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS TEST POINT TERMINALS ANALOG METER X100 RANGE Probe Probe Acceptable Meter Readings A NEG Greater than 1000 ohms B NEG Greater than 1000 ohms C NEG Greater than 1000 ohms A POS Approx 500 ohms B POS Approx 500 ohms C POS Approx 500 ohms A Approx 500 ohms B Approx 500 ohms C Approx 500 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms INVERTEC V450 PRO LINCOLN B 24 NOTES INVERTEC V450 PRO LINCOLN F 24 DOL 19159 01 DOL 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i olg gt 5 5 Dllo amp Return to Section TOC Return to Master TOC F 25 INPUT CONTACTOR TEST PROCEDURE WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel
68. des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage 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 zones l on pique le laitier i SAFETY iv 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie 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 les galvanis es plomb
69. drain terminal will allow the IGBT to con duct and supply current to the circuit components cou pled to the source Current will flow through the con ducting IGBT to downstream components as long as the positive gate signal is present This is similar to turning ON a light switch INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO nds Of dc gt 5 5 Dllo 2 Return to Section TOC Return to Master TOC ER THEORY OF OPERATION FIGURE 7 TYPICAL IGBT OUTPUTS 1 usec 48 usec 50 usec 1 usec MINIMUM OUTPUT 24 usec 2 usec 50 usec 24 usec MAXIMUM OUTPUT PULSE WIDTH MODULATION The term Pulse Width Modulation is used to describe how much time is devoted to conduction in the positive and negative portions of the cycle Changing the pulse width is known as modulation Pulse Width Modulation PWM is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine MINIMUM OUTPUT By controlling the duration of the gate signal the IGBT is turned on and off for different durations during the cycle The top drawing in Figure E 7 shows the mini mum output signal possible over a 50 microsecond time period The positive portion of the signal represents one IGBT group conducting for one microsecon
70. each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 INVERTEC V450 PRO LINCOLN B F 2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 42 2 Return to Section Return to Master TOC o 5 o 2 TROUBLESHOOTING AND REPAIR Fs PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION 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
71. 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 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 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 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place INVERTEC V450 PRO LINCOLN B Return to Master Return to Master TOC o 5 o gt 2 tc Return to Master TOC SAFETY Electromagnetic Compatibility EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the
72. gt 251 gt ND CONTROL BOARD Schematic 63789 Located on left side of control box P Additional input outputs are lt 15 VOLT SPI 32 95 VOLT SPI 3 3 lt ISS 434 lt CS1 43 5 Cg 436 lt CS3 437 lt MISO lt sx 3 9 MOSI 4340 lt GROUND SPI SPI CIRCUIT Positive 2060 Output Stu nstall _ 202 19 Polarity Switch for wire feeder meter Field Install See page 1 S2 Located next to 14 pin amphenol 4 CC Stick soft 3212 4614 3207 3206 4614 CC Stick cris 3204 480 5 000000 T 10V HOV P START CONTROL 3213 lt 5 a pe SWITCH MODE PANEL 3203 3205 ADVANCED PROCESS PANEL Schematic 525288150 OPTIONAL Schematic 63872 1 1 Return to Section TOC Return to Master TOC 00000 o900000 25555 el SPI CIRCUIT 24 9 41 42 o 15V 15V men me 415V 15V 3313 r 8 3303 0 3316 3315 LOCAL REMOTE 2J333 16 gt 3316 A08 1333 15 3318 3314 3 ps 3312 1604 3 2433344 gt 3314 3305 Je084 3304 0 4 2J333 13 3
73. i 23 1 2 123456 4 5 6 34 7 8 910 11 12 J42 J41 J43 PROCEDURE 1 TROUBLESHOOTING AND REPAIR POWER BOARD TEST continued FIGURE F 9 POWER BOARD J42 J41 J43 Remove input power to the V 450 PRO 2 Using the 3 8 nut driver remove the case top 3 Perform the Capacitor Discharge Procedure 4 Locate the Power Board and plugs J42 and 5 J43 Do not remove plugs or leads from the Power Board See Figure F 9 Carefully apply input power to the V 450 PRO WARNING ELECTRIC SHOCK can kill Imm High voltage is present when input power is applied to the machine Turn on the INVERTEC V 450 PRO Carefully test for the correct voltages at the Power Board according to Table F 4 either of the 40 voltages is low or not present at plug J41 check capacitor C3 and the rectifier bridge See the Wiring Diagram Also perform the T1 Auxiliary Transformer Test If any of the DC voltages are low or not present at plugs J42 and or 43 the Power Board may be faulty Install the case top using the 3 8 nut driver INVERTEC V450 PRO LINCOLN B F 40 Return to Section TOC Return to Master
74. idR sige REEL RIS px Rx uh RE Ree aee gue Rx Rn F 63 Input Contactor REG ERR RR Rad RR RACE ERG ARR aad F 65 Aux Transformer NO 2 x i deere e Ru KG au Rs dec RE Nu F 67 Aux Transformer esee mk omae emi c ee de te Re e ande F 71 Control Remote Mode or F 75 o Current Transducer e le kai wena aea Ra pado ead F 77 5 SWitehi BOATA Du a 81 Retest and deen eben be wee eed bene we eee eee edt bea e eR Pese e gid F 84 E V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e 2 Return to Section Return to Master TOC o 5 o gt 2 r TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual
75. knob control During hot start arc force is set at high and is fast response For gouging applications Turn current up to 570 amps The tig mode produces a soft steady constant current waveform for either touch start or high frequency assisted start DC GTAW applica tions Hot Start Min to Mid range Touch start with low OCV Mid to Max range High frequency assisted starting with adjustable OCV up to 70 volts The GMAW CV mode is the best selection for general MIG welding Metal core and gas shielded applications Arc Control Pinch Min min pinch softest arc Max 2 max pinch crispest arc The FCAW SS mode is designed for Self Shielded Innershield products that require tight voltage control For example the NR 203 series or NR 207 Arc Control Pinch Min min pinch softest arc Max 2 max pinch crispest arc ADVANCED PULSE PANEL WELDING PROGRAMS 60 570 amps 0 1 20 KW The gouging mode is specifically designed for carbon arc gouging with electrodes up to 3 8 The GMAW power mode is similar in operation to other GMAW modes The power mode features a very stable short arc performance which is especially good when welding small diameter 025 and 030 steel and stainless wires for low procedures The short arc steel and stainless applications a fast response for spray applications and a drooper type spray mode characteristic for Aluminum INVERTEC V450 PRO LINCOLN B 8 OPERATION B
76. maximum OCV The Arc Control is not used in the TIG mode The Hot Start control is not used in the CV INNER SHIELD mode The Arc Control regulates pinch effect At the mini mum setting 10 minimizes pinch and results in a soft arc At the maximum setting 410 maximizes pinch effect and results in a crisp arc Most self shield ed wires work well at an Arc Control setting of 5 INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i olg gt 5 5 gt amp Return to Section TOC Return to Master TOC Return to Master TOC B 5 8A WELD MODE SELECT FOR MACHINES EQUIPPED WITH OPTIONAL ADVANCED PROCESS PANEL See Figure B 2 UPPER AND MIDDLE SECTION See WELD MODE DETAILS in this section To program welding modes the SELECT knob is used to Scroll through all welding modes The MEMORY button is used to store and access welding modes into locations M1 thru M8 Modes In addition to the 5 welding modes described in SEC TION 7 the Advance Process Panel allows you to select the Following additional modes Constant Power mode In the Power Mode The work point will be in the Volts window The Amp window will have CP displayed indicating Constant Power Once current starts flowing and during the 5 second Hold feature the displays will show Volts and Amps respectively OPERATION
77. only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of either the power board or the control board MATERIALS NEEDED 3 8 in Nut Driver Phillips Head Screwdriver Anti Static Wrist Strap INVERTEC V450 PRO LINCOLN B F 59 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 09129 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC F 60 TROUBLESHOOTING AND REPAIR F 60 CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 16 BOARD LOCTION COMPARTMENT COVER CONTROL BOARD REMOVAL PROCEDURE Remove input power to the V450 PRO Remove the case top sides and front Perform the Capacitor Discharge Procedure Observe all static electricit
78. perform the B may by faulty Auxiliary Transformer 1 Test 7 Reconnect lead X4 to the main input contac This 24 VAC is the coil voltage for main tor CR1 coil terminal input contactor CR1 It will normally be present approximately 12 seconds after 8 Carefully apply the correct input voltage to input line switch SW1 is activated the INVERTEC V 450 PRO 10 When the test is completed remove input WARNING power from the INVERTEC V 450 PRO 11 Install the case top using the 3 8 nut driver ELECTRIC SHOCK can kill High voltage is present when input power is applied to the machine Return to Section TOC Return to Master TOC eio 091 5 5 Dllo amp c Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B Fue TROUBLESHOOTING AND REPAIR Fe INPUT BOARD TEST PROCEDURE continued TABLE 2 INPUT BOARD VOLTAGE CHECKS LEAD EXPECTED TEST POINTS NUMBERS VOLTAGE COMMENTS READINGS Return to Section TOC Return to Master TOC PLUG J61 PIN 8 H1D SAME AS Present when Input TO INPUT Switch SW1 is closed PLUG J61 PIN 2 612 VOLTAGE PLUG J61 PIN 10 T3 A LITTLE LESS This is Pre Charge Voltage and TO THAN INPUT will normally be present 6 sec PLUG J61 PIN 2 T1 VOLTAGE onds after activating Input Switch SW1 The Pre Charge Voltage should remain for approximately 6 seconds and t
79. 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 6 c and 8 i SAFETY ARC RAYS can burn 4 8 Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to
80. 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 Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy 022690 9101 Do not use a welding power source for pipe thawing CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may 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 o
81. shorted to ground or is open MATERIALS NEEDED Digital Volt Ohmmeter INVERTEC V450 PRO LINCOLN B F 53 pem TROUBLESHOOTING AND REPAIR pet CHOKE TEST PROCEDURE continued FIGURE F 14 CHOKE ASSEMBLY Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC CHOKE IRON PROCEDURE 1 Using Ohmmeter make sure that the windings or terminal connections should look choke windings are not grounded to the burned or over heated AC welding may cause lamination gt 1megohm choke to buzz slightly eio OJO f i olg gt fom eo cre 5 5 amp Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO nd gt 5 2 amp c Return to Section TOC Return to Master TOC F 55 F 55 TROUBLESHOOTING AND REPAIR CONTROL BOARD CHECK Since the functions of the Control Board are primarily software related there are not very many tests to be per formed that will help in diagnosing a problem with the board itself Elimination of problems in the areas where loss of function is taking place will help decide by process of elimination if the Control Board is the defective component As a result the troubleshooting chart will typically recommend othe
82. supply apply 24 VAC to the terminals of the input contactor coil If the contactor does NOT activate the input contactor is faulty Replace INVERTEC V450 PRO LINCOLN B F 26 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i fom eo cre 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR ju INPUT CONTACTOR TEST PROCEDURE continued FIGURE F 5 INPUT CONTACTOR TEST POINTS L3 S 2 2 e L1 Q e 7 T3 T2 T1 5 With the input contactor activated check the 7 Reconnect the two leads 601 X4 to the input continuity across the three sets of contacts contactor coil Zero ohms or very low resistance is normal See Figure F 5 If the resistance is high the input contactor is faulty Replace the input con tactor 6 When the contactor is NOT activated the resis tance should be infinite or very high across the contacts If the resistance is low the input con tactor is faulty INVERTEC V450 PRO LINCOLN B 8 Install the input access door and case top using the 3 8 nut driver NOTES EUR INVERTEC V450 PRO LINCOLN F 28 DOL 19159 01 DOL 01 DOL D
83. the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN amp ine TE machine INVERTEC V450 PRO
84. the control PC board Install the PC board compartment cover using the 3 8 in nutdriver Install the case top and sides using the 3 8 in nut driver and Phillips screwdriver INVERTEC V450 PRO LINCOLN B 62 NOTES INVERTEC V450 PRO LINCOLN F 62 DOL 19159 01 DOL 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 nee TROUBLESHOOTING AND REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the input rectifi er module MATERIALS NEEDED 3 8 Nut Driver 3 16 Allen Wrench Phillips Head Screwdriver Return to Se
85. 313 2J333 12 gt 3312 OUTPUT CONTROL WELD TERMINALS 2333 8 gt 1 276 0 333 7 gt 275 __ gt 0333 6 277 333 5 gt 3305 333 4 gt 3304 333 3 gt 3303 333 2 gt WIRE FEEDER REMOTE 333 1 CL 332 16 gt 3216 332 15 5 3215 ANE 332 14 7 332 13 gt 3213 332 12 gt 3212 2332 11 3211 graphical representation gt J332 7 gt 4 3207 of potentiometer connection 4 po oe Open view of Control Panel REMOTE BOARD gt J332 4 gt 3204 Schematic 64017 100 gt 4332 3 3203 gt J332 2 571 3202 DISPLAY PANEL gt J332 1 gt 4 3201 Schematic L11108 3 iy E e 1331 53 331 6 J331 5 J331 4 SOLENOID COIL J331 2 J331 9 SOLENOID COIL gt J331 8 14 PIN S 4 LEAD J331 10 To 115 Case Front Recepticle f 7 For Domestic used only Not on CE Models ee 77 LEAD 14 PIN S 76 LEAD 75 LEAD 6 PIN S 76 LEAD 6 PIN S 4 LEAD 5 Yn oO 2 E tc o H c ip B E N SPI CIRCUIT amp AMPHENOLS ARE VIEWED FROM FRONT OF MACHINE AMPS VOLT Average
86. 356 65 400 Steel Argon Blends Argon with CO additions from 2 to 20 96 or Oxygen additions from 2 to 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Stainless Argon Blends Argon with Oxygen additions up to 2 Stainless He Ar 90 Helium 7 1 2 Argon 2 1 2 CO Aluminum 10096 Argon The Nickel Alloy pulse programs are non adaptive The operator sets the output control knob to deliver the correct arc length at the desired wire feed speed and stick out While welding the operator 035 Nickel Alloys Non Adaptive 60 700 manipulates the stick out to maintain the correct arc length This 045 Nickel Alloys Non Adaptive 60 600 method of operation produces very stable arc performance consid ering the nature of nickel alloys Preferred gas Argon Helium Blends for the best results add helium to the argon base from 0 25 PULSE ON PULSE 035 4043 Arc Control Pulse on Pulse frequency For faster travel speed welds the arc control should be increased For larger puddle slower travel speeds the arc control should be decreased eio OJO E f i 091 o gt 5 5 Dilo amp c 1 16 5356 5x Pulse on Pulse IPM INCHES PER MINUTE Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC
