V 300eng PDF

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SVM101-A
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December 1995
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INVERTEC V300-I
For use with machines Code Numbers 9826
9827
10036
10037
10132
10133
Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-

ful operation on your part. DO
View Safety Info
NOT INSTALL, OPERATE OR

REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
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SERVICE MANUAL
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World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
i SAFETY
WARNING
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 pur-
chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER-
FORMED ONLY BY QUALIFIED INDIVIDUALS.
ELECTRIC SHOCK can ARC RAYS can burn.

2.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
1.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on.
open arc welding. Headshield and filter lens

Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
1.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 2.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or FUMES AND GASES
scaffolds; when in cramped positions such as sitting,
kneeling or Iying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 3.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When

1.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
1.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
1.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
1.f. Maintain the electrode holder, work clamp, welding cable and 3.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace coming from degreasing, cleaning or spraying operations.
damaged insulation. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
1.g. Never dip the electrode in water for cooling. products.
1.h. Never simultaneously touch electrically “hot” parts of 3.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage especially in confined areas, to insure breathing air is safe.
of both welders.
3.d. Read and understand the manufacturer’s instructions for this
1.i. When working above floor level, use a safety belt to protect equipment and the consumables to be used, including the
yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
1.j. Also see Items 4.c. and 6. your welding distributor or from the manufacturer.
3.e. Also see item 7b.
Apr. ‘93
INVERTEC V300-I
Return to Master TOC SAFETY ii
WELDING SPARKS can CYLINDER may explode

cause fire or explosion. if damaged.
4.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 5.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
4.b. Where compressed gases are to be used at the job site, 5.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 5.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
4.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact • A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
4.d. Do not heat, cut or weld tanks, drums or containers until the 5.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 5.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 5.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
(see address above). use.
4.e. Vent hollow castings or containers before heating, cutting or 5.g. Read and follow the instructions on compressed gas
welding. They may explode. cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
4.f. Sparks and spatter are thrown from the welding arc. Wear oil Cylinders,” available from the Compressed Gas Association
free protective garments such as leather gloves, heavy shirt, 1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area.
powered equipment.
4.g. Connect the work cable to the work as close to the welding 6.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building switch at the fuse box before working on
framework or other locations away from the welding area the equipment.
increase the possibility of the welding current passing
6.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate cir-
Electrical Code, all local codes and the manufacturer’s
cuits. This can create fire hazards or overheat lifting chains
recommendations.
or cables until they fail.
6.c. Ground the equipment in accordance with the U.S. National
4.h. Also see item 7c.
Electrical Code and the manufacturer’s recommendations.
Mar. ‘93
INVERTEC V300-I
Return to Master TOC iii SAFETY
FOR ENGINE ELECTRIC AND MAGNETIC
powered equipment. FIELDS
7.a. Turn the engine off before troubleshooting and maintenance may be dangerous
work unless the maintenance work requires it to be running.
____________________________________________________
8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
7.b. Operate engines in open, well-ventilated current creates EMF fields around welding cables and
areas or vent the engine exhaust fumes welding machines
outdoors.
8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
____________________________________________________ before welding.
8.c. Exposure to EMF fields in welding may have other health

7.c. Do not add the fuel near an open flame effects which are now not known.
welding arc or when the engine is running.
Stop the engine and allow it to cool before 8d. All welders should use the following procedures in order to
refueling to prevent spilled fuel from minimize exposure to EMF fields from the welding circuit:
vaporizing on contact with hot engine parts

and igniting. Do not spill fuel when filling 8.d.1. Route the electrode and work cables together - Secure
tank. If fuel is spilled, wipe it up and do not them with tape when possible.
start engine until fumes have been
eliminated. 8.d.2. Never coil the electrode lead around your body.
____________________________________________________ 8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
7.d. Keep all equipment safety guards, covers
and devices in position and in good repair. 8.d.4. Connect the work cable to the workpiece as close as
Keep hands, hair, clothing and tools away possible to the area being welded.
from V-belts, gears, fans and all other
moving parts when starting, operating or 8.d.5. Do not work next to welding power source.
repairing equipment.
____________________________________________________ Mar. ‘93
7.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove

guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
___________________________________________________
7.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
hot.
INVERTEC V300-I
Return to Master TOC SAFETY iv
5. Toujours porter des lunettes de sécurité dans la zone de

PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
Pour votre propre protection lire et observer toutes les instruc- zones où l’on pique le laitier.
tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté 6. Eloigner les matériaux inflammables ou les recouvrir afin de
générales suivantes: prévenir tout risque d’incendie dû aux étincelles.
Sûreté Pour Soudage A L’Arc 7. Quand on ne soude pas, poser la pince à une endroit isolé de
1. Protegez-vous contre la secousse électrique: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours 8. S’assurer que la masse est connectée le plus prés possible
tout contact entre les parties sous tension et la peau nue de la zone de travail qu’il est pratique de le faire. Si on place
ou les vétements mouillés. Porter des gants secs et sans la masse sur la charpente de la construction ou d’autres
trous pour isoler les mains. endroits éloignés de la zone de travail, on augmente le risque
b. Faire trés attention de bien s’isoler de la masse quand on de voir passer le courant de soudage par les chaines de lev-
soude dans des endroits humides, ou sur un plancher age, câbles de grue, ou autres circuits. Cela peut provoquer
metallique ou des grilles metalliques, principalement dans des risques d’incendie ou d’echauffement des chaines et des
les positions assis ou couché pour lesquelles une câbles jusqu’à ce qu’ils se rompent.
grande partie du corps peut être en contact avec la
masse. 9. Assurer une ventilation suffisante dans la zone de soudage.
c. Maintenir le porte-électrode, la pince de masse, le câble Ceci est particuliérement important pour le soudage de tôles
de soudage et la machine à souder en bon et sûr état galvanisées plombées, ou cadmiées ou tout autre métal qui
defonctionnement. produit des fumeés toxiques.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir. 10. Ne pas souder en présence de vapeurs de chlore provenant
e. Ne jamais toucher simultanément les parties sous tension d’opérations de dégraissage, nettoyage ou pistolage. La
des porte-électrodes connectés à deux machines à soud- chaleur ou les rayons de l’arc peuvent réagir avec les
er parce que la tension entre les deux pinces peut être le vapeurs du solvant pour produire du phosgéne (gas forte-
total de la tension à vide des deux machines. ment toxique) ou autres produits irritants.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions 11. Pour obtenir de plus amples renseignements sur la sûreté,
pour le porte-électrode s’applicuent aussi au pistolet de voir le code “Code for safety in welding and cutting” CSA
soudage. Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se pro-

téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
TRANSFORMATEUR ET À
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude 1. Relier à la terre le chassis du poste conformement au code
ou quand on regarde l’arc. de l’électricité et aux recommendations du fabricant. Le dis-
b. Porter des vêtements convenables afin de protéger la positif de montage ou la piece à souder doit être branché à
peau de soudeur et des aides contre le rayonnement de une bonne mise à la terre.
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au 2. Autant que possible, I’installation et l’entretien du poste
soudage à l’aide d’écrans appropriés et non-inflamma- seront effectués par un électricien qualifié.
bles.
3. Avant de faires des travaux à l’interieur de poste, la
4. Des gouttes de laitier en fusion sont émises de l’arc de debrancher à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leur
pantalons sans revers, et chaussures montantes. place.
Mar. ‘93
INVERTEC V300-I
v
RETURN TO MAIN INDEX
MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page
Safety ........................................................................................................................i-iv
Installation.........................................................................................................Section A
Technical Specifications .........................................................................................A-1
Location ..................................................................................................................A-2
Machine Grounding ................................................................................................A-2
Input Connections...................................................................................................A-2
Output Connections ................................................................................................A-4
Operation...........................................................................................................Section B
Safety Precautions..................................................................................................B-1
General Description ................................................................................................B-2
Controls and Settings .............................................................................................B-2
Welding Operation ..................................................................................................B-4
Auxillary Power .......................................................................................................B-5
Overload Protection ................................................................................................B-5
Accessories.......................................................................................................Section C
Options/Accessories...............................................................................................C-1
Wire Feeder Connections .........................................................................C-2 — C-13
Maintenance ......................................................................................................Section D
Input Filter Capacitor Discharge Procedure ...........................................................D-1
Preventive maintenance .........................................................................................D-2
Theory of Operation..........................................................................................Section E
Power Supply Operation.........................................................................................E-1
Field Effect Transistor (FET) Operation..................................................................E-5
Pulse Width Modulation ..........................................................................................E-6
Protective Circuits...................................................................................................E-7
Troubleshooting and Repair ............................................................................Section F