87. 450 PRO LINCOLN F 12 DOL 19159 01 DOL 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 13 TROUBLESHOOTING AND REPAIR F 13 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE A WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will drain off any charge stored in the four large capacitors that are part of the switch board assembly This procedure MUST be performed as a safety precau tion before conducting any test or repair procedure that requires you to touch inter
88. 5 minutes after the output is disabled CAUTION 120VAC is used to run the fan function eio OJO c 9 gt 5 5 Dllo amp c CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f gt 091 ms 9 gt 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC po TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELD AND ARC QUALITY PROBLEMS General degradation of weld 1 Wire feed problem Check for proper wire speed performance and consistent feeding Check for poor connections 2 Cabling problems and or excessive loops in the weld cables NOTE The presence of heat in external welding circuits indicates poor connections or undersized weld cables 3 Verify weld mode is correct for process 4 Machine calibration 3 Select the correct weld mode for the application Refer
89. Board TeSt aca ze EE E e pesci mw a Roe P ERES F 19 Input Rectifier TeSt o e Ro eme e e RD F 21 Input Contactor F 25 Input Board crue Fe ED 0 F 29 E Aux Transformer No 2 1 F 33 E Aux TIranstormer Test ceca Rer RE Pee ERG REX F 35 3 Power Board Test 2 eae E 39 E Current Transducer Test F 43 Thermostat Test Thermal Protection F 47 Fan Control and Motor 1 F 49 Output Rectifier Test i secre kb ERI pede Pee a Pewee dpe xk dark oboe eee ed ee F 51 Choke Test semau dees F 53 Control 55 E SPI Cable Resistance and Voltage Test F 57 4 Removal and Replacement 2 F 59 E Control or Power Board F 59 E Input Rectifier
90. C MAY NOT BE DUPLICATED COMMUNICATED g Vi 7 Vespi PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC 4 2 GSPI SINCE COMPONENTS OR CIRCUITRY ON p T T I E a PRINTED CIRCUIT BOARO MAY CHANGE DESIGN INFORMATION REFERENCE EQUIPMEN COMMON CONTROLS PAGE 02 OF 2 WITHOUT AFFECTING THE INTERCHANGE DRAWN BY ABILITY OF A COMPLETE BOARD THIS ol mem c SUBJECT SCHEMATIC SPI REMOTE UI PCB DOCUMEN COMPONENTS OR CIRCUITRY OF CONTROLS s MATERIAL APPROVAL HAVING COMMON CODE NUMBER APPROVED DRAWING orsPosiriow 02 03 2003 Reduction G 4017 1E0 01 5 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp ur V450 PRO G 16 ELECTRICAL DIAGRAMS 6 16 SCHEMATIC DISPLAY PC BOARD 111108 SS PL g SA Return to Section TOC Return to Master TOC 12 1 HC14AD A2 HC3680 4 STROBE DATA OUT BANK2p
91. C V450 PRO LINCOLN B F 82 Return to Section TOC Return to Master TOC 1 TROUBLESHOOTING AND REPAIR SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT continued REPLACEMENT PROCEDURE If the filter capacitor is to be replaced careful ly slide the new capacitor into the mounting bracket Position the capacitor so the correct polarity terminal is lined up with the correct hole on the switch board All heat sink and IGBT mounting surfaces Make sure the capacitor is positioned correctly Connect leads 19 and 20C D to the cor rect terminals Tighten to 55 in lbs Position and mount the two nylon screws fiber spacers and washers Torque from 4 to 8 in Ibs F 83 must be clean 8 Connect leads 15 16 to the correct terminal Apply a thin coat of thermal compound 9 Penetrox A13 0 005 to 0 010 inches thick to the mating surfaces Do not apply around mounting holes Connect leads 17 18 to the correct terminal 10 Install the mylar insulating shield covering leads 15 16 Replace the cable tie Connect molex plug J40 J50 to the top of the Switch board 4 Apply a thin coat of Penetrox A13 to the 11 capacitor terminals Be careful not to apply compound to screw threads or threaded area 12 Using the 5 16 nut driver install the plastic of terminals high voltage protective shield 5 Mount the new switch board and tighten the 13 four cap head screws in the follow
92. C SMD CMOS HEX INVERTING BUFFER 3 ST SS 517900 105 IC SMDCMOS REGISTER SHFT S PI SO 8 BIT SS 520496 15 IC SMD CMOS DRIVER DISPLAY LED CC MCU C1 C2 C3 C5 C11 C12 C19 C20 DISP1 DISP2 J37 LED1 LED2 LED3 LED4 LED5 LED6 LED7 R6 R16 R9 R10 R11 R12 R13 R14 R20 R21 R25 R26 R28 R29 Return to Section TOC Return to Master TOC w a 3 gt a SPI DISPLAY 11130 5 NOTES N A DO NOT COAT WITH ENCAPSULATION MATERIAL CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY SEE E2454 BEFORE HANDLING Return to Master TOC Return to Section TOC DISP2 E N C USE 2 TO STAND LED1 LED2 LED3 AND LED4 FROM THE P C BOARD THERE U 00 MUST NOT BE MORE THAN 020 GAP BETWEEN SPACER AND P C BOARD OR BETWEEN SPACER AND LED ENCAPSULATE P C BOARD SPACER AND LOWER HALF OF LED TOP 1 4 OF LED BODY MUST BE FREE OF ENCAPSULATION 1397 R14 DISP DISP 2MUST ALWAYS BE MATCHED BY VENDOR NAME AND EACH MUST HAVE THE SAME INTENSITY LETTER CODE G H J E
93. CITOR NS z E VOLTAGE FEEDBACK Ul RIGHT SWITCH BOARD J OUTPUT TERMINAL CONTROL SIGNALS CAPACITOR PWM DRIVE VOLTAGE FEEDBACK THERMOSTATS RECTIFIER CURRENT FEEDBACK CONTROL BOARD VOLTAGE FEEDBACK E RECONNECT s AUx TRANS 5 MOTOR POWER 77 BOARD gt dh ES STATUS ERAL EIGHT E WIRE FEEDER 85232 VOLTAGE Ine 5 115VAC RECEPTACLE _ SENSE D RECEPTACLE RECEPTACLE V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f gt olg gt 5 5 Dllo amp c Return to Section TOC Return to Master TOC ET THEORY OF OPERATION FIGURE 2 INPUT VOLTAGE AND PRECHARGE INPUT CONTACTOR RECTIFIER CAPACITOR VOLTAGE FEEDBACK 4omzzooma SWITCH BOARD CURRENT SENSOR OUTPUT TERMINAL OUTPUT TERMINAL THERMOSTATS CURRENT FEEDBACK CONTROL BOARD POWER BOARD VOLTAGE THERMAL WIRE FEEDER 5232 AGE 115VAC RECEPTACLE POWER SOURCE GENERAL DESCRIPTION The INVERTEC V450 PRO is an inverter based welding power source that is designed to be a multi process welding system Itis a high performance dig itally controlled inverter capable of complex high speed waveform control With the appropriate modu lar components it can support constant current con sta
94. CONNECTIONS PER E1880 R2 519400 6811 _ RESISTOR MF 1 4W 6 81K 1 R3 RB 19400 1002 RESISTOR MF 1 4W 10 0K 196 ENCAPSULATE COMPONENT SIDE OF P C BOARD A THICKNESS 30 12 00 IN AREA SHOWN R4 R13 R14 R17 R18 N U ENCAPSULATE NON COMPONENT SIDE OF P C BOARD A THICKNESS OF 25 12 00 pon 520 R23 R24 519400 1080 RESISTOR MF 1 4W 10 0 196 N V ENCAPSULATION MATERIAL MUST EXTEND BEYOND EDGES OF P C BOARD 12 12 00 R5 R9 519400 2001 RESISTOR MF 1 4W 2 00K 196 R6 519400 2213 5 1 4 221 1 N W ENCAPSULATE OPPOSITE COMPONENT SIDE OF P C BOARD IN AREAS SHOWN TO A MAXIMUM THICKNESS OF 20 R7 519400 1000 RESISTOR MF 1 4W 100 1 R10 R12 R15 519400 1003 RESISTOR MF 1 4W 100K 196 N X BOTH P C BOARD SHIELDS SOLDER INTO THE SAME MOUNTING HOLES ITEM 3 I5 MOUNTED ON NON COMPONENT SIDE RH S19400 6191 RESISTOR MF 1 4W 6 8K 1 OF P C BOARD f R16 R22 519400 1001 5 5 174 1 00 1 N Y APPLY A BEAD OF ITEM 6 TO COVER R28 R29 R30 R31 AND R32 828 R29 R30 R31 R32 T14648 9 RESISTOR WW 5W 2 5K 5 SQ REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW Return to Master TOC Return to Section TOC T12737 7 TRANSFORMER PULSE 3 WINDING
95. D PER NATIONAL ELECTRICAL CODE Q047uF 440 SWITCH LEAD FILTER FRONT HORIZONTAL HORIZONTAL BAFFLE BAFFLE FAN RECONNECT RECONNECT SHROUD SHELL CASE FRONT REAR AUX AUX NF FRONT UPPER UPPER 2 1 BASE _ BASE PROTECTIVE BONDING CIRCUI COMPONENT VALUE UNITS CAPACITOR MFD VOLTS RESISTOR OHMSIWATTS CONNECTOR PIN NUMBERS 12 PIN CONNECTOR 12 6 900090 000000 7 12 LATCH VIEW OF CONNECTOR ON PC BOARD COMPONENT VALUES CAPACITORS MFD VOLTS RESISTORS OHMSIWATTS ELECTRICAL SYMBOLS PER E1537 c G4923PRINT NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN amp ELECTRIC INVERTEC V450 PRO G 3 ELECTRICAL DIAGRAMS SCHEMATIC COMPLETE MACHINE G4875 SHEET 1 61879 ENGINEERING CONTROLLED CHANGE DETAIL CB2 AND FUSE REVISED AMPS MANUFACTURER No REVISED NOTE N B Heatsink isolated from Switch Boards SWITCH BOARD 1 TRANSFORMER T1 Undervoltage 200V Schematic L11385 Located Front Center of Machine Overvoltage 467V Located on left side of Machine OUTPUT DIODES 01 04 Top Rear Located above Main transformer RECONNECT INPUT Conductive Heatsink 2060 TO 14 PIN AMPHENOL RECTIFIER SWITCH pie 380 575V 208 230V
96. E SPECIFIED i CR 2 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 4 NOTES DIODES 14 400V UNLESS OTHERWISE SPECIFIED EE del SUPPLY VOLTAGE NE SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY POWER SUPPLY SOURCE POINT NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE 57 COMMON CONNECTION NUMBER F3 FRAME CONNECTION gt EARTH GROUND CONNECTION 0 EQUIP PROPRIETARY amp CONFIDENTIAL THIS DOCUMENT REFERENCE 5 Pow EB PAGE 10F 1 CONTAINS PROPRIETARY INFORMATION OWNED THE LINCOLN ELEC RIC CO TYPE INVER ER WELDERS BY LINCOLN ELECTRIC GLOBAL INC AND MAY CLEVELAND OHIO U S A SUBJECT SCHEMATIC INPUT PCB DOCUMENT NOT BE DUPLICATED COMMUNICARED TO OTHER PARTIES USED FOR ANY PURPOSE WITHOUT DO NOT ENCR MLD SCALE NONE E 5 MATERIAL APPROVAL PROJECT DOC THE EXPRESS WRITTEN PERMISSION OF SCALE THIS pg gv MAB APPD DISPOSITION N A Dar 2006 CRM38146 6 io 19528 280 LINCOLN ELECTRIC GLOBAL INC DRAWING 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 B INVERTEC V450 PRO 12 PC BOARD ASSEMBLY INPUT PC BOARD 111396 ELECTRICAL DIAGRAMS G 12
97. GLOBAL INC 2 eem m one es MISCELLANEOUS OR ALL ANGLES S BOF A DECREE SUBJECT DISPLAY BOARD ASSEMBLY REVISION DO NOT SCALE THIS DRAWING PINCH 1031 2008 L11130 5 D 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 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 ON ALL ANGLES IS 5 OF A DEGREE A2SIZE NUMBER WITH PUBLISHED STANDARDS PROJECT REFERENCE machine INVERTEC V450 PRO Return to Section TOC Return to Master TOC NOTE LINCOLN B G 18 ELECTRICAL DIAGRAMS G 18 les SCHEMATIC LED POTENTIOMETER PC BOARD S25258 JE x FEE E gt LOVREF 5 ala 15V 15V amp LEDI J61 161 SWITCH E FO Of 61 w LED 36 S1 POT 1 15 gt 221 10
98. HOOTING AND REPAIR SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the switch board s and or filter capacitor s MATERIALS NEEDED 3 8 Nut Driver 7 16 Wrench 3 16 Allen Wrench Slot Head Screwdriver Penetrox A13 Thermal Joint Compound INVERTEC V450 PRO LINCOLN B F 81 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i olg gt 5 5 gt amp Return to Section TOC Return to Master TOC Return to Master TOC F 82 TROUBLESHOOTING AND REPAIR SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT continued FIGURE F 23 SWITCH BOARD LOCATION REMOVAL PROCEDURE NOTE Observe all static electricity pr
99. L 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i olg gt 5 5 Dllo amp Return to Section TOC Return to Master TOC F 43 CURRENT TRANSDUCER TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the V450 PRO current transducer and associated wiring are functioning correctly MATERIALS NEEDED 3 8 Nut Driver Volt Ohmmeter INVERTEC V450 PRO LINCOLN B F 43 TROUBLESHOOTING AND REPAIR indi TROUBLESHOOTING AND REPAIR p CURRENT TRANSDUCER TEST continued FIGURE F 10 CURRENT TRANSDUCER TEST CONTROL BOARD Return to Section TOC Return to Master TOC
100. L uonoeg oi ODOL uonoeg ODOL uonoeg ODOL uonoeg NOTES pe INVERTEC V450 PRO LINCOLN D 4 DOL 19159 01 DOL 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 E TABLE OF CONTENTS THEORY OF OPERATION SECTION o 9 Section o 1 z Block Logic Diagram Posed mh RAE ee E 1 o c i 5 General Description Input Voltage E 2 a Switch BOards zebra Eva Sek ek Dee d Pat adn E 3 Control lt Pee eben E 4 Output Rectifier ss tae eb XE Rupe ohn Rx quie Rb EG RR Se be eee Ae ee eee d E 5 Thermal Protection eere sess ceed ter EOD EP d qua prx p EE Ra ht d d EE E 6 IGBT Operation onec arm eek E 7 Typical IGBT Qutputs 24 6 stad 8 o 5 o gt 9 tc FIGURE E 1 BLOCK LOGIC DIAGRAM TRANSFORMER rid CURRENT aq SENSOR LEFT SWITCH BOARD OUTPUT TERMINAL INPUT INPUT 5 CONTACTOR RECTIFIER p R CN Xs E CAPA
101. LL ANGLES IS 5 OF A DEGREE MATERIAL TOLERANCE TO AGREE WITH PUBLISHED STANDARDS DO NOT SCALE THIS DRAWING DESIGN INFORMATION _ REFERENCE EQUIPMENT TYPE INVERTER WELDER mme e m SCHEMATIC DIGITAL CONTROL PAGE 2 or 4 DOCUMENT UMEN NUMBER REVISION MATERIAL APPROVAL PROJECT 5 2 None UF our 1026206 10 26 2006 G3789 2FO B INVERTEC V450 PRO G6 ELECTRICAL DIAGRAMS of SCHEMATIC DIGITAL CONTROL PC BOARD G3789 SHEET 3 ENGINEERING CONTROLLED 03 6829 MANUFACTURER Yes 2 7 be visi Return to Master TOC 13 mag _ m em NISI dcm Return to Section TOC ETE usse l COSSERSIOR xm m acts 9 EA E ur i Pesos rip F 2 5M Y i i SIT CURRENT 7 i T E Mf x Em 9 ha T 25 ES U UU UD NM E LO am gt TEM 2 Return to Section Return to Master TOC LIREN SUBRENT HL IRIRI ARLE THE FETS AS S
102. May be a thermal shutdown by an error code Check to see if the Thermal The Diagnostic Utility is also ON available on the Service Navigator Possible short in output circuit Turn machine off Remove all leads from the output of the machine Perform the Input Contactor Perform the Input Board The primary current limit has been exceeded CR1 drops out when the output is initiated The power source upper section has failed If nothing is evident from a visual inspection perform tests as shown Perform the Transformer test for T 1 Preform the Input Rectifier Return to Section TOC Return to Master TOC NOTE Error codes as indicated by LED 9 and 10 on the Control Board Perform IGBT Switch 9 Perform the 10 Perform the Control Board Control Board may be faulty eio OJO f gt 091 olg 9 gt 5 5 Dllo amp CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 V450 PRO LINCOLN B Return to Section TOC Return to Master TOC vf TROUBLESHOOTING AND REPAIR d Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS
103. N OF LINCOLN GLOBAL INC UNLESS OTHERWISE SPECIFIED TOLERANC EQUIPMENT TYPE INVERTER WELDERS rc EE SWITCH P C BD ASSEMBLY EET ITH PUBLISHED STANDARDS WATERAL REFERENCE NOT SCALE THIS DRAWING INCH pseosmow UF CRM41517 3734 G3734 3 PROPRIETARY 8 CONFIDENTIAL DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED 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 amp ine TE machine INVERTEC V450 PRO ELECTRICAL DIAGRAMS G15 SCHEMATIC SPI REMOTE CONTROL PC BOARD G4017
104. NB 232 MAIN CONTACTOR CONTROL POWER left side 200 208V Located on top Located in rear of machine FAN CONTROL 15 VDC right of case front OFF 220 230V behnid reconnect panel 440 460V CRD 47 16 lt CONTROL LEGEND 550 575V STE ON POWER DOWN RS232 COM 15V SPI Fan comes on when output is enable 34 3 lt SPI 2 5V 5V 11 3 lt ARCLINK COM 44 1 lt SPI COM DASHED OPTION AUXILIARY PC BOARDS Toroid from Toroid from PHANTOM mn T 4 SOLID main harness main harness LEAD COLOR CODE 115V xc Located in Rear of POWER BD RECT B BLACK 550 575 Powersours Located center right of lift bale G GREEN Hi O ORANGE 440 460 POS R RED H4 _ _ U BLUE 980 415 T 24000uF 100V I m NEG Y YELLOW 220 230 LABELS H2 459 3 42 5 COMMON 200 208 5 Yn oO 2 E tc 226 f 4 6 lt RS232 5V 228 K 44 5 266 267 268 o H c ip B E sual 142 4 J43 4 343 9 443 6 43 3 4 POWER BOARD Schematic 63631 Located on rear of control box