How To Use Troubleshooting Guide.......................................................................F-1
PC Board Troubleshooting Procedures ..................................................................F-2
Matched Parts.........................................................................................................F-2
Troubleshooting Guide............................................................................................F-3
Test Procedures
Capacitor Replacement ........................................................................................F-50
Switch PC Board Replacement.............................................................................F-54
Test After Repair of Switch Boards and/or Capacitors .........................................F-56
Output Diode Replacement...................................................................................F-58
Input Filter Capacitor Conditioning........................................................................F-59
Environmental Protection......................................................................................F-59
Retest After Repair ...............................................................................................F-60
Electrical Diagram ............................................................................................Section G
Parts Manual
INVERTEC V300-I
TABLE OF CONTENTS Section A
- INSTALLATION SECTION -
Installation.........................................................................................................Section A
Technical Specifications .........................................................................................A-1
Input and Output Specifications
Cable and Fuse Sizes
Physical Dimensions
Location ..................................................................................................................A-2
High Frequency Precautions ..................................................................................A-2
Input Connections...................................................................................................A-2
Ground Connections .......................................................................................A-3
Input Power Cord Connection.........................................................................A-3
Input Power Connection .................................................................................A-3
Input Fuse and Supply Wires..........................................................................A-3
Input Voltage Reconnect Procedure ...............................................................A-3

Output Connections ................................................................................................A-4
Work and Electrode Cable Connections .........................................................A-4
Amphenol Receptacle.....................................................................................A-4
INVERTEC V300-I
A-1 INSTALLATION
Return to Section TOC
INPUT
THREE PHASE SINGLE PHASE
Standard Input Current Code Standard Input Current Code
Voltage at Rated Output Number Voltage at Rated Output Number
200/230/280-415/440 43/39/25- 9826, 9827, 200/230/380-415/440 53/47/32- 9826, 9827,
50/60 25/22 10036, 10037, 50/60 32/29 10036, 10037,
10132, 10133 10132, 10133
RATED OUTPUT
Volts at Volts at
Rated Rated
Duty Cycle Amps Amperes Duty Cycle Amps Amperes
60% Duty Cycle 300 32 60% Duty Cycle 200 28
100% Duty Cycle 250 30 100% Duty Cycle 165 26.5
OUTPUT
Welding Constant Open Auxiliary Welding Constant Open Auxiliary
Current Range Circuit Voltage Power Current Range Circuit Voltage Power
5-300 Amps 60-70 VDC 42 VAC, 5.5 Amps 5-200 Amps 60-70 VDC 42 VAC, 5.5 Amps
24 VAC, 1 Amp 24 VAC, 1 Amp
*115 VAC, 2 Amps *115 VAC, 2 Amps
*Not on all codes *Not on all codes
RECOMMENDED INPUT WIRE AND FUSE SIZES

Type 75°C Type 75°C
Type 75°C Copper Type 75°C Copper
Fuse Input Copper Ground Fuse Input Copper Ground
(Superlag) Ampere Wire in Wire in (Superlag) Ampere Wire in Wire in

Input or Rating Conduit Conduit Input or Rating Conduit Conduit
Voltage Breaker on AWG (IEC) AWG (IEC) Voltage Breaker on AWG (IEC) AWG (IEC)
Frequency(1) Size Nameplate Sizes Sizes Frequency(1) Size Nameplate Sizes Sizes
200/50-60 60 43 6 (16mm2) 10 (6mm2) 200/50-60 80 53 6 (16mm2) 10 (6mm2)

220/50-60 60 39 8 (10mm2) 10 (6mm2) 220/50-60 70 47 6 (16mm2) 10 (6mm2)
380/50-60 35 25 10 (6mm2) 10 (6mm2) 380/50-60 50 32 8 (10mm2) 10 (6mm2)
415/50-60 35 25 10 (6mm2) 10 (6mm2) 415/50-60 50 32 8 (10mm2) 10 (6mm2)
440/50-60 35 22 10 (6mm2) 10 (6mm2) 440/50-60 50 29 10 (6mm2) 10 (6mm2)
PHYSICAL DIMENSIONS
Height Width Depth Weight
18.7 in. 10.8 in. 22.2 in. 64 lbs.
475 mm 274 mm 564 mm 29 Kg

(1) Input voltage must be within ±10% of rated value.
INVERTEC V300-I
INSTALLATION A-2
Read entire installation section before starting TILTING

installation.
Place machine directly on a secure, level surface or
SAFETY PRECAUTIONS on a recommended undercarriage. The machine may
topple over if this procedure is not followed.
WARNING
HIGH FREQUENCY PRECAUTIONS
ELECTRIC SHOCK can kill.
• Only qualified personnel should
If possible, locate the V300-I away from radio con-
perform this installation.
trolled machinery. The normal operation of the V300-I
• Turn the input power OFF at the
disconnect switch or fuse box may adversely affect the operation of RF controlled
before working on this equipment, which may result in bodily injury or dam-
equipment. age to the equipment.
• Do not touch electrically hot
parts.
• Always connect the V300-I INPUT CONNECTIONS

grounding terminal (located on the
bottom of the input connection box)
to a good electrical earth ground. Be sure the voltage, phase, and frequency of the input
power is as specified on the rating plate. See Figure
A.1 for the location of the rating plate.
FIGURE A.1 — RATING PLATE LOCATION

ON/OFF POWER SWITCH
SELECT SUITABLE LOCATION 14 PIN AMPHENOL
INPUT CORD 6 AMP BREAKER

NOTE: The Invertec V300-I is capable of operating in ACCESS HOLE 115 V CIRCUIT
2 AMP BREAKER
harsh environments. However, it is important to use 42 V CIRCUIT
METER POLARITY
the machine in appropriate locations to assure reliable SWITCH
RATING PLATE
operation and long life. Failure to follow these precau-
tions can result in excessive operating temperatures
causing nuisance shutdown of the machine.
1. Verify the machine will be located in an area where
• free circulation of air into the sides and out the

front and bottom of the machine will not be
restricted. MACHINE BACK
• dust and dirt is kept to a minimum.