105. OL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC F 29 INPUT BOARD TEST PROCEDURE WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the Input Board is sending the correct voltages as well as if the Input Board is regulating and producing the correct DC voltages MATERIALS NEEDED 3 8 Nut Driver Volt Ohmmeter Wiring Diagram INVERTEC V450 PRO LINCOLN B F 29 TROUBLESHOOTING AND REPAIR dis TROUBLESHOOTING AND REPAIR Ep INPUT BOARD TEST PROCEDURE continued FIGURE F 6 INPUT CONTAC
106. OQA AS ERNST CUHHENT 13 GRERIET Tran LEVEL Taavavaan s PIES gt 5 5 is D diss Susi pea 5 FDR R elo olg c gt 5 5 c 4 3 2 Jaa vols CH CONNECTOR E cnn aues H 1 11 al TEE dee TS 4 i ze oul 251 2 il ub 574 4 te THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY 8 CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC MANUFACTURING TOLERANCE PER Ezoss DESIGNINFORMATION REFERENCE EQUIPMENT TYPE pace 3 or4 WIRE EMEN m pomme rr INVERTER WELDER EE AN AN MATERIAL TOLERANCE 5 SCHEMATIC DIGITAL CONTROL NUMBER REVISION MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING UF 1026 2006 uneer CRM22115 GA G3789 2FO B Return to Section TOC Return
107. OUTPUT PULSE PULSE AND AUXILIARY POWER FREQUENCY BACKGROUND CIRCUIT BREAKER PROTECTED TIME RANGE 0 15 1000 Hz 5 55 VDC 100 MICRO SEC 3 3 24VAC SEC 42VAC AT 10 AMPS 115VAC AT 15 AMPS OPEN CIRCUIT VOLTAGE PROCESS CURRENT RANGE DC CURRENT 50 570 Average Amps 40 570 Average Amps 55 570 Average Amps 5 570 Average Amps 5 750 Peak Amps RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT INPUT TYPE 75 C TYPE 75 C TYPE 75 C VOLTAGE COPPER WIRE IN GROUND WIRE IN SUPER LAG FREQUENCY CONDUIT AWG MM2 CONDUIT AWG MM OR BREAKER SIZE AMPS 208 50 60HZ 230 50 60HZ 460 50 60HZ 575 50 60HZ HEIGHT WEIGHT 26 10 in 86 i 881 293 Ibs 663 mm 133 kg TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 20 to 40 40 to 40 Earlier models used 10 amps circuit breaker INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e 2 Return to Section TOC Return to Master TOC o 5 o gt 2 r A 3 INSTALLATION 3 SAFETY PRECAUTIONS Read this entire installation section before you start installation WARNING e ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF at the disconnect switch or fuse box before working on this
108. PPROPRIATE MANUFACTURING WORK INSTRUCTIONS 516668 11 ICAPACITOR CEMO 0 1 50 10 516668 5 022 50 20 J 75 116 CRIMP HEIGHT 5 C6 516668 6 CAPACITOR CEMO 4700pF 50V 10 N J ELECTRONIC MODULES TO BE ASSEMBLED SOLDERED AND SEALED TO PC BOARD PER E38 MX 513490 93 CAPACITOR TAEL 27 35V 1096 N M DO NOT COAT THE TOP SURFACES OR THE THREADS WITH ENCAPSULANT MATERIAL 1 TERMINAL COPPER SIDE C9 C11 C12 520500 1 0 1 1000 10 MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS C13 C14 C15 C16 C17 Di D2 112705 44 DIODE AXLDS 1A 1000V FR 818 BRACKET MUST HAVE FULL MATING CONTACT WITH POWER TERMINAL AND HAVE HOLES ALIGNED D3 D4 D5 D6 D7 D8 DIODE TO220 15A 600 FR MUR1560 D9 D10 D11 D12 NR ELECTRONIC MODULES ON A COMMON P C BOARD ASSEMBLY TO EYELET DETAIL 071 11270224 ZENER DIODE TW 20V ANATATA HAVE THE SAME VENDOR CODE 072 073 075 076 12702 29 ZENER DIODE 1W 15V 596 1N4744A 024 077 T12702 40 ZENER DIODE 1W 6 2V 596 1N4735A e g M21214 2 X XX 40 524020 6 CONNECTOR MOLEX MINI PCB 6 PIN TIN AP uf L1 L2 L3 L4 L5 L6 17 VENDOR CODE ned N 12218 15 CHOKE RF FERRITE BEAD 180 OHM a VCE SAT 18 19 110 515000 22 OPTOCOUPLER PHOTO Q 70V CNY17 3 VDE VGE TH R1 516296 5 TRIMMER MT 1 2W 10K 10 LINEAR N S AFTER SOLDERING INSPECT TERMINAL
109. Return to Master Return to Master TOC 5 o gt 2 tc Return to Master TOC View Safety Info View Safety Info View Safety Info View Safety Info SVM199 A July 2010 INVERTEL V450 PRO 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 ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT most importantly think before you act and be careful For use with machine code number 11212 LI NCOLN Copyright Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 888 935 3877 FAX 216 486 1751 WEB SITE www lincolnelectric com Return to Master Return to Master TOC o 5 o gt 2 tc Return to Master TOC SAFETY i WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm The engine exhaust from this product contains chemicals known to the State of California to cause cancer bir
110. TC DO NOT MIX DIFFERENT VENDORS ON THE SAME BOARD ASSEMBLY ENCAPSULATE LEADS AND SOLDER CONNECTIONS OF DISPLAYS FACE OF DISPLAYS MUST BE KEPT FREE OF ENCAPSULATION ENCAPSULATION AROUND UPPER HALF OF DISPLAYS MUST NOT EXCEED 006 PER SIDE _ GROUND SIDE UNLESS OTHERWISE SPECIFIED CAPACITORS MFD VOLTS INDUCTANCE HENRIES RESISTANCE OHMS NF CONNECTOR MUST BE GREASED WITH ITEM 3 PRIOR TO PLACING IN STOCK MOUNT FLEX CABLE BETWEEN CONNECTOR AND BOARD ON SOLDER SIDE IDENTIFY FINISHED ASSEMBLY WITH SERIAL NUMBER AND MANUFACTURING CODE PLACE LABEL ON NON COMPONENT SIDE N G PRINT L11130 5 ON ITEM 5 AND PLACE OVER EXISTING PART NUMBER MAKE AS 0 L11130 5F0 ALL COMPONENTS AND MATERIALS USED IN THIS ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253 olg o c gt 3 55 Dio cio L11757 2 MUST BE REVIEWED WHEN MODIFYING THIS BOARD FRONT SIDE OF CONNECTOR MANUFACTURE PER E1911 ROHS ENCAPSULATE WITH HUMISEAL 1A27LU PER E1844 OR WITH EQUIVALENT AS APPROVED BY LINCOLN ELECTRIC COMPANY 2 5 SCHEMATIC REFERENCE L11108 5F0 TEST PER E3856 D THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN
111. TOR 1 Q 9 is E E c Return to Master TOC J60 J61 olo ale 5 5 5 1234 1234 5 2 g 2 INPUT 5 5 cc 5678 6 7 8 910 J60 J61 olo P i 912 FE E gt 212 PROCEDURE WARNING E 2 1 Remove input power to the INVERTEC 450 PRO Y ELECTRIC SHOCK can kill 2 Using the 3 8 nut driver remove the case top High voltage is present when input 3 Remove lead X4 from the coil terminal of main power is applied to the machine input contactor CR1 Insulate lead X4 See Figure F 6 5 Turn on the INVERTEC 450 PRO Carefull 4 Carefully apply input power to the test for the correct voltages according to 450 PRO Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B Fs TROUBLESHOOTING AND REPAIR ted INPUT BOARD TEST PROCEDURE continued 5 5 6 Remove input power to the INVERTEC V 9 Turn on the V 450 PRO 5 450 PRO any of the voltages are low Check for the presence of 24 VAC from not present perform the Input Contactor lead X4 to lead 601 See Figure F 6 the If that checks out the Input Board voltage is not present
112. UBLESHOOTING AND REPAIR be OUTPUT RECTIFIER TEST PROCEDURE continued olo 5 5 FIGURE 13 OUTPUT TERMINAL LOCATION c 3 c c HE 2 n on on n be i FERH 4 Amps VoLrs m e OUTPUT WELD TERMINALS e aye 5H e olo 2 5 5 2 N 2 4 X g 2 2 N E 2 513 N 8 5 2 c NEGATIVE POSITIVE OUTPUT 5 TERMINAL TERMINAL o S PROCEDURE Sis 1 Remove main input supply power to the V450 5 Remove the case top perform the Input Filter Capacitor Discharge procedure o 9 1 ele 2 Remove any output load that may be connect 6 Using the 5 16 wrench remove and insulate 5 ed to the V450 PRO lead 202A from the negative output terminal elc Repeat step 4 to confirm if it is less than 10 3 With the analog ohmmeter measure the resis ohms short tance between the positive and negative output terminals Refer to Figure 13 7 Reconnect lead 202A to the negative output ter minal Important The positive meter probe must be attached to the positive output terminal and the 8 Replac
113. UMENT DOCUMENT ON ALL ANGLES 15 5 OF DEGREE SUBJECT MATERIAL TOLERANCE t TO AGREE ENGINEER SCALE LED POT P C BOARD ASSEMBLY SUMER REVISION WITH PUBLISHED STANDARDS MATERIAL APPROVAL PROJECT DO SCALE THIS DRAWING 1 1 Disposition UF 4 5 2007 NUMBER CRM38610 M19874 2 C m 9 CATHODE SQUARE ANODE ROUND 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 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 amp ine TE machine INVERTEC V450 PRO G 20 ELECTRICAL DIAGRAMS 6 20 SCHEMATIC LED SELECT PC BOARD 525259 gt LEDI gt LED4 oa 0 Return to Section TOC Return to Master TOC gt LED2 gt LEDS v 05A 05 gt LED3 06 05 gt 05 gt LED BANK 4 LED BANK 2 LED BANK 1 2 Return to Section Return to Master TOC
114. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the input contactor is functional and if the contacts are functioning correctly MATERIALS NEEDED 3 8 Nut Driver Volt Ohmmeter External 24 VAC supply INVERTEC V450 PRO LINCOLN B F 25 TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i olg gt fom eo cre Sl amp Return to Section TOC Return to Master TOC F 26 TROUBLESHOOTING AND REPAIR INPUT CONTACTOR TEST PROCEDURE continued FIGURE F 4 INPUT CONTACTOR COIL PROCEDURE 1 Remove input power to the INVERTEC V450 PRO Using the 3 8 nut driver remove the input access panel and case top Locate mark and remove the two leads 601 X4 that are connected to the input contactor coil See Figure F 4 INPUT CONTACTOR Using the external 24 VAC
115. VAL PROCEDURE 1 Remove input power to the V450 PRO 4 2 Using the 3 8 nut driver remove the case top 5 input access panel and case sides 6 3 Perform the Capacitor Discharge Procedure TRANSFORMER 2 Using the 3 8 nut driver remove the case back Disconnect plugs P50 P51 and P52 and clean Using the 3 8 nut driver remove the two trans former mounting screws See Figure F19 Label and clean all leads for transformer removal INVERTEC V450 PRO LINCOLN B TROUBLESHOOTING AND REPAIR 5769 AUXILIARY TRANSFORMER 2 REMOVAL AND REPLACEMENT PROCEDURE continued REPLACEMENT PROCEDURE 1 Carefully place the transformer into the V450 4 Connect any leads and install cable ties as nec PRO essary 2 Install the two mounting screws that hold the 5 Install the case back using the 3 8 nut driver transformer to the machine base using the 3 8 nut driver 3 Connect plugs P50 P51 and P52 Return to Section TOC Return to Master TOC Install the case top sides and input access panel using the 3 8 nut driver Return to Section TOC Return to Master TOC eio OJO f i olg gt 5 5 Dllo amp Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B NOTES INVERTEC V450 PRO LINCOLN F 70 DOL 19159 01 DOL 01 DOL DOL 19139 uunjeH
116. VISION DIAGRAM MAY NOT SHOW THE EXAC ENGINEER CH COMPONENTS OR CIRCUITRY OF CONTROLS E CALE MATERIAL APPROVAL 45 55 PROJECT m z A HAVING COMMON CODE NUMBER APPROVED DRAWING DISPOSITION NA DATE 02 27 2003 500072 522258 180 01 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 B INVERTEC V450 PRO Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC elo olg o c gt 3 55 Dio cio Return to Section TOC Return to Master TOC G 19 ELECTRICAL DIAGRAMS 6 19 PC BOARD ASSEMBLY LED PC BOARD 19874 C VLS6LIN ENGINEERING CONTROLLED CHANGE DETAIL REVISED NOTE AND ADDED NOTE REVISED DETAIL GRAPHICS MANUFACTURER ITEM USED WITH QTY PART NUMBER DESCRIPTION 1 1 SEE BLANK INFO PC BOARD BLANK 2 LED1 LED2 LED3 LED4 LED5 5 T15176 LED SPACER 0 220 HIGH REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW P C BOARD BLANK INFORMATION REFERENCES QTY NUMBER DESCRIPTION BUY COMPLETE AS M19874 C 2 LAYER BOARD PER E3281 CONNECTOR PCB WW MALE RT L 15 PIN MAKES 18 BOARDS PER PANEL SEE ELECTRONIC FILE LED1 LED2 LED3 LED4 LEDS 5 T13657 13 LED T 1 3 4 RED HIGH INTENSITY OVAL 2 5
117. WARNING Only a qualified electrician should connect the input leads to the V450 PRO Connections should be made in accordance with all local and national electrical codes and the connection diagram locat ed on the inside of the reconnect input access door of the machine Failure to do so may result in bodily injury or death Use a three phase supply line A 1 75 inch 45 mm diameter access hole for the input supply is located on the upper left case back next to the input access door Connect L1 L2 L3 and ground according to the Input Supply Connection Diagram decal located on the inside of the input access door or refer to Figure A 1 on the following page INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e 69 2 Return to Section Return to Master TOC 5 o gt 2 r ax INSTALLATION a FIGURE A 1 CONNECTION DIAGRAM ON CONNECTION INPUT ACCESS DOOR INPUT SUPPLY CONNECTION DIAGRAM Disconnect input power before inspecting or servicing machine Do not operate with covers removed Do not touch electrically live parts Only qualified persons should install use or service this equipment VOLTAGE 220 230V 200 208 220 230V 440 460 550 575
118. actual current Average actual voltage ESV LEAD COLOR CODE LAST No USED COMPONENT VALUE UNITS B BLACK d CAPACITOR MFDIVOLTS GREEN RESISTOR OHMSWATTS RAD 2 Located in the middle of U BLUE CONNECTOR PIN NUMBERS WAWHITE 12 PIN CONNECTOR Control Panel LEGEND Bde Schematic numbers are given for reference only src EP E 7154 158 205959 COMMON J61 Mode PCB 7 2 PROPRIETARY amp CONFIDENTIAL DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT DUPLICATED COMMUNICATED 77 FRAME GROUND J608 J60B MATCH TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC OLENA T ina 191 831 TUM FARTH GROUND 32333 PIECE ETUR NIORT ness OTs ONTO CLEVELAND ONE EQUIPMENT TYPE INVERTEC V450 PRO PAGE 2 or 3 ON ALL ANGLES IS 5 OF A DEGREE SUBJECT MACHINE SCHEMATIC ASTE REVISION WITH PUBLISHED STANDARDS MATERIAL or REFERENCE DO NOT SCALE THIS DRAWING INCH Dares 742207 omeen CRM36847 64421 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 amp INVERTEC V450 PRO Return to Section TOC Return to Master TOC Return to Section TOC elo
119. apacitors are connected in parallel When the machine is configured for higher input volt ages 300 VAC and above the input capacitors are connected in series When the input capacitors are fully charged they act as power supplies for the IGBT switching circuit The Insulated Gate Bipolar Transistors switch the DC power from the input capacitors on and off thus sup plying pulsed DC current to the main transformer pri mary windings See IGBT Operation Discussion and Diagrams in this section NSE LIGHT SI RECEPTACLE Each switch board feeds current to a separate oppo sitely wound primary winding of the main transformer The reverse directions of current flow through the main transformer primaries and the offset timing of the IGBT switch boards induce an AC square wave output signal at the secondary of the main transformer These pri mary currents are monitored by the current transformer CT If the primary currents become abnormally high the control board will shut off the IGBTs thus disabling machine output The DC current flow through each pri mary winding is clamped back to each respective input capacitor when the IGBTs are turned off This is need ed due to the inductance of the transformer primary winding The firing of the two switch boards occurs during halves of a 50 microsecond interval creating a constant 20 kHz output NOTE Unshaded areas of Block Logic Diagram are the subject of discussion
120. aster TOC eio OJO c is 5 5 Dllo amp c Return to Section TOC Return to Master TOC F 48 TROUBLESHOOTING AND REPAIR F 48 THERMOSTAT TEST THERMAL PROTECTION continued FIGURE F 11 THERMOSTAT CIRCUIT THERMOSTAT NORMALLY CLOSED THERMOSTAT CONTROL BOARD 291 224 OUTPUT RECTIFIER CHOKE THERMOSTAT THERMOSTAT BOLTED CONNECTION CONNECTED W EPOXY Thermostat nooooooo oe 2000 000000 r m oo Hooooooo oo LT SIMPLIFIED TEST PROCEDURE NOTE Never run the V 450 PRO under load when any of the thermostats are bypassed This is only a means of isolating the inoperative or open thermostat 1 Temporarily bypass thermostat circuits with a shorting jumper as follows All thermostats at the Control Board 245 to 345 Choke thermostat only 224A to 291 Output Rectifier thermostat only 220 to 291 Located on the Output Rectifier Heat Sink All thermostats are normally closed so moving the jumper as indicated and watching the Thermal LED should help determine which thermostat or a