WARNING
• it will remain dry, sheltered from rain and snow. Only a qualified electrician should connect the input
leads to the V300-I. Connections should be made in
• it will not be placed on wet ground or in puddles. accordance with all local and national electrical codes
and the connection diagram located on the inside of
the reconnect/input access door of the machine.
STACKING Failure to do so may result in bodily injury or death.
___________________________________________
V300-I’s cannot be stacked.
CAUTION
Failure to follow these instructions can cause immedi-
ate failure of components within the welder.
___________________________________________
INVERTEC V300-I
A-3 INSTALLATION
INPUT VOLTAGE RECONNECT
GROUND CONNECTIONS
PROCEDURE
Connect terminal on Case Back marked to earth
ground per National Electrical Code. NOTE: The invertec V300-I should be connected only
by a qualified electrician. Installation should be made
in accordance with all local and national electrical
INSTALL INPUT POWER CORD codes and the information detailed in this manual.
CONNECTOR
1. To connect 200/220/380-415/440 AC MULTIPLE
NOTE: The Invertec V300-I is supplied with one cord voltage machines, follow procedures shown below
connector. The cord connector provides a strain relief and refer to Figure A.2.
for the input power cord as it passes through the right
rear access hole. The cord connector is designed for a 2. To connect 575 VAC single-voltage machine, no
cord diameter of .310 – 1.070 in. (7.9 – 27.2mm). internal reconnection for other input voltages is
possible. The 575 VAC machine can only be con-
1. Strip away outer jacket of cord and trim insulating nected to 575 VAC.
fillers. Insert conductors through cord connector.

The jacketed portion of cord must go through cord NOTE: Turn main power to machine OFF before
connector. performing reconnect procedure. Failure to do so
will result in damage to the machine. DO NOT
2. Tighten both connector screws. switch the reconnect bar with machine power ON.
INPUT POWER CONNECTIONS To Operate at Procedure
Connect AC power supply lines to Power Line Switch 440 VAC 1. No setup is typically required.
S1. Machine is factory-connected
to operate at 440 volts. Verify
• Single-phase operation — Connect supply lines to input voltage swith in 380-460V
the upper and lower terminals of Power Line Switch. position. Verify lead “A” in
Torque to (3.0 Nm) 27.5 in.-lbs. Upper terminal is 440-460V terminal.
labeled “U”, and lower terminal is labeled “W”.

200 or 220 VAC 1. Open reconnect panel access
• Three-phase operation — Connect 3 phase supply door on wrap-around.
lines to Power Line Switch terminals labeled “U”, “V” 2. Move input voltage switch to
and “W”. Torque to (3.0 Nm) 27.5 in.-lbs. Voltage = 200-230V position.
3. Move lead “A” to terminal that
NOTE: Input voltage must be within 10% of rated matches input voltage:
value. Input Use Terminal
200 VAC 200-208 VAC
220 VAC 220-230 VAC
INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS 380, 415 or 1. Open reconnect panel access
or 440 VAC door on wrap-around.
Refer to Technical Specifications Sheet at beginning 2. Move input voltage switch to
of this chapter for proper fuse sizes and input cable Voltage = 380-460V position.
sizes. 3. Move lead “A” to terminal that

matches input voltage:
• Fuse input circuit with recommended super lag Input Use Terminal
fuses or delay type circuit breakers. 380 VAC 380-415V
415 VAC 380-415V
• Install proper fuse in fuse holder in reconnect panel. 440 VAC 440-460V
See Specifications at beginning of this chapter.
INVERTEC V300-I
INSTALLATION A-4
FIGURE A.2 — RECONNECT PANEL

OUTPUT CONNECTIONS WORK AND ELECTRODE CABLE

CONNECTIONS
Refer to Figure A.3 for location of Output Terminals
and 14 pin Amphenol Receptacle. Size
FIGURE A.3 — OUTPUT CONNECTIONS Select output cable size based on Table A.1.
NOTE: A quick disconnect system is used for welding

cable connections. The welding plug included with the
machine is designed to accept a welding cable size of
1/0 to 2/0.
1. Remove 1 in. (25mm) of welding cable insulation.
2. Slide rubber boot onto cable end. Boot end may be

trimmed to match cable diameter. Soap or other

lubricant will help to slide boot over the cable.
LINCOLN
3. Slide copper tube into brass plug.
4. Insert cable into copper tube.
- + 5. Tighten set screw to collapse copper tube. Screw

must apply pressure against welding cable. Top of
set screw sill be well below the surface of the brass
plug after tightening.
OUTPUT TERMINALS
6. Slide rubber boot over brass plug. Rubber boot
TABLE A.1 must be positioned to cover all electrical surfaces
Cable Sizes for Combined Length of Electrode completely after plug is locked into receptacle.
and Work Cable (Copper Cable Rated at 75°C).
Length AMPHENOL RECEPTACLE

Duty Current Up to 200-250 Ft.
Cycle Current 200 Ft. (61M) (61-76M) The 14 Pin Amphenol is used to connect various
100% 250 1/0 (50mm2) 1/0 (50mm2) options and accessories to the V300-I. Refer to the
60% 300 1/0 (50mm2) 2/0 (70mm2) Accessory Section of this manual for available acces-
sories and connection instructions.
INVERTEC V300-I
Section B TABLE OF CONTENTS
- OPERATION SECTION -
Operation...........................................................................................................Section B
Safety Precautions.................................................................................................B-1
General Description ...............................................................................................B-2
Recommended Processes and Equipment ...................................................B-2
Operational Features and Controls................................................................B-2
Welding Capability .........................................................................................B-2
Limitations......................................................................................................B-2
Controls and Settings ............................................................................................B-2
Welding Operation .................................................................................................B-4
Auxillary Power ......................................................................................................B-5
Overload Protection ...............................................................................................B-5
INVERTEC V300-I
OPERATION B-1
OPERATING INSTRUCTIONS
Read and understand entire Operation Section prior to
operating machine.
GENERAL WARNINGS
WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts

or electrode with skin or wet
clothing.
• Insulate yourself from work and

ground.
• Always wear dry insulating

gloves.
FUMES AND GASES

can be dangerous.
• Keep your head out of fumes.

• Use ventilation or exhaust to

remove fumes from breathing
zone.
WELDING SPARKS
can cause fire or
explosion
• Keep flammable material away.
• Do not weld on containers that

have held combustibles.
ARC RAYS
can burn.
• Wear eye, ear and body

protection.
Observe additional Safety Guidelines detailed in

the beginning of this manual.
INVERTEC V300-I
B-2 OPERATION
GENERAL DESCRIPTION OPERATIONAL FEATURES AND
CONTROLS
The Invertec V300-I is a 300-amp arc welding power
source that utilizes single- or thee-phase input power The Invertec V300-I provides continuous total range
to produce either constant voltage or constant current output current or voltage adjustment, selectable weld-
outputs. The V300-I is designed for 50/60 Hz supply ing modes and local or remote output control.
systems. The welding response of the Invertec has Additionally, a digital meter displays either preset or
actual output. Welding characteristics can be con-
been optimized for GMAW, SMAW, TIG and FCAW
trolled via an arc force and inductance control.
processes. It is designed to be used with the LN-25,
LN-7 and LN-9 GMA Semiautomatic Wire Feeders.
WELDING CAPABILITY
RECOMMENDED PROCESSES AND The International V300-I Invertec is rated for 200
EQUIPMENT amps at a 60% duty cycle for single-phase input and
300 amps at a 60% duty cycle for three-phase unit.
The Invertec V300-I is recommended for constant
voltage welding processes like GMAW and FCAW,

and constant current processes such as SMAW (stick) LIMITATIONS
and GTAW (TIG). Additionally the V300-I will perform
air carbon arc cutting. NOTE: Do not exceed the rated The V300-I is not recommended for pipe thawing.
current and duty cycle when air carbon arc cutting.
CONTROLS AND SETTINGS