121. ates 15VDC from power supply board is present Indicates 15VDC from power supply board is present C C Stick Soft 0 Indicates 45VDC for 5SPI from power supply board is present C C Stick crisp Indicates 15VDC for 15SPI from power supply board is present Tig Gtaw Indicates 5VDC for 45V from power supply board is present 9 Indicates 5VDC for 5VRS232 from power supply board is present CV Wire ho FAULT Signal See software group for coding CV Innershield Indicates 45VDC for 5 from power supply board is present ArcLink Status Indicators Main System Master ArcLink Connection Solid Green only when functional See software for error codes Alpha Numeric Display 5232 Advance Process Panel Optional Select Memory 1 56 5 LU Memory Select weld process Select Hot Start Mist amp control encoder or Arc Weld encoder G3632 Digital Power Supply Board FUNCTION Indicates 5VDC SPI supply is present Indicates 5VDC control supply is present POWER BOARDS Description of LED functions on the Invertec V450 PRO For reference only IPROPRIETARY amp CONFIDENTIAI DO NOT SCALE THIS DRAWING NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual
122. be caused by improper input configuration or an open short circuit in the primary side of the machine 34 Capacitor A over voltage Left side facing machine 35 Capacitor B over voltage Right side facing machine Excess voltage on the main capacitors May be caused by improper input configuration or an open short circuit in the primary side of the machine Thermal error Indicates over temperature Usually accompanied by Thermal LED Check fan operation Be sure process does not exceed duty cycle limit of the machine Softstart error Capacitor precharge failed Usually accompanied by codes 32 35 Control Panel Description of LED functions on the Invertec V450 PRO Factory Mode Panel For reference only RS232 Secondary overcurrent error The secondary weld current limit has been exceeded When this occurs the machine output will phase back to 100 amps typically resulting in a condition refered toas noodle welding Capacitor delta error The maximum voltage difference between the main capacitors has been exceeded May be accompanied by errors 32 35 Single phase error Indicates machine is running on single phase input power Usually caused by the loss of the middle leg L2 Other Use Snap Shot to interpret other errors or Diagnostic Sofware L11088 Digital Control PC Board FUNCTION WELD MODE Arc Control Indic
123. cables and welding machines 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes nave DEEN eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in posi tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts Exposure to fields in welding may have other health when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan
124. cally live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES be dangerous Keep your head out of fumes Use ventilation or exhaust to remove M fumes from breathing zone A n WELDING SPARKS can cause fire or TX X explosion Keep flammable material away Do not weld on closed containers ARC RAYS can burn eyes and skin Wear eye ear and body protection 5 NM See additional warning information at front of this operator s manual GENERAL DESCRIPTION The Invertec V450 Pro offers multi process CC and DC welding and is rated 570 amps 43 volts at a 6096 duty cycle DUTY CYCLE The V450 Pro is rated at 570 amps 6096 duty cycle based on a 10 minute cycle It is also rated at 450 amps 100 duty cycle OPERATIONAL FEATURES and CONTROLS UPPER CONTROL PANEL 1 ON OFF SWITCH 2 AMPS Meter Prior to STICK or TIG operation current flow the meter displays preset current value either 2 amps or 396 e g 3 amps on 100 whichever is greater Prior to CV operation the meter displays four dash es indicating AMPS unable to be preset During welding this meter displays actual average amps After welding the meter holds the actual current value for 5 seconds Output adjustment while in the hold period results in the prior to operation char acteristics stated
125. cking CC STICK CRISP The Stick Crisp mode features contin uous control from 5 to 570 amps with a crisp shorting response optimized for E6010 type electrodes Arc Gouging Setting the output of the Crisp mode to 570 amps or setting the arc control to maximum will enable the arc gouging mode The actual output cur rent will depend on the size of carbon used The rec ommended maximum size carbon is 3 8 9 5mm The Hot Start control regulates the starting current at arc initiation Hot Start can adjust starting current up or down by 25 of the preset value The recommended setting for Hot Start is 5 where the initial current is equal to the preset current INVERTEC V450 PRO LINCOLN B BT OPERATION zie The Arc Control regulates the Arc Force to adjust the CV WIRE The CV WIRE mode features continuous short circuit current The minimum setting 10 will control from 10 to 40 volts This mode was intended for produce a soft arc and will produce minimal spat most GMAW FCAW and MCAW applications Return to Section TOC Return to Master TOC ter The maximum setting 10 will produce a crisp arc and will minimize electrode sticking TIG GTAW The TIG mode features continuous control from 5 to 570 amps The TIG mode can be run in either the TIG touch start or high frequency optional equip ment required assisted start mode The Hot Start control selects the starting mode desired A setting of less than 5 the TIG l
126. 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 amp machine INVERTEC V450 PRO G 13 SCHEMATIC SWITCH PC BOARD L11385 ELECTRICAL DIAGRAMS G 13 ENGINEERING CONTROLLED CHANGE DETAIL NEW MANUFACTURER No Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC elo Due Ax og 5 5 5 cio P void Pera MENTA THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED ROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC oe omor CLEVELAND SCALE EQUIPMENT TYPE PW 455 rhum em sii 0s azsize_ SUBJECT SCHEMATIC SWITCH PCB NUMBER REVISION WITH PUBLISHED STANDARDS UNITS A MATERIAL APPROVAL REFERENCE DO NOT SCALE THIS DRAWING Joisposition NA numer CRM41517 L11385 2D1 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Master TOC LINCOLN B INVERTEC V450 PRO
127. ction TOC Return to Master TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR F 64 INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 17 INPUT RECTIFIER LOCATION INPUT RECTIFIER REMOVAL PROCEDURE Remove input power to the V450 PRO Using the 3 8 nut driver remove the case top input access panel and sides 3 Perform the Capacitor Discharge Procedure 4 Locate and remove the RTV sealant from the input rectifier connection terminals See Figure F 17 Label and using the Phillips head screwdriver carefully remove the five leads from the input rectifier terminals Note placement for reassembly See Figure F 17 Using the 3 16 allen wrench remove the two mounting screws and washers from the rectifier module Carefully remove the input rectifier module POS REPLACEMENT PROCEDURE 1 Clean heat sink surfaces 2 Apply an even coating of joint compound Penetrox A 13 to both the heat sink and mod ule mounting surfaces The joint compound should be 0 002
128. ctivities are to be carried out INVERTEC V450 PRO LINCOLN B Return to Master Return to Master TOC o 5 o gt 2 tc Return to Master TOC vi SAFETY vi Electromagnetic Compatibility EMC The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommen dations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equip ment is in operation The welding equipment should not be modified in any way exc
129. d The negative portion is the other IGBT group The dwell time off time is 48 microseconds both IGBT groups off Since only two microseconds of the 50 microsecond time period is devoted to conducting the output power is minimized MAXIMUM OUTPUT By holding the gate signal on for 24 microseconds each and allowing only two microseconds of dwell time off time during the 50 microsecond cycle the output is maximized The darkened area under the top curve can be compared to the area under the bottom curve The more dark area that is under the curve indi cates that more power is present 1 IGBT group consists of two IGBT modules feeding one trans former primary winding INVERTEC V450 PRO LINCOLN B F TABLE OF CONTENTS TROUBLESHOOTING AND REPAIR F Troubleshooting and Repair F 1 How to Use Troubleshooting Guide F 2 E PC Board Troubleshooting Procedures F 3 E Troubleshooting Guide 1 1 2 4 5 Input Filter Capacitor Discharge Procedure F 13 Voltage and Current Calibration Procedure F 15 Test Procedures oz so betes eee we aes F 19
130. de NOTE In TIG mode 10 volts supplied to lead 76 would produce the current that has been set by the Invertec V450 Pro s front panel Output Control INVERTEC V450 PRO LINCOLN B B 10 OPERATION B 10 olo Types of Remote WELD TERMINAL Control LIMITATIONS OIO Invertec V450 Pro s Weld Terminals can be The V450 Pro is not recommended for processes je E controlled from each of the MS style connectors other than those listed m 2 The circuit has a nominal OCV of 15VDC and The V450 Pro can only be used with the recom E requires a dry contact closure less than 100 ohms mended equipment and options to activate the output of the Invertec V450 Pro 14 Pin MS style connector the Weld Terminals are RECOMMENDED PROCESSES B controlled from pin C lead 2 and pin D lead 4 Pin Properly equipped the Invertec V450 Pro sup C is positive ports GMAW P FCAW SMAW GTAW and CAC A 6 Pin MS style connector the Weld Terminals are processes for a variety of materials including mild controlled from pin D lead 2 and pin E lead 4 In steel stainless steel cored wires and aluminum the 6 pin MS style connector pin D is positive Return to Section TOC Return to Master TOC eio OJO f i olg gt fom eo cre 5 2 Dllo amp Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B E TABLE OF CONTENTS ACCESSORIES SECTION
131. ds The appropriate pulse width modulation PWM signal See Modulation in this section is sent to the switch board IGBTs In this manner the digitally controlled high speed welding waveform is created eio OJO nds gt 5 5 Dllo amp c NOTE Unshaded areas of Block Logic Diagram are the subject of discussion V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f gt 5 5 amp Return to Section TOC Return to Master TOC ES THEORY OF OPERATION E FIGURE 5 OUTPUT RECTIFIER AND CHOKE MAIN TRANSFORMER CURRENT SENSOR OUTPUT TERMINAL INPUT INPUT CONTACTOR RECTIFIER CAPACITOR VOLTAGE FEEDBACK R E N N T OUTPUT TERMINAL THERMOSTATS CURRENT FEEDBACK CONTROL BOARD VOLTAGE FEEDBACK C STATUS LIGHT WIRE FEEDER 5232 VOLTAGE THERMAL 115 RECEPTACLE SENSE LIGHT RECEPTACLE RECEPTACLE OUTPUT RECTIFIER AND CHOKE The output rectifier receives the AC output from the main transformer secondary and rectifies it to a DC voltage level Since the output choke is in series with the negative leg of the output rectifier and also in series with the welding load a filtered DC output is applied
132. e If a remote control such as K857 is to be used with the LN 742 the remote can be connected directly to the 6 pin MS style connector on the front of the Invertec or use K864 adapter to connect the LN 742 and the remote to the 14 pin MS style connector Cobramatic Connection Instructions Turn the Invertec power switch off Connect the control cable from the Cobramatic to the 14 pin MS style connector Connect the electrode cable to the output terminal of the polarity required by electrode Connect the work lead to the other terminal Set the meter polarity switch on the front of the Invertec to coincide with wire feeder polarity used If a remote control such as K857 is to be used with the Cobramatic the remote can be connected directly to the 6 pin MS style connector on the front of the Invertec or use a K864 adapter to connect the cobramatic and the remote to the 14 pin MS style connector TIG Module K930 2 The TIG Module connects to the Factory and Advanced Process V450 Pro versions with a K936 1 9 14 pin control cable Connect the K936 1 to the 14 MS style connector General Instructions for Connection of Wire Feeders to V450 Pro Wire feeders other than those listed above may be used provided that the auxiliary power supply rating of the V450 Pro is not exceeded and the V450 PRO out put is not actively controlled by the wire feeder Like an LN 9 K867 universal adapter plug is required See connectio
133. e Control Board With the V 450 PRO triggered check the feed back voltage from the current transducer The current feedback voltage can be read at plug J8 on the Control Board A Pin 1 lead 211 to pin 6 lead 216 should read 2 0 VDC machine loaded to 250 amps 8 10 If for any reason the machine cannot be loaded to 250 amps Table F 5 shows what feedback voltage is produced at various current loads If the correct supply voltages are applied to the current transducer and with the machine loaded the feedback voltage is missing or not correct the current transducer may be faulty Also make certain that lead 211 plug J8 pin 1 has continuity zero ohms between the current transducer and the control board See the Wiring Diagram Install the right side case cover using the 3 8 nut driver TABLE F 5 CURRENT FEEDBACK AT VARIOUS OUTPUT LOADS OUTPUT LOAD CURRENT EXPECTED TRANSDUCER FEEDBACK VOLTAGE INVERTEC V450 PRO LINCOLN B F 45 NOTES INVERTEC V450 PRO LINCOLN F 46 DOL 19159 01 DOL 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 TROUBLESHOOTING AND REPAIR pM THERMOSTAT TEST THERMAL PROTECTION WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs perf
134. e Control Board iCheck The Control Board may be faulty The Auxiliary Receptacle is dead 1 Check CB 2 on the case front Check the receptacle and asso No 120VAC present Reset if necessary ciated wiring See the Wiring Diagram or Machine Diagram in 2 Check CB 3 in the reconnect area Reset if necessary 2 Perform the 3 Make sure all three input phases Transformer Test 2 are present CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 V450 PRO LINCOLN B Return to Section TOC Return to Master TOC F 6 The does not have welding output The main input contactor CR1 is not activating TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S OUTPUT PROBLEMS INVERTECG V450 PRO 1 The input voltage may be too high or too low or reconnect panel may be incorrectly connected F 6 RECOMMENDED COURSE OF ACTION 1 Make certain that the input voltage is proper according to the Rating Plate located on the rear of the machine See Installation this manual See Thermal LED is ON in this section NOTE This problem will normally be accompanied