All operator controls and adjustments are located on the case front or case back of the V300-I. Refer to Figure
B.1and corresponding explanations.
FIGURE B.1 — CASE FRONT CONTROLS.
DIGITAL METER
SWITCH
L8608
SMAW
ON CRISP FCAW
OUTPUT
TERMINALS SMAW
SOFT GMAW MODE SWITCH
GTAW
OUTPUT TERMINALS REMOTE A V

ARC FORCE
SWITCH OUTPUT 5 6
REMOTE
4 7
U
D
N
I
4
5 6
7
A
R
C
F
AND INDUCTANCE
C O
3 8 T
A
N
3 8
E
R
C CONTROL
C 2 9
LOCAL/REMOTE 2
1 10
9 E 1 10
SWITCH
OUTPUT
CONTROL
HIGH TEMPERATURE ®
INVERTEC ™ V300-I
WARNING LIGHT
INVERTEC V300-I
OPERATION B-3
POWER SWITCH. The POWER SWITCH is located • CV GMAW — Short circuit, globe and spray trans-
on the control panel at the rear of the machine. Move fer solid wire and gas welding are done in this
the switch lever to the ON position to energize the mode. Low end procedures, less than 16V, may
machine. This also activates the DIGITAL METER operate better in the FCAW mode.
and the internal FAN.
OUTPUT TERMINALS SWITCH. This switch lets you
OUTPUT CONTROL. This control is used to adjust determine how the machine welding terminals will be
the power output of the machine. When the machine energized. Set the switch to the ON position when
is in the constant voltage mode, this control adjusts using processes or equipment that require energized
the output VOLTAGE. In the constant current mode, it machine terminals (stick, TIG, air-carbon arc cutting,
adjusts the output CURRENT. One turn of the control or LN-25 with electrically “hot” gun tip). Set the switch
knob covers the total output range. Power output can to REMOTE (OFF) position when using LN-25 with
be adjusted under both load and no-load conditions. K431 and K432 options, LN-9GMA or LN-7,
which will allow the gun trigger to energize the welding
LOCAL/REMOTE SWITCH. This switch determines terminals.
where the power output adjustment can be made, at
the machine or at a remote location. When the switch ARC FORCE & INDUCTANCE CONTROL. This con-
is set to LOCAL, the power adjustment can be made trol is used to adjust the ARC FORCE on constant
at the machine using the OUTPUT CONTROL. When current applications and tin INDUCTANCE (pinch
this switch is set to REMOTE, the output adjustment effect) on constant voltage applications. The full
can be made at the wire feeder or the optional adjustment range is 1 to 10 with 1 being very soft and
REMOTE CONTROL. 10 being very crisp. When adjusting arc force, the low
settings will produce a soft arc and the high settings
DIGITAL METER SWITCH. The DIGITAL METER will produce a more forceful, or driving, arc. The high
displays welding current or voltage, depending on the settings will produce higher spatter levels. When the
position of the DIGITAL METER SWITCH. When the control is used for FCAW, the maximum setting is
switch is set at A (for amps), the display is welding generally preferred. With GMAW, the upper half of the
current. When the switch is set at V (for volts), the dis- range (6 to 10) is preferred with CO2 or high content
play is welding voltage. When welding is not being- CO2 mixed. The lower half of the range (1 to 5) is pre-
done, the display indicates the output control setting. ferred for inert gas mixes.
During welding the display indicates the actual weld-
Normal Recommended
ing current or voltage. Method Process Setting Adjustment Range1
CC EXX18 thru 5 1 (gentle, may stick)
MODE SWITCH. Use this switch to select the type of SMAW 1 EXX28 stick to 9 (forceful,
welding desired: GTAW, CC Soft, CC Crisp, CV more spatter)
FCAW, or CV GMAW. The following settings are rec- CC EXX10 thru 6 3 to 10
SMAW 2 EXX14 stick
ommended:
Air Carbon Arc Cutting 1 NONE
CV FCAW Innershield® or 10 NONE
• GTAW — Optimized for both scratch start and Hi-
Outershield®
Freq™ kit use.
Air Carbon Arc Cutting 1 NONE
CV GMAW CO2 or 25% CO2 7.5 5 to 102
• CC Soft — Best for EXX181 thru EXX28 stick elec- or similar gas mixes
trodes. 98% Ar, 2% O2 or 5 1 to 10
90% Ar, 7.5% He,
2.5% CO2 and
• CC Crisp — Use this mode for stick welding with
other predominantly
EXX10 thru EXX14 electrodes. Non-welding appli- inert gases
cations, such as resistive heating or output tests

with resistive loads, should be done in this mode 1 Full range is 1 to 10; 1 is very soft; 10 is very crisp.
with Arc Force Control set to minimum. 2 1 = lowest pinch, highest inductance, and least spatter.
2 10 = highest pinch, lowest inductance, and most spatter.
• CV FCAW — This setting has been optimized for

Innershield ® and Outershield ® flux-cored elec-
trodes.
1 XX refers to tensile strength of electrode (i.e., 60, 70, etc.).
INVERTEC V300-I
B-4 OPERATION
METER POLARITY SWITCH. The switch is located
NOTE: Code 9827, 10037 and 10132 (European) can

on the control panel at the rear of the machine. It pro- not operate an LN-9 GMA or LN-7 since these require
vides a work-sensing connection (not the work lead) a 110 VAC auxiliary.
for wire feeder voltmeters. As shown in Figure B.1a, if CONSTANT CURRENT PROCESSES
the electrode polarity is negative (–), push the switch
to the left. If the electrode polarity is positive (+), push Manual Arc Welding (Stick)
the switch to the right. This switch does not change The Invertec may be utilized as a manual DC arc
welding polarity. welder with the electrode cable, work cable, and elec-
trode holder being the only equipment required.
Air Carbon Arc Cutting

Air carbon arc cutting may be performed with the
Invertec within its output rating using 5/32" (3.9mm)
and 3/16" (4.7mm) diameter carbon rods. Output
cables, an air carbon arc electrode cable assembly,
and a source of compressed air are required.
NOTE:
FIGURE B.1a 1. Air carbon arc cutting may be performed using
either Constant Voltage modes or Constant
Current modes; however, the cutting action will be
WELDING OPERATION smoother with Constant voltage modes. Best per-
formance will be at settings of 250 amps and
Familiarize yourself with the Controls and Display below.
Section before attempting operation of the V300-I.
2. The electrode protection circuit in the Invertec will
WARNING limit the current to approximately 325 amps.
If stick welding, TIG, or air carbon arc cutting is to be TIG Welding

done on the Invertec along with semiautomatic weld- The Invertec which is capable of scratch TIG welding,
ing, then all control, electrode and work leads to the can be mated with the K900-1 DC TIG starter. An
wire feed equipment must be disconnected from the electrode cable, work cable, TIG torch, and gas sup-
Invertec before connecting the Invertec for stick, TIG ply are required. Refer to Accessories section of this
or air carbon arc cutting. manual.
CONSTANT VOLTAGE PROCESSES
Gas Metal Arc Welding (GMAW)

GMAW welding may be performed with the Invertec
using the Lincoln Electric LN-9 GMA, LN-25 or LN-7
Wire Feeders. An appropriate GMAW gun and cable
assembly and a regulated supply of shielding gas are
required.
Innershield®/Outershield® (FCAW)
Semiautomatic flux-cored wire processes may be

done with the Invertec using the Lincoln Electric
LN-25 or LN-7 Wire Feeders. An appropriate gun and
cable assembly is required.
INVERTEC V300-I 12/95

OPERATION B-5
AUXILIARY POWER
Three AC auxiliary power supplies are included in the