135. e before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the machine is capable of producing welding output and to check and adjust if necessary the voltage and or current calibration MATERIALS NEEDED Resistive Load Bank Calibrated Test Voltmeter Calibrated Test Ammeter INVERTEC V450 PRO LINCOLN B F 15 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e 69 2 Return to Section Return to Master TOC o 5 o 2 r F 16 TROUBLESHOOTING AND REPAIR VOLTAGE AND CURRENT CALIBRATION PROCEDURE continued CALIBRATION CHECK The calibration of the V450 PRO can be checked using a resistive load bank with the V450 PRO in mode 200 Mode 200 is a constant current test mode NOTE Before attempting to calibrate the voltage or current setting of the V450 PRO be sure to read the entire voltage or current calibration section If the steps are not completed quickly the machine will auto matically leave the calibration mode with out changing the calibration settings The voltage and current calibration settings of the V450 PRO are completely indepen dent of each other Adjusting one will not affect the other Press and hold in the Mode SELECT button Turn on the V450 PRO Rotate the Output Knob while still holding the mode select button in until the disp
136. e input power to the V450 PRO 6 Label all leads to all output terminals Using the 5 16 wrench and the 3 4 wrench remove all 2 Using the 3 8 nut driver remove the case top leads from the two output terminals and sides and the control box cover 7 Cut any necessary cable ties Then carefully Perform the Capacitor Discharge Procedure swing the front panel aside 4 Using the 3 8 socket wrench or nut driver 8 remove the three screws along the bottom case front See Figure F 22 eio OJO f i olg gt cre LEN amp Remove the insulating tape from the heavy lead bolted connection Using the 9 16 wrenches remove the bolt lock washer and nut 5 Using the 3 8 socket wrench remove the four screws that hold the case front to the machine Return to Section TOC Return to Master TOC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i olg gt 5 5 Dllo amp Return to Section TOC Return to Master TOC F 79 F 79 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE continued 9 Using the Phillips head screwdriver remove 12 the screws and lock washers that hold the transducer to the front panel Remove the Current Transducer Remove the standoffs from the t
137. e machine TIG ON if remote output controls are not attached to the machine For all versions these trigger modes can be over ridden switched with the WELD TERMINALS push button When changed the unit will power up in the configuration it was in V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO E f i 3 c gt 5 5 Dllo amp c Return to Section TOC Return to Master TOC 6 THERMAL This status light indicates when the power source has been driven into thermal overload If the output terminals were ON the light will blink indicating that the output will be turned back on once the unit cools down to an accept able temperature level If the unit was operating in the mode the trigger will need to be opened before or after the thermal has cleared and closed after the machine has cooled down to an acceptable temperature to establish output 7 CONTROL REMOTE LOCAL Two status lights indicate the location of output control as pre determined by the power sources auto configure sys tem The LOCAL display will be lit when control is at the power Source The REMOTE display will be lit when a remote pot control is detected These Output Control configurations can be overridden switched with the CONTROL push button When changed the unit will power u
138. e resistor 25 1000 ohms 25 watts minimum electrically insulated gloves and pliers connect the resistor across the two capacitor terminals Hold the resistor in place for 10 seconds DO NOT TOUCH THE CAPACITOR TERMI NALS WITH YOUR BARE HANDS NEVER USE A SOLID CONDUCTOR W LESS THAN 25 OHM RESISTANCE FOR THIS PROCEDURE 7 Repeat procedure for the other capacitor 8 Recheck the voltage across the capacitor termi nals The voltage should be zero If any volt age remains repeat the discharge procedure INVERTEC V450 PRO LINCOLN B F 14 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 15 TROUBLESHOOTING AND REPAIR VOLTAGE AND CURRENT CALIBRATION PROCEDURE WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistanc
139. e the shorted modules if necessary negative meter probe must be attached to the negative output terminal 4 f the reading is approx 50 ohms the output rectifier modules are not shorted If the reading is less than 10 ohms one or more of the rectifi er modules may be shorted Reverse meter probe and verify low reading Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 53 TROUBLESHOOTING AND REPAIR CHOKE TEST PROCEDURE WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The Weld Choke is located down and behind the work stud This test will help determine whether the Choke is
140. ecautions Lead and plug references below use a slash to indicate machine right side left side wire number differences 1 2 Remove input power to the V450 PRO Using the 3 8 nut driver remove the case top and sides 3 Perform the Capacitor Discharge Procedure Using the 3 8 nutdriver remove the screw mounting the plastic high voltage protective shield Remove the shield and it s mount from the machine Remove molex plug J50 from the top of the switch board See Figure F 24 Remove the mylar insulating shield covering leads 13 14 or 17 18 marked clearly on the board Cut any necessary cable ties Using the 7 16 wrench remove leads 13 14 or 17 18 from the switch board See Figure F 24 SWITCH BOARD Using the 7 16 wrench remove leads 11 12 or 15 16 from the switch board See Figure F 24 Using the 7 16 wrench remove leads 19 and 20C D from the switch board capacitor connection bolts See Figure 24 With the slot head screwdriver remove the two nylon mounting screws at the bottom of the switch board placement of the shake proof washers and fiber spacers Using the 3 16 allen wrench carefully remove the four cap screws that mount the switch board to the heat sink Carefully remove the switch board from the heat sink If the filter capacitor is to be removed careful ly slide it out of the mounting bracket INVERTE
141. echnical troubleshooting assistance before you proceed Call 1 888 935 3877 INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Section TOC Return to Master TOC eio OJO E M i 091 olg 9 gt oe 5 5 Dllo amp Return to Section TOC Return to Master TOC Return to Master TOC F 10 TROUBLESHOOTING AND REPAIR F 10 Observe Safety Guidelines detailed in the beginning of this manual STATUS LIGHTS ARE LED S 9 AND 10 ON CENTER TOP OF CONTROL BOARD Fault Codes Description Corrective Action Primary over current If condition persists contact an authorized Lincoln Field Service Shop The machine needs to be turned off and back on to reset the machine CAP bank A under voltage Check input power CAP bank B under voltage reconnect to make sure CAP bank A over voltage the machine CAP bank B over voltage is connected for the input Soft start Failed power being supplied Self clearing as condition ceases Cycle power Glitch on the primary over current fault interrupt possibly caused by noise or a signal level misc hardware fault 71 Check the machine ground If problem persists contact an authorized Lincoln Field Service Shop CAP delta CAP A and B are out of balance Check input power reconnect to make sure the machine is connected for the input power being supplied Main CPU p
142. ed a 10 amp circuit breaker REMOTE CONTROL SELECTION The Invertec amp V450 Pro has auto sensing of remote output controls If after connecting or removing a remote the Invertec V450 Pro did not configure the way you would like the local or remote control settings can be changed by push ing the OUTPUT CONTROL or WELD TERMINAL button A user cannot select between the 6 and 14 pin MS style con nectors CV modes The remote will default to the 14 pin MS style connector if a remote is connected If no remote is connected to the 14 pin MS style connector then the remote will default to the 6 pin MS style connector if a remote is connected to it In all of the CV modes the WELD TERMINAL control will default to REMOTE TIG Mode remote will default to the 6 pin MS style if a remote control is connected to the 6 pin MS style and to the 14 pin MS style connector If a remote is not connected to the 6 pin MS style connector then the remote will default to the 14 pin MS style con nector if a remote is connected If a remote control is connected to any of the MS style connectors the WELD TERMINAL control will default to REMOTE If there are not any remote con trol devices attached the WELD TERMINAL control will default to ON CC Stick Modes The remote will default to only the 6 pin MS style connector if a remote is connected to it The WELD TERMINAL control will default to ON with or without a remote connec
143. emote to the idu MS style connector LN 25 with Remote Control 6 Pin K444 1 and 14 pin K444 2 remotes can be connected directly to the 6 pin amp 14 pin MS style connectors The 42 Volt Remote Voltage and Output Control K624 1 Kit can be connected to the Return to Section TOC Return to Master TOC LN 25 Connection Instructions Turn the Invertec power switch off LN 10 DH 10 Connection Instructions Turn the Invertec power switch off ojo V450 s 14 pin MS style connector using Remote Control Connect the K1505 control cable from the LN 10 to the p 14 pin MS style connector Cable assembly K627 LN 25s with a 431 1 remote kit 5 5 Connect the electrode cable to the output terminal of can be connected to the V450 s 14 pin MS style connector D polarity required by the electrode Connect the work lead using a K432 cable and K876 adapter See connection gt to the other terminal diagram 819899 Or the K432 cable could be modified O n H H pe Set the meter polarity switch on the front of the Invertec with a K867 Universal Adapter Plug See connecuon dia 5 to coincide with wire feeder polarity used gram 519405 to connect it to the V450 s 14 pin MS style E See the LN 10 manual for details on accessing Control connector DIP Switch Dip Switches for the V350 and the same set tings may be used for the V450 FIGURE A 4 ACROSS THE ARC MODEL Vasto OUTPUT TERMINALS ALWAYS HOT
144. ept for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the con nection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capaci tance selected according to national re
145. equipment Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on the equipment Do not touch electrically hot parts Always connect the V450 PRO grounding lug located inside the reconnect input access door to a proper safety Earth ground SELECT SUITABLE LOCATION Do not use the Invertec in outdoor environments with out appropriate protection The V450 PRO power source should not be subjected to falling water nor should any parts of it be submerged in water Doing so may cause improper operation as well as pose a safe ty hazard The best practice is to keep the machine in a dry sheltered area WARNING Do not mount the V450 PRO over combustible sur faces Where there is a combustible surface direct ly under stationary or fixed electrical equipment that surface shall be covered with a steel plate at least 060 1 6mm thick which shall extend not less than 5 90 150mm beyond the equipment on all sides Place the welder where clean cooling air can freely cir culate in through the rear louvers and out through the case sides and bottom Water Dirt dust or any foreign material that can be drawn into the welder should be kept at a minimum Failure to observe these precau tions can result in excessive operating temperatures and nuisance shutdowns Machines are equipped with F A N fan as needed cir cuitry The fan runs wheneve
146. es mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou 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 on utilise la machine souder comme une source de 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 contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc 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 quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et
147. eturn to Section TOC Return to Master TOC i TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical Contact the Lincoln Electric damage is evident when the Service Department at 1 888 sheet metal covers are removed 935 3877 The input fuses repeatedly fail or 1 Input fuses or breakers may be 1 Check the reconnect panel the input circuit breakers keep improperly sized connections and associated tripping wiring See the Wiring The reconnect panel may not Diagram and Input be configured properly for the Information in Section A for applied voltage the proper input voltage Check the input voltage and make sure it is correct The input fuses fail or input Input fuses or breakers may be 1 Check the re connect panel breakers trip after the CR 1 improperly sized connections and associated contactor closes wiring See the Wiring The reconnect panel may not Diagram and be configured properly for the Information in Section A applied voltage 2 Perform the Input Rectifier A component in the input Test If the Input Rectifier is circuitry has failed defective perform tests 3 and 4 3 Perform the IGBT Switch 4 Perform the Input Board Test CAUTION If for any reason you do not understand the test procedures or are unab
148. failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 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 can 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 ATTENTION to a grounded part of the Static Sensitive equipment frame Devices If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Handle only at Static Safe Workstations 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 shield ing bag the PC board uses protective shorting jumpers don t remove them until installation is complete you return a PC board to The Lincoln Electric Company for c
149. ghout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct voltage is being applied to the primary of Auxiliary Transformer No 1 as well as if the correct voltage is being induced on the secondary windings of the transformer MATERIALS NEEDED Volt Ohmmeter Multimeter 3 8 in Nut Driver Wiring Diagram INVERTEC V450 PRO LINCOLN B F 35 AUXILIARY TRANSFORMER NO 1 TEST Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 3 5 5 51 amp Return to Section TOC Return to Master TOC Return to Master TOC F 36 TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER NO 1 TEST continued FIGURE F 8 TEST LEAD LOCATIONS TRANSFORMER 1 _ _ PROCEDURE 1 Remove the main input supply power to the V450 PRO Using the 3 8 in nut driver remove the case sides and top Perform the Capacitor Discharge Procedure Locate leads X8 and 41B at Power Board Bridge Locate secondary leads X3 and X5 fan motor leads Locate secondary lead X4 at main contactor Carefully apply the correct input voltage to the INVERTEC V450 PRO
150. gulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applica tions 1 1 Portions of the preceding text are contained in EN 60974 10 Electromagnetic Compatibility EMC product standard for arc welding equipment INVERTEC V450 PRO LINCOLN B MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Accessories a Section gt gt Section D Theory of Operation _ _ Section E Troubleshooting and Repair Section F Electrical Diagrams 2 0 i xksa ee ee oA Section G Parts Mant al gas rccte ace aac Rl c d ca da e RC zT d ca a d o RC P 525 INVERTEC V450 PRO LINCOLN B Return to Master Return to Master TOC o 5 o gt 2 t Return to Master TOC A 1 TABLE OF CONTENTS INSTALLATION SECTION Installation 1 Technical Specifications 0 2 Safety Precautions cms x A 3
151. he input board to energize the main input contactor making all three phases of input power without current limiting avail able to the input capacitors At this point the INVERTEC V450 PRO is in the Run Mode of oper ation If the capacitors become under or overvoltage the control board will signal the input board to de energize the input contactor and the INVERTEC V450 PRO will be disabled NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO E f i gt 5 5 Dllo 2 c Return to Section TOC Return to Master TOC THEORY OPERATION id FIGURE E 3 SWITCH BOARDS AND MAIN TRANSFORMER INPUT CONTACTOR RECTIFIER CAPACITOR VOLTAGE FEEDBACK R E N N E CURRENT SENSOR OUTPUT TERMINAL OUTPUT TERMINAL THERMOSTATS CURRENT FEEDBACK VOLTAGE FEEDBACK WIRE FEEDER RS232 VOLTAGE 115VAC RECEPTACLE CONN RECEPTACLE SWITCH BOARDS AND MAIN TRANSFORMER There are two switch boards in the INVERTEC V450 PRO each containing an input capacitor and insulated gate bipolar transistor IGBT switching circuitry Refer to Figure E 3 When the machine reconnect switches are configured for a lower input voltage below 300 VAC the input c
152. hen be removed Return to Section TOC Return to Master TOC PLUG J60 PIN 3 238 13 15 VDC This is the Coil Voltage for the TO Pre Charge Relay Normally this PLUG J60 PIN 4 604 DC Voltage will be present 6 sec 238 604 onds after Input Switch SW1 is i activated This 13 15 VDC will remain for approximately 6 sec 2 onds and then be removed Relay is controlled by the Control Board See the Wiring Diagram PLUG J60 PIN 3 238 13 15 VDC This is the DC Coil Voltage for the TO Control Relay Normally this DC PLUG J60 PIN 5 232 Voltage will be present approxi mately 12 seconds after Input Switch SW1 is activated The Relay is controlled by the Control PC Board See the Wiring Diagram eio OJO E f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC F 33 TROUBLESHOOTING AND REPAIR WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid
153. iagram locat ed on the inside of the input access door If the main reconnect switch or link position is placed in the wrong position the welder will not produce output power If the Auxiliary A lead is placed in the wrong position there are two possible results If the lead is placed in a position higher than the applied line voltage the welder may not come on at all If the Auxiliary A lead is placed in a position lower than the applied line voltage the welder will not come on and the two circuit break ers or fuses in the reconnect area will open If this occurs turn off the input voltage properly connect the A lead reset the breakers and try again For machines equipped with a fuse in the reconnect area turn off the input voltage and replace the fuse with the spare fuse that is attached to the reconnect switch pin ELECTRODE AND WORK CABLE CONNECTIONS Connect a work lead of sufficient size and length Per Table 1 between the proper output terminal on the power source and the work Be sure the connection to the work makes tight metal to metal electrical contact To avoid interference problems with other equipment and to achieve the best possible operation route all cables directly to the work and wire feeder Avoid excessive lengths and do not coil excess cable Minimum work and electrode cable sizes are as follows TABLE A 1 Current 60 Duty Cycle MINIMUM COPPER WORK CABLE SIZE AWG Up To 100 Ft Length 30 m
154. ift start mode is selected The OCV is controlled below 10v and the short circuit TIG touch current is main tained at 25 amps independent of the preset current The Hot Start control is not used in the CV WIRE mode Arc Control regulates pinch effect At the mini mum setting 10 minimizes pinch and results in a soft arc Low pinch settings are preferable for weld ing with gas mixes containing mostly inert gases At the maximum setting 4 10 maximizes pinch effect and results in a crisp arc High pinch settings are preferable for welding FCAW and GMAW with CO2 CV INNERSHIELD The CV INNERSHIELD mode features continuous control from 10 to 45 volts This mode was designed for self shielded flux cored wires that require tight voltage control When the tungsten is lifted an arc is initiated and the output is regulated at the preset value Hot start settings between 0 and 5 regulate the arc initiation Return to Section TOC Return to Master TOC eio OJO f i olg gt 5 5 Dllo amp Return to Section TOC Return to Master TOC current A setting of 5 results in the most positive arc initiation A setting of O reduces hot start Hot Start settings between 5 and 10 select high fre quency assisted starting TIG mode In this range the OCV of the machine is controlled between 50 and 70 volts If using the Lincoln K930 1 TIG Module set the Hot start to 10 for
155. ill indicate the error code the machine was removed from a multi machine application be sure to write down their position before changing them so they can be properly reset when the machine is 2 If any of the Green LED s 1 through 8 are not lit or returned to it s position are dimmer than the others Turn the power off and disconnect all of the Control Board Molex connectors except J4 and turn the power back on If the LED s in question stay the same Check the DC voltage levels in connector J4 See the Machine Schematic correct read ings If voltages are correct replace the Control Board If not replace the Power Board INVERTEC V450 PRO LINCOLN B NOTES dads INVERTEC V450 PRO LINCOLN F 56 DOL 19159 01 DOL 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Poe TROUBLESHOOTING AND REPAIR Par SPI CABLE RESISTANCE AND VOLTAGE TEST PROCEDURE WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Mas
156. ing manner Install the case top and sides using the 3 8 nut driver Return to Section TOC Return to Master TOC Tighten all until snug Tighten all from 24 to 28 in lbs Tighten all from 40 to 48 in lbs FIGURE F 24 SWITCH BOARD LEADS PLUG J40 J50 7 16 NUT Leads 13 14 or 17 18 9 mmm 00 eio OJO f i 5 5 Dllo amp c 7 16 NUT Leads 11 12 or 15 16 716 NUT Leads 19C D 20C D Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC indi TROUBLESHOOTING AND REPAIR IST RETEST AFTER REPAIR Retest a machine If it is rejected under test for any reason that requires you to remove any part which could affect the machine s electrical characteristics OR If you repair or replace any electrical components INPUT IDLE AMPS AND WATTS Input Volts Hertz Maximum Idle Amps Maximum Idle KW 208 60 230 60 400 60 460 60 575 60 MAXIMUM OUTPUT VOLTAGES Output Terminals 115 Volt Receptacles 208 60 230 60 OCV 10 Amp Load 400 60 50
157. lays read mode 200 NOTE Machines with an Advanced Process Panels do not have a mode select button Use the same procedure except hold in the Memory button on the advanced process panel instead of the mode select button Release the Mode SELECT MEMORY but ton and the machine will be in mode 200 With the machine in mode 200 apply a resis tive load to the welding output terminals approximately 087 ohms set the machine output to 300 amps and enable the Weld Terminals Weld Terminals Select ON Using the test meters note the output voltage and current The V450 PRO voltmeter must match the test meter reading to within 1 volt The V450 PRO ammeter must match the test meter within 5 amps If the voltmeter does not meet the specification then proceed to the Voltage Calibration 10 If the ammeter does not meet the specification then proceed to the Current Calibration VOLTAGE CALIBRATION NOTE If the Mode SELECT MEMORY button is 10 not pressed within 30 seconds after adjusting the Output Control knob the machine will leave the calibration mode and use the previous calibration settings Connect the resistive load band approximate ly 087 ohms and test voltmeter to the welding output terminals Press and hold in the Mode SELECT MEMO RY button Turn on the V450 PRO Rotate the Output Control knob until the dis play reads vol cAL Release the Mode SELECT MEMORY but ton Adju
158. le to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO EM i 9 gt 5 5 Dllo amp Return to Section TOC Return to Master TOC rh TROUBLESHOOTING AND REPAIR r Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The machine is dead no lights 1 Make sure the input power Check the input power switch no output the machine switch SW1 is in the ON SW1 for proper operation appears to have no power position Also check the associated leads for loose or faulty connections See the Wiring Diagram or Machine Diagram for the welder in Check the main input fuses or breakers and make sure all three phases are present Check the breaker located in the reconnect area Reset if tripped Replace or reset input fuses or breaker If CB 3 opens repeatedly perform the Transformer Test 4 The power board rectifier may be faulty Check the rectifier and associated wiring See the Wiring Diagram or Machine Diagram for the welder in Section G Perform the Perform th
159. lled in the same location they were removed from Install the right and left case sides and top using the 3 8 nut driver INVERTEC V450 PRO LINCOLN B F 20 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 21 TROUBLESHOOTING AND REPAIR INPUT RECTIFIER TEST PROCEDURE WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the input rectifier has shorted or diodes MATERIALS NEEDED Analog Voltmeter Ohmmeter Multimeter 5 16 Nut Driver Phillips Head Screwdriver Wiring Diagram INVERTEC V450 PRO LINCOLN B F 21 nee TROUBLESHOOTING AND REPAIR a INPUT RECTIFIER TEST PROCEDURE continued
160. n compressed gas cylinders associated equipment and CGA publication 1 Precautions for Safe Handling of Compressed 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 Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http Awww lincolnelectric com safety for additional safety information INVERTEC V450 PRO LINCOLN B Return to Master Return to Master TOC o 5 o gt 2 tc Return to Master TOC PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions 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 l
161. n diagram 524985 in Operator Manual REMOTE CONTROL OF Remote Control K857 Hand Amptrol K963 and Foot Amptrol K870 may be used PARALLEL OPERATION The V450 Pro are operable in parallel in CC mode For best results the currents of each machine should be reasonably equally balanced As an example with two machines set up in parallel for a 800 amps procedure each machine should be set to deliver approximately 400 amps not 450 amps from one and 350 amps from the other This will minimize nuisance shutdown condi tions In general more than two machines in parallel will not be effective due to the voltage requirements of procedures in that power range To set machine outputs start with output control pots and arc control pots in identical positions Use the out put control pots to balance the currents and maintain the desired current The arc control pots should be kept identical on the two machines INVERTEC V450 PRO LINCOLN B 8 NOTES INVERTEC V450 PRO LINCOLN A 8 DOL 19159 01 DOL 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Master Return to Master TOC o 5 o gt 2 t Return to Master TOC B 1 TABLE OF CONTENTS OPERATION SECTION E Operation cbe e
162. nal components of the machine MATERIALS NEEDED 5 16 Nut Driver Insulated Pliers Insulated Gloves High Wattage Resistor 25 1000 ohms and 25 watts minimum DC Volt Meter INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i olg gt 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE continued FIGURE CAPACITOR TERMINAL LOCATION RESISTOR TT m Remove input power to the INVERTEC V450 PRO Using the 3 8 nut driver remove the left and right case sides Be careful not to make contact with the capaci tor terminals that are located in the bottom cen ter of the left and right side switch boards See Figure F 1 Carefully check for a DC voltage at the capaci tor terminals on both boards Note the polarity is marked on the PC board and also lead 719 is positive If any voltage is present proceed to Step 6 If no voltage is present the capacitors are dis charged NOTE Normally the capacitors discharge in about two minutes after input power is removed RESISTOR 9 Tr ANJ CAPACITOR A TERMINALS CAPACITOR TERMINALS aC PROCEDURE 6 Using the high wattag
163. ngth B work length C See Figure A 2 FIGURE A 2 V450 PRO a For long work piece lengths a sliding ground should be considered to keep the total welding loop length less than 50 ft 15 24m See Figure A 3 FIGURE A 3 SLIDING WORK K1796 COAXIAL CABLE MEASURE FROM END OF OUTER JACKET OF CABLE Output connections on some V450 PRO are made via 1 2 13 threaded output studs located beneath the spring loaded output cover at the bottom of the case front Most welding applications run with the electrode being positive For those applications connect the elec trode cable between the wire feeder and the positive output stud on the power source located beneath the spring loaded output cover near the bottom of the case front Connect the other end of the electrode cable to the wire drive feed plate The electrode cable lug must be against the feed plate Be sure the con nection to the feed plate makes tight metal to metal electrical contact The electrode cable should be sized according to the specifications given in the work cable connections section Connect a work lead from the negative power source output stud to the work piece The work piece connection must be firm and secure especially if pulse welding is planned For additional Safety information regarding the elec trode and work cable set up See the standard SAFE TY INFORMATION located in the front of the I
164. nly be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the power section of the switch boards are functioning cor rectly This test will NOT indicate if the entire PC board is functional This resistance test is preferable to a voltage test with the machine energized because this board can be dam aged easily In addition it is dangerous to work on this board with the machine energized MATERIALS NEEDED Analog Volt Ohmmeter 5 16 in Wrench 7 16 in Wrench INVERTEC V450 PRO LINCOLN B F 19 MAIN SWITCH BOARD TEST PROCEDURE Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i olg gt 5 5 51 amp Return to Section TOC Return to Master TOC Return to Master TOC F 20 CAPACITOR TERMINALS TROUBLESHOOTING AND REPAIR MAIN SWITCH BOARD TEST PROCEDURE conti