Invertec V300-I: 24 VAC, 42 VAC and 115 VAC.
The 24 VAC supply is rated at 1 amp and provides

power for the LN-25 wire feeder. Protection is provid-
ed by a self-resetting current limited.
The 42 VAC supply is rated at 5.5 amps and provides

power for other wire feeders. Protection is provided by
a 6-amp circuit breaker with a reset button located on
the rear control handle.
The 115 VAC supply is rated at 2 amps and provides

power for the LN-7 wire feeder. Protection is provided
by a 2.5-amp circuit breaker with a reset button locat-

ed on the rear control panel.
The 24, 42 and 115 VAC supplies must not be loaded

at the same time.
NOTE: 110/115 VAC is not available on Codes 9827,

10037 and 10133.
OVERLOAD PROTECTION
The machine is electrically protected from producing
high output currents. Should the output current
exceed 340-360A, an electronic protection circuit will

reduce the current (“Fold Back”) to approximately
150A. The machine will continue to produce this low
current until the protection circuit is reset. Reset
occurs when the output load is removed.
THERMAL PROTECTION
Thermostats protect the machine from excessive

operating temperatures. Excessive temperatures may
be caused by a lack of cooling air or operating the
machine beyond the duty cycle and output rating. If
excessive operating temperature should occur, the
thermostat will prevent output voltage or current. The
meter will remain energized during this time.
INVERTEC V300-I
Section C TABLE OF CONTENTS
- ACCESSORIES SECTION -
Accessories.......................................................................................................Section C
Options/Accessories..............................................................................................C-1
Connecting a LN-25 Wire Feeder..........................................................................C-2
Connecting a LN-7 Wire Feeder............................................................................C-4
Connecting a LN-9 GMA Wire Feeder...................................................................C-6
Connecting Other Wire Feeders............................................................................C-8
Connecting a K900-1 DC TIG Starter..................................................................C-11
Connecting for Parallel Operation .......................................................................C-12

ACCESSORIES C-1
OPTIONS / ACCESSORIES K876 REMOTE CONTROL

ADAPTER
CABLE PLUGS
For operating an LN-25 wire feeder. The
Cable Plug Kit for 1/0-2/0 cable (K852-70) adapter connects to the 14-pin receptacle of
attaches to welding cable to provide quick Invertec power sources and to the 6-pin
disconnect from machine. connector of the LN-25 K432 remote control
cable.
Cable Plug Kit for 2.0-3/0 cable (K852-95).
NOTE: Two K852-70 plugs are included K900-1 DC TIG STARTER

with the V300-I.
Solid state GTAW starting unit. Rated 300,
60%.
K864 REMOTE CONTROL
ADAPTER
Plugs into the 14-pin receptacle on the rear

panel of the Invertec. Adapter splits remote
control circuitry to a 6-pin receptacle and to
a 14-pin receptacle. Adapter permits remote
output control of Invertec by means of K857
Remote Control, K812 Hand Amptrol or
K870 Foot Amptrol. Allows remote while
using LN-7 K480-7 control cable.
K867 UNIVERSAL ADAPTER

PLUG
Consisting of a 14-pin plug connected to

labeled wires, the adapter allows user con-

nection of any suitable accessory or wire
feeder to the remote control, contactor, and
auxiliary power circuitry of the Invertec.
12/95 INVERTEC V300-I

C-2 ACCESSORIES
CONNECTING A LN-25 WIRE K432 cable or modify K432 cable with K867
FEEDER universal adapter plug. See connection dia-

grams S19899 and S19309 or S19405.
1. Turn Invertec power switch OFF.
4. Place local/remote switch in “Remote”
2. Connect electrode cable to output termi- position if output control is desired at
nal of polarity required by electrode. wire feeder rather than at Invertec.
(LN-25 must have K431 and K432
3. Connect work lead to other terminal. options for remote output control opera-
tion.)
NOTE: LN-25 with remote control options
K431 and K432: Use K876 adapter with
S19899
K876 ADAPTER TO LN-25 - CONNECTION DIAGRAM
WARNING
Turn off input power to the Welding Power Source
using the disconnect switch at the fuse box
Before connecting the wire feeder.
Only qualified persons should install, use or

ELECTRIC
SHOCK service this machine.
CAN KILL
ELECTRODE CABLE
LN-25 WITH
TO LN-25
K431 OPTION
14 PIN 6 PIN
TO
AMPHENOL AMPHENOL
WORK
-
+ K876 ADAPTER
K432 REMOTE
CONTROL CABLE
INVERTEC
POWER SOURCE
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLE AT POWER SOURCE.
N.C. FOR INVERTECS WITH 6 PIN AMPHENOL, K432 CABLE CAN BE CONNECTED DIRECTLY.
R 1-25-91
S19899
CLEVELAND, OHIO U.S.A.
INVERTEC V300-I
ACCESSORIES C-3
S19309
K864 & K876 REMOTE CONTROL ADAPTERS
TURN THE POWER SWITCH OF THE WELDING POWER

SOURCE "OFF" BEFORE INSTALLING PLUGS ON CABLES
OR WHEN CONNECTING OR DISCONNECTING PLUGS TO
WELDING POWER SOURCE.
STRAIGHT PLUG (14 PIN)

CABLE RECEPTACLE (6 SOCKET)
TO POWER SOURCE
TO: 1) K857 REMOTE CONTROL
2) K812 HAND AMPTROL
K864 3) K870 FOOT AMPTROL
TO: 1) LN-7 WIRE FEEDERS


TO POWER SOURCE

K876
R 1-25-91
S19309
K867 PLUG TO LN-25 - CONNECTION DIAGRAM S19405
WARNING


ELECTRIC
CAN KILL
21
82
81
ELECTRODE CABLE 42
N.C.
41 LN-25 WITH
TO LN-25
GND K431 OPTION
14 PIN
TO
AMPHENOL 31
WORK
32
2 E
- 4 F
SPARE D
75 A
+ K867 ADAPTER
76 B K432 REMOTE
77 C CONTROL CABLE
INVERTEC
POWER SOURCE N.E. N.D.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.D. REMOVE 6 PIN PLUG FROM K432 CABLE IN ORDER TO CONNECT K867 PLUG.
LABEL EACH LEAD (A THRU F) AS THEY ARE REMOVED FROM 6 PIN PLUG.
N.E. SPLICE LEADS AND INSULATE.
R 1-25-91
S19405
INVERTEC V300-I
C-4 ACCESSORIES
CONNECTING A LN-7 WIRE Invertec. (K864 remote control adapter and

FEEDER K857 remote control are required for remote
output control.) See connection diagram
1. Turn Invertec power switch OFF. S19901.
2. Connect K480 control cable from LN-7 to 6. Set meter polarity switch on rear of the
Invertec control cable connector. The Invertec to coincide with wire feeder
control cable connector is located at the polarity used. The wire feeder will not
rear of the Invertec. display welding voltage.
3. Connect electrode cable to output termi- NOTE: If K480 is not available, see con-
nal of polarity required by electrode. nection diagram S19404 for modification of
K291 or K404 LN-7 input cable with K867
4. Connect work lead to other terminal. universal adapter plug.
5. Place local/remote switch in “Local” posi-

tion to allow output control at the
S19901
K864 ADAPTER TO LN-7 & REMOTE CONTROL - CONNECTION DIAGRAM
WARNING

ELECTRIC
LN-7
CAN KILL
CONTROL
BOX
14 PIN
ELECTRODE CABLE AMPHENOL
TO LN-7
14 PIN
TO
AMPHENOL
WORK
- K480-7 INPUT CABLE
6 PIN
AMPHENOL
+ K864 K857
ADAPTER REMOTE CONTROL
INVERTEC OR
POWER SOURCE K812
WITH 115VAC HAND AMPTROL
AUXILIARY POWER OR
K870
FOOT AMPTROL
N.C. K480-7 INPUT CABLE CAN BE CONNECTED DIRECTLY IF REMOTE CONTROL IS NOT REQUIRED.
N.D. K864 ADAPTER CANNOT BE USED WITH AN LN-25.
R 1-25-91
S19901
INVERTEC V300-I
ACCESSORIES C-5
S19404
K867 PLUG TO LN-7 - CONNECTION DIAGRAM
WARNING

ELECTRIC
CAN KILL
SPARE
ELECTRODE CABLE 82 LN-7

TO LN-7 81 N.C. CONTROL
14 PIN 42 BOX
TO
AMPHENOL 41
WORK
31 31
- 32 32
2 2
4 4
+
21 21
K291 OR K404
K867 UNIVERSAL
GND GND INPUT CABLE
ADAPTER PLUG
GREEN
INVERTEC
75 75
POWER SOURCE 76 76
WITH 115VAC 77 77
AUXILIARY POWER K775 OPTIONAL
N.D. REMOTE CONTROL

N.D. SPLICE LEADS AND INSULATE.
R 1-25-91
S19404
INVERTEC V300-I
C-6 ACCESSORIES
CONNECTING A LN-9 GMA polarity used. The wire feeder will now
(Applies only to machines with 115V auxil- display the welding voltage.
iary)
NOTE: K608-1 adapter is required in LN-9
1. Turn Invertec power switch OFF. GMA for LN-9 type control. K608-1 is
installed in line with P10 connection at the
2. Connect K596 control cable assembly LN-9 GMA voltage board. See connection
from LN-9 GMA to Invertec control cable diagram S20607.
connector. The control cable connector
is located at rear of the Invertec. K442-1 pulse power filter board is also
required for GMAW but should be discon-
3. Connect electrode cable to output termi- nected for FCAW.
nal of polarity required by electrode.
Connect work lead to other terminal. If K596 is not available, see connection dia-
gram S20608 for modification of K196 LN-9
4. Place local/remote switch in “Remote” GMA input cable with K867 universal
position to allow output control at the adapter plug.

LN-9 GMA.
5. Set meter polarity switch on rear of the

Invertec to coincide with wire feeder
LN-9 GMA WITH K596 CABLE TO INVERTEC - CONNECTION DIAGRAM S20607
WARNING

ELECTRIC
CAN KILL
K608-1
CONNECTION
LN-9 GMA WITH DETAIL
ELECTRODE CABLE
K608-1 AND
TO LN-9 GMA P10,J10' P10',J10
K442-1 KITS.
14 PIN 2 530A 2
TO
AMPHENOL
WORK 3 521 3
4 500 4
- 5 500 5
6 524 6
7 C 11
+ K596 REMOTE 10
CONTROL CABLE 3.9K
ASSEMBLY 11 B 7
INVERTEC
POWER SOURCE 12 533 12
WITH 110/115V AUX.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF", REVERSE
ELECTRODE AND WORK CABLE AT POWER SOURCE. SET METER POLARITY SWITCH ON REAR
OF INVERTEC TO COINCIDE WITH POLARITY USED. SET LN-9 GMA POLARITY SWITCH ALSO.
N.C. INSTALL K608-1 ADAPTER IN LINE WITH P10 TO LN-9 GMA VOLTAGE BOARD AND SECURE TO
ADJACENT HARNESS WITH WIRE TIE PROVIDED. TURN "START" TRIMMER ON VOLTAGE BOARD FULLY 'CCW'.
N.D. FOR GMAW WELDING, INSTALL PULSE POWER FILTER KIT K442-1 IN LN-9 GMA.
R
9-11-92
S20607
INVERTEC V300-I
ACCESSORIES C-7
S20608
LN-9 GMA WITH K196 CABLE AND K867 PLUG TO INVERTEC - CONNECTION DIAGRAM
K608-1
WARNING CONNECTION
Turn off input power to the Welding Power Source DETAIL

P10,J10' P10',J10
Before connecting the wire feeder. 2 530A 2
3 521 3
ELECTRIC
SHOCK service this machine. 4 500 4
CAN KILL
5 500 5
6 524 6
SPARE
ELECTRODE CABLE 82 7 C 11
TO LN-9 GMA 81 N.C. 10
14 PIN 42 K196
TO 3.9K
AMPHENOL 41 INPUT CABLE
WORK
11 B 7
31 31
-
12 533 12
32 32
2 2
4 4
+ 21 21
K867 UNIVERSAL
GND GND
ADAPTER PLUG
INVERTEC
75 A LN-9 GMA WITH
POWER SOURCE
76 B K608-1 AND
WITH 110/115V AUX.
77 K442-1 KITS.
C
N.D.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF", REVERSE
ELECTRODE AND WORK CABLE AT POWER SOURCE. SET METER POLARITY SWITCH ON REAR
OF INVERTEC TO COINCIDE WITH POLARITY USED. SET LN-9 GMA POLARITY SWITCH ALSO.
N.D. SPLICE LEADS AND INSULATE.

N.E. INSTALL K608-1 ADAPTER IN LINE WITH P10 TO LN-9 GMA VOLTAGE BOARD AND SECURE TO
ADJACENT HARNESS WITH WIRE TIE PROVIDED. TURN "START" TRIMMER ON VOLTAGE BOARD FULLY 'CCW'.
N.F. FOR GMAW WELDING, INSTALL PULSE POWER FILTER KIT K442-1 IN LN-9 GMA.
9-11-92
R
CLEVELAND, OHIO U.S.A. S20608

INVERTEC V300-I
C-8 ACCESSORIES
CONNECTING OTHER WIRE
FEEDERS
NOTE: Wire feeders other than LN-7, LN-25
and LN-9 GMA can be used provided the
auxiliary power supply capacity of the
Invertec is not exceeded. K867 universal
adapter plug is required. See connection
diagram S19406 for more information.
S19406
K867 UNIVERSAL ADAPTER / INVERTEC - CONNECTION DIAGRAM
WARNING

ELECTRIC
CAN KILL
N.C.
81
NOT USED ON INVERTEC
82
N.D.
ELECTRODE CABLE SPARE
24 VAC / 1 AMP
2
CONNECT TOGETHER FOR
TO 4
WELDING OUTPUT
WORK 14 PIN 41
42 VAC / 5.5 AMP
AMPHENOL 42
- 31
115 VAC / 2 AMP

32
GND INVERTEC FRAME CONNECTION
21 WIRE FEEDER VOLTMETER CONNECTION
+ CONNECTS TO (WORK TERMINAL) OF INVERTEC
77 10K
K867 UNIVERSAL
INVERTEC 76 REMOTE OUTPUT CONTROL
ADAPTER PLUG
POWER SOURCE 75 MIN.
WITH 115VAC
AUXILIARY POWER
N.D.FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION
RELAY TO CLOSE LEADS 2 & 4. 2
TO TO
K867 WIRE FEEDER
4
R A
S19406
INVERTEC V300-I
ACCESSORIES C-9
CONNECTING INVERTEC
REMOTE CONTROLS
Remote control K857, hand Amptrol K812,
and foot Amptrol K870 require K864 remote
control adapter. See connection diagram
S19309.
K864 & K876 REMOTE CONTROL ADAPTERS

S19309
TURN THE POWER SWITCH OF THE WELDING POWER

SOURCE "OFF" BEFORE INSTALLING PLUGS ON CABLES
OR WHEN CONNECTING OR DISCONNECTING PLUGS TO
WELDING POWER SOURCE.