165. nstruction Manuals CAUTION Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding performance NEGATIVE ELECTRODE POLARITY When negative electrode polarity is required such as in some Innershield applications switch the output con nections at the power source electrode cable to the negative stud and work cable to the positive stud INVERTEC V450 PRO LINCOLN B ii INSTALLATION ae CONNECTIONS OF WIRE FEEDERS TO V450 PRO LN 15 Connection Instructions See Figure A 4 LF 72 74 Connection Instructions dd the 1 off Turn the Invertec power switch off onnect the electrode cable to the output terminal of polar Connect the K1797 control cable from the LF 72 74 ity required by electrode See Figures below to the 14 MS style connector Set the meter polarity switch on the front of the Invertec Connect the electrode cable to the output terminal of the to coincide with wire feeder polarity used polarity required by electrode Connect the work lead to the other terminal If a remote control such as K857 is to be used with the LF 72 74 the remote can be connected directly to the 6 Connect the electrode cable to the output terminal of polar pin MS style connector on the front of the Invertec or ity required by electrode Connect the work lead to the ther terminal use a K864 adapter to connect the LF 72 74 and the d r
166. nt voltage and pulse welding processes The output rating is 450 amps at 36 volts with a 100 duty cycle INPUT VOLTAGE AND PRECHARGE The INVERTEC V450 PRO can be connected for a variety of three phase voltages Refer to Figure E 2 The initial input power is applied to the INVERTEC V450 PRO through a line switch located on the front of the machine Two phases of the three phase input power is applied to the input board and both auxiliary transformers The various secondary voltages devel oped by the 1 auxiliary transformer are applied to the input board the power board rectifier and the fan motor The 115 VAC secondary voltage developed by the No 2 auxiliary transformer is applied to the 115 VAC receptacle RECEPTACLE CONN VOLTAGE FEEDBACK SEI RECEPTACLE The 65 VDC produced from the power board rectifier is utilized by the power board to provide various DC volt ages for the control board and wire feeder The two phases which are connected to the input board through the power switch are connected to the input rectifier During precharge or soft start these two phases are current limited by the input board This AC input voltage is rectified and the resultant DC volt age is applied through the reconnect switches to the input capacitors located on the switch boards The control board monitors the voltage across the capaci tors When the capacitors have charged to an accept able level the control board signals t
167. nue to produce this low current until the protection cir cuit is reset Reset occurs when the output load is removed THERMAL PROTECTION Thermostats protect the machine from excessive oper ating temperatures Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating If excessive operating temperature should occur the thermostat will prevent output voltage or current The meter will remain energized during this time Thermostats are self resetting once the machine cools sufficiently If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally the Power Switch may be left on and the reset should occur within a 15 minute period See Voltage Current Calibration Procedure INVERTEC V450 PRO LINCOLN B D 3 W 22 n i 21 o e c c gt Can lt 2 D 7 D o E LIZ gt 2 Lu Roy gt S f VA z 5 E 6 lt gt z z o2 52 y 52024 5 0 5 o 5 lt 150 lt LL gt 5 c o 2 x lt 5 9 o o lt oe252529 so E Oom roo OR DOL 19159 01 DOL 01 DOL DOL 19139 uunjeH ODO
168. nued FIGURE F 2 CAPACITOR TERMINAL LOCATIONS RESISTOR RESISTOR TT JT CAPACITOR TERMINALS o TEST PROCEDURE 1 Remove input power to the INVERTEC V450 PRO 2 Perform the Capacitor Discharge Procedure 3 Use a DC voltmeter to check that the voltage is not present across the terminals on three capacitors Locate label and remove leads 19C and 19D from the reconnect switches with the 3 8 wrench Note lead placement for reassembly Clear leads See Figure F 2 Using the Analog ohmmeter perform the following resistance tests See Figure F 2 for the test points Any readings below 100 ohms can be considered a Short circuit However readings usually are below 30 ohms A short on any of the following points indicates a possible failed switch board 6 T 8 9 Check 11 12 to 20 and 11 12 to 19 Check 15 16 to 20 and 15 16 to 19 Check 13 14 to 20 and 19 to 13 14 Check 17 18 to 20 and 19 to 17 18 If any test fails measures a short isolate the PC board and retest if board still fails replace switch board See Switch Board Removal and Replacement If the switch board tests are OK check the molex pin connections and associated wiring from the switch boards to the control board See the Wiring Diagram Reconnect leads 19C and 19D to the reconnect switches Ensure that the leads are insta
169. o Section TOC Return to Master TOC Return to Master TOC F 77 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the Current Transducer MATERIALS NEEDED 3 8 Nut driver 5 16 Open End Wrench 9 16 Wrench 3 4 Wrench Phillips Head Screwdriver Wire Cutters Wiring Diagram INVERTEC V450 PRO LINCOLN B F 77 TROUBLESHOOTING REPAIR pur CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE continued 5 5 FIGURE F 22 CURRENT TRANSDUCER LOCATION TRANSDUCER HEAVY LEAD BOLTED CONNECTION BEHIND CASE FRONT Return to Section TOC Return to Master TOC 3 8 SCREWS AT BOTTOM OF CASE FRONT 3 REMOVAL PROCEDURE 1 Remov
170. oing back to the original settings will not bring the M1 back You will need to push the MEMORY button to recall the original settings in M1 NOTE After all memory M1 thru 8 are used and the welder needs to store another welding process a new welding process will overwrite what was originally in the memory and will read Save to MEM M1 Overwrite M1 which previously stored Pulse Mig is now over written with the new welding process INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f gt dc 9 1 5 5 Dllo amp c Return to Section TOC Return to Master TOC B 7 OPERATION 8 WELD MODE DETAILS GTAW Tig mode FCAW SS GMAW Power 55 570 amps 55 570 amps 5 570 amps 10 45 volts 10 45 volts Comments The stick soft mode is the best selection for general stick applications Arc Control Arc Force Hot Start Initial hot start current min start a match set amps Max greatest hot start current During hot start arc force is set at high and is fast response For gouging applications Turn current up to 570 amps The stick crisp mode features an aggressive arc force routine well suit ed for Exx10 Exx11 series electrodes Arc Control Arc Force Hot Start Initial hot start current Mid range welding current and will vary up and down with
171. ormed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 NOTE The procedures and tests described in this test are written with the under standing that the repair technician fully understands the process of locating and accessing within the welding machine the specific board or device involved in each procedure or test TEST DESCRIPTION The Thermostats are located in various locations within the welding machine See Machine Diagram for specific locations Return to Section TOC Return to Master TOC This test will determine if a thermostat is intermittently opening or is fully open MATERIALS NEEDED Small gauge 18 short jumper wire Wire should be approximately 4 inches in length eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to M
172. p in the configuration it was in when it was last powered down Hidden Middle Control Panel Process Set Up Panel The middle control panel is removable to allow for upgrades see Field Installed Options Accessories Additionally this panel is hidden by an access door to provide protection to the controls 8 WELD MODE SELECT Figure B 1 The Mode Control button selects from the following welding modes STANDARD See FIGURE B 1 B 3 OPERATION B 3 CC STICK SOFT The Stick Soft process features contin uous control ranging from 5 to 570 amps This mode was intended for most SMAW applications and Arc Gouging Arc Gouging Setting the output of the Stick Soft mode to 570 amps or setting the arc control to maxi mum will enable the arc gouging mode The actual out put current will depend on the size of carbon used The recommended maximum size carbon is 3 8 9 5mm The Hot Start control regulates the starting current at arc initiation Hot Start can be adjusted from minimum 0 with no additional current added at arc start to maximum 10 with double the preset current or 570 amps max of machine added for the first second after arc initiation The Arc Control regulates the Arc Force to adjust the short circuit current The minimum setting 10 will pro duce a soft arc and will produce minimal spatter The maximum setting 10 will produce a crisp arc and will minimize electrode sti
173. primary and secondary leads See Wiring Diagram Return to Section TOC Return to Master TOC 5 Reposition any wire leads and install cable ties as necessary 6 Install the case back using the 3 8 nut driver 7 Install the case top sides and input access panel using the 3 8 nut driver eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B 74 NOTES INVERTEC V450 PRO LINCOLN F 74 DOL 19159 01 DOL 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 75 TROUBLESHOOTING AND REPAIR CONTROL REMOTE MODE OR DISPLAY PC BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughou
174. r areas to be tested before the Control Board If the Control Board does seem to be the most likely solution perform the checks outlined below and then try downloading the latest software into the machine If a solution is still not evident use the Diagnostic facility to take a snapshot that can then be sent to the Lincoln Service Department via e mail for assistance in determin ing where the problem Contact the Lincoln Service Department at 1 888 935 3877 TEST PROCEDURE 1 Check the LED s on the Control Board Compare 3 the pattern to Page 3 of the Machine Schematic Normal operation will show 8 Green LED s ON and both Red LED s OFF If LED s 9 amp 10 are flashing an error code and all other LED s are correct Check the Error Code list in this section to deter mine where the problem may be Green LED s 1 through 8 indicate the pres ence of the various DC supplies to the Board If the Error Code is not listed contact the Lincoln Service Department for determination LED 7 red will only be ON in the event of a Primary Over Current Cycle the Power Switch to reset LED 7 4 Check the DIP switches In a single machine set up switches 1 through 7 should be OFF Switch 8 should be ON if a remote sense lead is attached LED s 9 green amp 10 red will mimic the NOTE If any switches need to be changed because Status LED on the front panel in the event of an error If the Status LED is OFF these will st
175. r the output is enabled whether under loaded or open circuit conditions The fan also runs for a period of time approximately 5 min utes after the output is disabled to ensure all compo nents are properly cooled If desired the F A N feature can be disabled causing the fan to run whenever the power source is on To dis able F A N connect leads 444 and X3A together at the output of the solid state fan control relay located on the back of the Control PC board enclosure See Wiring Diagram LIFTING Lift the machine by the lift bail only The lift bail is designed to lift the power source only Do not attempt to lift the V450 PRO with accessories attached to it STACKING V450 PRO machines can be stacked to a maximum of 3 high CAUTION The bottom machine must always be placed on a firm secure level surface There is a danger of machines toppling over if this precaution is not taken MACHINE GROUNDING The frame of the welder must be grounded A ground terminal marked with the symbol is located inside the reconnect input access door for this purpose See your local and national electrical codes for proper grounding methods HIGH FREQUENCY PROTECTION Locate the V450 PRO away from radio controlled machinery CAUTION The normal operation of the V450 PRO may adversely affect the operation of RF controlled equipment which may result in bodily injury or damage to the equipment INPUT CONNECTION
176. ransducer and save them for reassembly with the new transducer Note placement upon removal Remove plug P91 See Wiring Diagram REPLACEMENT PROCEDURE 1 Attach the stand offs to the transducer 2 Position the transducer on the back of the front panel and attach it with the two phillips screws and lock washers Feed the output leads through the transducer Note direction of output lead through current transducer 3 Run the heavy lead through transducer and secure the bolted connection with the 9 16 bolt lock washer and nut Replace the insulating tape around the connection Replace plug P91 into the new current trans ducer Using the 5 16 wrench and the 3 4 wrench attach all leads previously removed to the three output terminals See the Wiring Diagram 6 Replace any cable ties cut during removal 7 Install the case top and sides using the 3 8 nut driver INVERTEC V450 PRO LINCOLN B NOTES INVERTEC V450 PRO LINCOLN F 80 DOL 19159 01 DOL 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i olg gt 5 2 amp Return to Section TOC Return to Master TOC Return to Master TOC F 81 TROUBLES
177. redit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting 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 INVERTEC V450 PRO LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO c 9 gt 5 5 Dllo amp c R
178. roblem The DSP has detected a problem with the CPU Check the machine ground Possible erroneous electrical noise on Voltage Frequence capacitor feed back circuit misc hardware fault 72 If problem persists contact an authorized Lincoln Field Service Shop Self clearing as condition ceases The main contactor opened unexpectedly misc hardware fault 3 If condition persist contact an authorized Lincoln Field Service Shop Self clearing The selected weld mode does not exist in the weld table that is presently loaded in the machine If condition persists contact an authorized Lincoln Field Service Shop CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Press the Mode Select button to select a different mode INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO E f 1 gt 5 5 Dllo amp Return to Section TOC Return to Master TOC F 11 TROUBLESHOOTING AND REPAIR F 11 Observe Safety Guidelines detailed in the beginning of this manual Displays Description Scrolling dash Appears at power up while the machine is going thro
179. ssociated wiring is defective Don t forget to check the incline splice 224 to 224A as a possible open INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC F 49 FAN CONTROL AND MOTOR TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This test will help determine if the fan motor control board switch board and associated leads and connectors are functioning correctly MATERIALS NEEDED Voltmeter 3 8 Nut Driver INVERTEC V450 PRO LINCOLN B F 49 TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC eio OJO gt 091 gt cre 5 5 Dllo
180. st the Output Control knob until the actu al output voltage reading on the test voltmeter is 20volts 5 volts Wait for the machine s output to be automati cally turned off and then back on Adjust the Output Control knob again if nec essary to make the actual voltage output 20 volts 5 volts Wait for the machine s output to be automati cally turned off and then back on Repeat the above two steps if necessary Press and release the Mode SELECT MEM ORY button to save the calibration INVERTEC V450 PRO LINCOLN B F 16 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i olg gt 5 2 amp Return to Section TOC Return to Master TOC Return to Master TOC 17 TROUBLESHOOTING AND REPAIR VOLTAGE AND CURRENT CALIBRATION PROCEDURE continued CURRENT CALIBRATION PROCEDURE NOTE If the Mode SELECT MEMORY button is not pressed within 30 seconds after adjusting the Output Control knob the machine will leave the calibration mode 9 and use the previous calibration settings 1 Connect the resistive load band approximate ly 087 ohms and test ammeter to the welding 10 output terminals 2 Press and hold in the Mode SELECT MEMO RY button 3 Turn on the V450 PRO 12 4 Rotate the Output Control knob until the dis 13 play reads cur cAL 5 Release the Mode SELECT MEMORY but 14 ton
181. t could involve construction of an electromagnetic screen enclosing the power source and the work com plete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equip ment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob lems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment b radio and television transmitters and receivers C computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement 0 the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h the time of day that welding or other a
182. t running the fan motor may be faulty See Wiring Diagram WARNING HIGH VOLTAGE IS PRESENT AT THE FAN LEADS c e HIGH VOLTAGE IS PRESENT AT THE SWITCH BOARD ELECTRIC SHOCK can kill A High voltage is present when input power is applied to the machine INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC F 51 TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER TEST PROCEDURE WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if any of the output rectifiers are shorted MATERIALS NEEDED Analog Volt Ohmmeter 3 8 Nut driver 5 16 Wrench INVERTEC V450 PRO LINCOLN B F 51 din TRO
183. t this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the Control Board Remote Board Mode Board or Display PC Board MATERIALS NEEDED 3 8 Nut Driver Anti Static Wrist Strap INVERTEC V450 PRO LINCOLN B F 75 nae TROUBLESHOOTING AND REPAIR CONTROL REMOTE MODE OR DISPLAY PC BOARD REMOVAL AND REPLACEMENT continued FIGURE F 21 BOARD LOCATIONS Return to Section TOC Return to Master TOC DISPLAY BOARD CONTROL BOARD e 69 9 E Return to Master 3 8 MOUNTING BOLTS 4 4 5 REMOVAL PROCEDURE S 5 1 Remove input power to the 450 3 Observe all static electricity precautions 918 2 Using the Phillips screwdriver remove the case 4 Remove replace and add panels as needed front mounting screws and tilt forward and or follow advanced process panel kit 2 instructions rio Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 5 Dllo amp c Return t
184. ted Types of Remote OUTPUT CONTROL Invertec V450 Pro s Output Control can be controlled by either a potentiometer connected between 77 amp 75 with the wiper connected to 76 or a OV to 10V DC supply connected between 76 amp 75 76 needs to be positive 14 Pin Ms style connector lead 75 is pin G lead 76 is pin F and lead 77 is pin E 6 Pin Ms style connector lead 75 is pin C lead 76 is pin B and lead 77 is pin A Potentiometer Control The total resistance should be between 2 000 ohms 2K and 10 000 ohms 10K The machine output will be at minimum when lead 76 wiper is at the end of the potentiometer that is connected to 75 The machine s output will increase as the wiper of the potentiometer is moved to the end that is connected to 77 Note In TIG mode moving the lead 76 wiper to lead 77 would produce the cur rent that has been set by the Invertec V450 Pro s front panel Output Control Remotes of this type offered by Lincoln Electric are the K857 K812 and K870 Voltage Control The supply should be an isolated supply Not refer enced to earth ground any auxiliary power from the Invertec V450 Pro or the welding output The sup ply should be capable of supplying at least 20mA 0 volts supplied to 76 will set the Invertec V450 Pro to minimum output for the mode that has been selected while 10 volts supplied to 76 will set the Invertec amp V450 Pro to the maximum output for the mo
185. ter TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if there is a possible open in the SPI cable and also if the correct supply voltages are being applied to the boards in the SPI network MATERIALS NEEDED Volt Ohmmeter 5 16 Nut Driver Phillips Head Screwdriver Return to Section TOC Return to Master TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC INVERTEC V450 PRO LINCOLN B 58 F 58 TROUBLESHOOTING AND REPAIR SPI CABLE RESISTANCE AND VOLTAGE TEST PROCEDURE continued TEST PROCEDURE Return to Section TOC Return to Master TOC Return to Section TOC eio OJO E f gt 5 5 51 amp Return to Section TOC Return to Master TOC Return to Master TOC J33 Remove the input power to the V450 PRO Using the 2 Phillips screwdriver remove the case front panel Locate and remove plug J33 from the control board See Figure F 15 Check the resistance and continuity of the SPI cable by testing with the ohmmeter from each pin on plug J33 to the corresponding pins on plug J34 See the Wiring Diagram
186. th defects or other reproductive harm The Above For Diesel Engines Ihe Above For Gasoline Engines ARC WELDING can be hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 o 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 23 ELECTRIC AND MAGNETIC FIELDS 58 may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding
187. then the power must be removed from the machine and the fan problem or air obstruction cor rected The F A N fan as needed system is con trolled by the control board via a solid state relay PROTECTIVE CIRCUITS Protective circuits are designed into the INVERTEC V450 PRO to sense trouble and shut down the machine before damage occurs to the machine s inter nal components OVER CURRENT PROTECTION If the average current exceeds 590 amps then the peak current will be limited to 100 amps until the aver age current decreases to fewer than 50 amps UNDER OVER VOLTAGE PROTEC TION A protective circuit is included on the control board to monitor the voltage across the input capacitors In the event that a capacitor voltage is too high or too low the protection circuit will de energize the input contactor Machine output will be disabled and the soft start mode will be repeated The protection circuit will prevent output if any of the following circumstances occur 1 Capacitor conditioning is required May be required if machine has been off for a long period of time and is connected for high input voltage operation 2 Voltage across a capacitor exceeds 390 volts High line surges or improper input voltage con nections 3 Voltage across a capacitor is under 70 volts Due to improper input voltage connections 4 Internal component damage INVERTEC V450 PRO LINCOLN B Return to Section TOC Ret
188. to the Instruction Manual 4 Perform Choke Test 5 Perform Testland Check Sense Lead Routing CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f gt 091 ms 9 gt 5 5 Dllo amp c Return to Section TOC Return to Master TOC Return to Master TOC py TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELD AND ARC QUALITY PROBLEMS Machine shuts down during a weld 1 Secondary over current 1 Adjust parameters to minimize occurred momentary shorting of the arc NOTE The Diagnostic Utility can be used to check the Check for single phase input event log to determine loss of L2 which will reduce cause of shut down the secondary current limit Check input fuses or current in all three phases for balance 5 amps CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for t
189. to the machine output terminals See Figure E 5 NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 5 5 Dllo amp c Return to Section TOC Return to Master TOC ES THEORY OF OPERATION ED THERMAL PROTECTION Two normally closed NC thermostats protect the machine from excessive operating temperatures These thermostats are wired in series and are con nected to the control board One of the thermostats is located on the heat sink of the output rectifier and the other is located near the fan On later production machines this thermostat is located on the output choke Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond its duty cycle or output rating If excessive operating tem peratures should occur the thermostats will prevent output from the machine The yellow thermal light located on the front of the machine will be illuminated The thermostats are self resetting once the machine cools sufficiently If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally the power switch may be left on and the reset should occur within a 15 minute period If the fan is not turning or the air intake louvers are obstructed
190. to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN LL INVERTEC V450 PRO Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC G 9 SCHEMATIC DIGITAL CONTROL PC BOARD G3789 SHEET 4 052 6829 ENGINEERING CONTROLLED MANUFACTURER Yes ELECTRICAL DIAGRAMS Vu m k Win 7 duF Tod Teen 4 setti 124 M nra 2148 18145 10149 1 10126 10125 13 140 Hr DIS ud Teu Te 1 XIL NX RESET SF 200 Hi Der zj PASE aeva acri poa S Apri speras EN sheng agreng 199 CIN Lu ee spun i x22 ABC ad 733207240 Moni RG 1 LRL NAMMTI CHa IDES eye SLD EE 2 2520 POZASI 5901 eat
191. to Section TOC Return to Master TOC Return to Section TOC eio OJO f gt olg gt 5 5 Dllo amp Return to Section TOC Return to Master TOC Return to Master TOC Em OPERATION P MEMORY SELECTIONS Sed Figure 2 location of controls The MEMORY button and SELECT knob are used together to select a welding process and store it in memory M1 thru M8 The SELECT knob scrolls through the welding process modes and memory M1 thru M8 The MEMORY button stores the welding process in memory SELECT button The right button selects between the Hot Start or Arc Control The will indicate the active feature shown below Right Digital Window Hot Start 10 to 0 10 Arc Control 0 to 10 lt The ADJUST knob adjusts the desired settings for the Hot Start or Arc Control feature that is active WELDING PROCESS MODES AVAILABLE Stick SMAW TIG GTAW Gouge CAG CV MIG GMAW CV Flux Core Pulse MIG ELECTRODE MATERIAL Steel Metal Core Stainless Aluminum Nickel EXAMPLE OF SAVING WELDING MODES TO MEM ORY The following example is how to select Pulse MIG using 035 steel and store it into memory 1 Turn the SELECT knob until welding process is dis played RIGHT WINDOW LEFT WINDOW Pulse MIG Argon Blends Steel 035 2 Wait two seconds and the right window will display Arc Control on the second line on the right side Pulse MIG Argon Blends
192. ugh its self con figuration Err HHHH Fault code display The first fault to occur will be displayed for three seconds The display will cycle through fault codes for all faults that persist after the initial three second period are displayed for 1 second each Weld mode is changing HHHH A constant voltage weld mode is selected machine output is off The numeric value in the right display is the work point HHHH A constant current weld mode is selected machine output is off The numeric value in the left display is either the work point or a work point limit depending on the weld mode and remote configu ration HHHH HHHH steady Machine output is on Left display is current right display is volt age If actively welding the displays are arc current and arc volt age If not actively welding the display will show work point HHHH HHHH blinking Weld just finished the average arc voltage and current will be blinked for 5 seconds following a weld If the work point changes during this 5 second period the display will revert to the above mode CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 INVERTEC V450 PRO LINCOLN B 12 NOTES INVERTEC V
193. urn to Master TOC Return to Section TOC Return to Master TOC eio OJO nd fom eo cre 5 5 amp Return to Section TOC Return to Master TOC 7 THEORY OF OPERATION E 7 FIGURE E 6 IGBT OPERATION POSITIVE VOLTAGE APPLIED 2 SOURCE GATE c SOURCE C nE prm nz J n J p 4 BODY REGION 2 BODY REGION n lt DRAIN DRIFT REGION n DRAIN DRIFT REGION nr BUFFER LAYER n BUFFER LAYER INJECTING LAYER INJECTING LAYER 2 DRAIN DRAIN A PASSIVE B ACTIVE INSULATED GATE BIPOLAR TRANSISTOR IGBT OPERATION An IGBT is a type of transistor IGBT are semiconduc tors well suited for high frequency switching and high current applications Example A in Figure E 6 shows an IGBT in passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain termi nal of the IGBT may be connected to a voltage supply but since there is no conduction the circuit will not sup ply current to components connected to the source The circuit is turned OFF like a light switch Example B shows the IGBT in an active mode When the gate signals a positive DC voltage relative to the source is applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply con nected to the
194. y precautions Using the 3 8 in nut driver remove the PC board compartment cover Refer to Figure F 16 Remove the molex plugs from the control board POWER BOARD Label and remove the two molex plugs and white and black wires with quick connects from the power PC board Using the 3 8 in nut driver remove the two screws holding the rear of the Control Box in place Clear the lead harnesses from the left and right sides and carefully remove the power and con trol PC board assembly 10 Remove either the power or the control board from the PC board assembly INVERTEC V450 PRO LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i olg gt 5 2 amp Return to Section TOC Return to Master TOC Return to Master TOC tu TROUBLESHOOTING AND REPAIR rel CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE continued INSTALLATION PROCEDURE 1 Install either the power or control board to the 5 PC board assembly and secure it in place 2 Carefully slide the power and control PC 6 board assembly into place making sure to clear the lead harnesses on the right and left side of the PC board compartment 7 3 Secure the rear of the control box in place 4 Connect two molex plugs and black and white wires with quick disconnects to the power PC board Connect the molex plugs to
195. y 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 INVERTEC V450 PRO LINCOLN B Return to Master Return to Master TOC o 5 o gt 2 tc Return to Master TOC SAFETY WELDING and CUTTING gt 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 hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used

Lincoln Electric INVERTEC SVM199-A User's Manual

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