TO POWER SOURCE
TO: 1) K857 REMOTE CONTROL
2) K812 HAND AMPTROL
K864 3) K870 FOOT AMPTROL


TO POWER SOURCE

K876
R 1-25-91
S19309
INVERTEC V300-I
C-10 NOTES
CONNECTING K799 HI-FREQ 4. Connect work lead to other Invertec out-
KIT put terminal.
1. Turn Invertec power switch OFF. 5. Set polarity switch on rear of Invertec to
coincide with TIG polarity used.
2. Use a K867 universal adapter to wire in
a 115V receptacle for the K799 plug on 6. Set local/remote switch appropriately for
leads 31, 32, and GND. Connect lead 21 control at the machine or using the
to 225 from the K799. remote Amptrol.
NOTE: For remote control, accessories 7. Set mode switch to GTAW.

K867, K775, K843, and K812 or K870 are
required. In this configuration, K775 remote 8. Energize output terminals utilizing output
control sets the upper current limit of K812 terminals switch on front panel.
hand Amptrol or K870 foot Amptrol. See
connection diagram S19432.

3. Connect an electrode cable from the

K799 to Invertec output terminal for
polarity preferred.

ACCESSORIES C-11
CONNECTING A K900-1 DC the Invertec by attaching to the 14-pin

TIG STARTER amphenols on the backs of each unit. Refer

to S20405 connection diagram. A negative
1. To secure the DC TIG starter kit to the output cable assembly is also supplied with
bottom of the Invertec and for more the DC TIG starter kit to connect the kit with
detailed instructions, refer to K900-1 the Invertec’s negative output terminal.
manual.
All Magnum one- and two-piece water-
NOTE: This versatile kit was made to mate cooled torches with 7/8" left-hand threads
with the Invertec. A control cable assembly and gas-cooled torches with 7/8" and 5/16"
is supplied with the kit to connect the kit to right-hand threads can be connected to the
an Inverted. The cable can be connected, starter kit.
either end, at the DC TIG starter kit and at
K900-1 DC TIG STARTER - CONNECTION DIAGRAM S20405
WARNING
Turn off input power to the Welding Power Source using the
disconnect switch at the fuse box before connecting the DC Tig
Starter to the power source, or the Amptrol or Wire Feeder
to the DC Tig Starter.
ELECTRIC
Only qualified persons should install, use or service this machine.
SHOCK
CAN KILL
WIRE FEEDER CONSULT INVERTEC INSTRUCTION MANUAL FOR

APPROPRIATE WIRE FEEDERS AMD CONNECTORS.
N.B.
BOTTOM 14 PIN
K812
AMPHENOL HAND AMPTROL
K900-1
OR
DC TIG STARTER
TO TIG K870
TOP 14 PIN OUT FOOT AMPTROL
AMPHENOL TORCH
OR
IN
K814
ARC START SWITCH
INVERTEC - N.C.
POWER SOURCE
WITH 5.5 AMP 42 VOLT
AUXILIARY POWER TO
+ WORK
N.B. A WIRE FEEDER CAN BE PLUGGED INTO THE DC TIG STARTER TO REDUCE PROCESS CONVERSION TIME.
N.C. SET UP SHOWN IS FOR DC NEGATIVE TIG WELDING. DC POSITIVE WELDING IS OBTAINED BY REVERSING
THE OUTPUT CONNECTIONS ON THE INVERTEC AND SETTING THE INVERTEC'S ELECTRODE POLARITY
SWITCH TO POSITIVE.
12-17-92
S20405
INVERTEC V300-I
C-12 ACCESSORIES
CONNECTING TWO V300-I’S
FOR PARALLEL OPERATING

NOTE: The Invertecs can be operated in
parallel in both constant current (CC) and
constant voltage (CV) modes. For best
results, currents of each machine should be
reasonably well shared. As an example,
with two machines set up in parallel for a
400-amp procedure, each machine should
be set to deliver approximately 200 amps,
not 300 amps from one and 100 amps from
the other. This will minimize nuisance feed-
back conditions. In general, more than two
machines in parallel will not be effective due
to voltage requirements of procedures in

that power range.
1. Set machine outputs by starting with out-

put control knob and arc force/pinch con-
trol knob and arc force/pinch control
knob in identical positions. If running in a
CC mode, adjust outputs and arc forces
to maintain current sharing while estab-
lishing proper output current. In CV
modes, output voltage should be set
while keeping both output control knobs
in identical positions. Then switch
machine meters to amps and adjust one
of the output control knobs for current
balance. Check the voltage, and if read-
justment is necessary, repeat the current

balancing step. Pinch settings should
also be kept identical on machines.
INVERTEC V300-I
TABLE OF CONTENTS Section D
- MAINTENANCE SECTION -
Maintenance .....................................................................................................Section D
Input Filter Capacitor Discharge Procedure .........................................................D-1
Preventive Maintenance ......................................................................................D-2
WARNING
• Prior to performing preventative

maintenance, perform the follow-
ing capacitor discharge procedure
to avoid electric shock.
• Only qualified personnel should

perform this maintenance.
• Turn the input power OFF at the

disconnect switch or fuse box

before working on this
equipment.
• Do not touch electrically hot

parts.
INVERTEC V300-I
D-1 MAINTENANCE
4. SHORTING STRAP FOR THIS PROCE-
WARNING DURE.
Failure to follow this
capacitor discharge proce- 5. Locate the two capacitor terminals (large
dure can result in electric hex head cap screws) shown in Figure
shock. D.1.
6. Use electrically insulated gloves and

INPUT FILTER CAPACITOR insulated pliers. Hold body of the resistor
DISCHARGE PROCEDURE and connect resistor leads across the
two capacitor terminals. Hold resistor in
1. Turn off input power or disconnect input place for 10 seconds. DO NOT TOUCH
power lines. CAPACITOR TERMINALS WITH YOUR
BARE HANDS.
2. Remove 14 5/16” hex head screws from
7. Repeat discharge procedure for capaci-
side and top of machine (6 screws on

each side and 2 screws on top) and tor on other side of machine. If you are
remove wrap-around machine cover. working on a 575 VAC machine, repeat
discharge procedure for second capaci-
3. Be careful not to make contact with the tor on each side of machine.
capacitor terminals that are located in
the center of the Switch Boards. 8. Check voltage across terminals of all
capacitors with a DC voltmeter. Polarity
4. Obtain a high resistance and high of capacitor terminals is marked on PC
wattage resistor (25-1000 ohms and 25 board above terminals. Voltage should
watts minimum). This resistor is not sup- be zero. If any voltage remains, repeat
plied with machine. NEVER USE A this capacitor discharge procedure.
FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS.

INVERTEC V300-I
MAINTENANCE D-2
PREVENTIVE MAINTENANCE • Input Filter Capacitors
1. Perform the following preventive mainte- • Output Terminalss

nance procedures at least once every six
months. It is good practice to keep a pre- 4. Examine capacitors for leakage or ooz-
ventive maintenance record; a record tag ing. Replace if needed.
attached to the machine works best.
5. Examine wrap-around cover for dents or
2. Remove the machine wrap-around cover breakage. Repair as needed. Cover
and perform the input filter capacitor dis- must be kept in good condition to assure
charge procedure (detail at the beginning high voltage parts are protected and cor-
of this chapter). rect spacings are maintained.
3. Clean the inside of the machine with a 6. Check electrical ground continuity. Using
low pressure airstream. Be sure to clean an ohmmeter, measure resistance
the following components thoroughly. between either output stud and an

See Figure D.2 for location of these com- unpainted surface of the machine case.
ponents. (See Figure D.2 for locations.) Meter
reading should be 500,000 ohms or
• Power Switch, Driver, Protection, and more. If meter reading is less than
Control printed circuit boards 500,000 ohms, check for electrical com-
ponents that are not properly insulated
• Power Switch from the case. Correct insulation if need-
ed.
• Main Transformer
7. Replace machine cover and screws.
• Input Rectifier
• Heat Sink Fins

INVERTEC V300-I
D-3 MAINTENANCE
FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS.
3
2 4
5
1
11
10
7
ITEM 8
COMPONENT QTY, NO.
PC BOARDS
CONTROL 1 1 9
DRIVER 1 2
PROTECTION 1 3
SWITCH 2 7
POWER 1 10
INPUT RECTIFIER 1 4
POWER SWITCH 1 5
HEAT SINK FINS 2 6
MAIN TRANSFORMER 1 8
OUTPUT STUDS 1 9
INPUT FILTER CAPACITORS 2 11
INVERTEC V300-I
TABLE OF CONTENTS Section E
- THEORY OF OPERATION SECTION -
Theory of Operation Section ...........................................................................Section E

Power Supply Operation ......................................................................................E-1
Field Effect Transistor (FET) Operation ...............................................................E-5
Pulse Width Modulation .......................................................................................E-6
Protective Circuits ................................................................................................E-7
INVERTEC V300-I
E-1 THEORY OF OPERATION
POWER SUPPLY OPERATION
FIGURE E.1 — INPUT POWER CIRCUITS.

POWER SWITCH
SECTIONS MAIN
20KHZ CHOKE RECTIFIER
TRANSFORMER HEATSINK
LEFT SWITCH BOARD
FET MODULES
TOP
CAP
1 DIODE
FET MODULES
CURRENT
1ø OR 3ø DETETCTION (H5)
TRANSFORMER
PRE-CHARGE
LINE INPUT DRIVER

SWITCH RECTIFIER BOARD 5 DIODES
CONTROL
CR1 BOARD
1 AC1 PROTECTION
2 AC2 PULSE
BOARD Y-Y FEEDBACK BOTTOM
3 AC3 TRAIN
3A CR2
A-LEAD
24VDC
PRE-CHARGE
AUXILIARY RIGHT SWITCH BOARD

FAN
TRANSFORMER 2ND STEP PWM 5 DIODES
18VAC FET MODULES
POWERBOARD CAP
24VAC
TOP
FET MODULES
<1 VDC
1 DIODE
TO CHOKE CHOKE
WIREFEEDER
LOCAL
METER MODE POT POT VOLTAGE FEEDBACK
REMOTE
1ST STEP PWM VOLTAGE CURRENT FEEDBACK-PROTECTION

SHUNT
15VDC-CONTROL BOARD FUNCTION VOLTAGE
24VAC-THERMOSTATS-GUN TRIGGERING
INPUT LINE VOLTAGE iary transformer for the appropriate input

voltage.
The single-phase or three-phase input
power of 200, 220, 380, 415, or 440 volts The auxiliary transformer develops the
AC is connected through a line switch on appropriate AC voltages to operate the
the rear panel. Cooling Fan, the PC boards, and a wire
feeder (if connected). See Figure E.1.
A reconnect panel allows the user to switch
to low or high voltage and connect the auxil-
NOTE: Unshaded areas of block logic diagram are the subject of discussion.
INVERTEC V300-I
THEORY OF OPERATION E-2
FIGURE E.2 — PRECHARGE CIRCUITS.

POWER SWITCH
SECTIONS MAIN
LEFT SWITCH BOARD
FET MODULES
TOP
CAP
1 DIODE
FET MODULES
CURRENT
TRANSFORMER
PRE-CHARGE
LINE INPUT DRIVER

CONTROL
CR1 BOARD
1 AC1 PROTECTION
2 AC2 PULSE
3 AC3 TRAIN
3A CR2
A-LEAD
24VDC
PRE-CHARGE

FAN
18VAC FET MODULES
POWERBOARD CAP
24VAC
TOP
FET MODULES
<1 VDC
1 DIODE
TO CHOKE CHOKE
WIREFEEDER
LOCAL
REMOTE

SHUNT
PRECHARGE SWITCH BOARD

The input line voltage is rectified and the When the filter capacitors are fully charged,
DC voltage applied to the Driver Board. they act as power supplies for the Switch
The Driver Board contains precharging cir- Boards. The Switch Boards contain the
cuitry for the safe charging of the input filter Field Effect Transistors (FETs) which, when
capacitors. Once the capacitors are switched on, supply the main transformer
precharged, the input relays are energized, primary windings with DC current flow. See
connecting full input power to the input filter FET operation discussion and diagrams
capacitors. The Protection Board monitors Figures E.5 and E-6.
the capacitors for voltage balance and/or
overvoltage and will de-energize the input
relays and precharge circuitry if either
occurs. The machine output will also be
disabled. See Figure E.-2.
INVERTEC V300-I
FIGURE E.3 — SWITCH BOARD CIRCUITS.
POWER SWITCH
SECTIONS MAIN
LEFT SWITCH BOARD
FET MODULES
TOP
CAP
1 DIODE
FET MODULES
CURRENT
TRANSFORMER
PRE-CHARGE
LINE INPUT DRIVER

CONTROL
CR1 BOARD
1 AC1 PROTECTION
2 AC2 PULSE
3 AC3 TRAIN
3A CR2
A-LEAD
24VDC
PRE-CHARGE

FAN
18VAC FET MODULES
POWERBOARD CAP
24VAC
TOP
FET MODULES
<1 VDC
1 DIODE
TO CHOKE CHOKE
WIREFEEDER
LOCAL
REMOTE

SHUNT
MAIN TRANSFORMER each respective power capacitor when the

FETs are turned off. This is needed due to

Each Switch Board assembly works as a the inductance of the transformer primary
switch pair. Each board feeds a separate, windings. The cross coupling of the pri-
oppositely wound primary winding of the maries along with the clamping action of the
main transformer. The opposite directions diode serve to maintain capacitor balance
of current flow through the main transformer when connected in the series (higher volt-
primary and the offset timing of the Switch age) input configuration.
Boards induce an AC square wave output
signal at the secondary of the main trans- The firing of both Switch Board pairs occurs
former. during halves of the 50 microsecond inter-
vals, creating a constant 20 KHZ output.
The DC current flow through each primary
winding is redirected or “clamped” back to
INVERTEC V300-I
FIGURE E.4— OUTPUT CIRCUITS.

POWER SWITCH
SECTIONS MAIN
LEFT SWITCH BOARD
FET MODULES
TOP
CAP
1 DIODE
FET MODULES
CURRENT
TRANSFORMER
PRE-CHARGE
LINE INPUT DRIVER

CONTROL
CR1 BOARD
1 AC1 PROTECTION
2 AC2 PULSE
3 AC3 TRAIN
3A CR2
A-LEAD
24VDC
PRE-CHARGE

FAN
FET MODULES
18VAC
POWERBOARD CAP
24VAC
TOP
FET MODULES
<1 VDC
1 DIODE
TO CHOKE CHOKE
WIREFEEDER
LOCAL
REMOTE

SHUNT
OUTPUT RECTIFICATION AND GENERAL DESIGN

WELDING CONTROL CONSIDERATIONS
The AC output from the main transformer FET semiconductors are well suited for
secondary is rectified to a DC output. operating at high frequencies. This is the
Output voltage and current (feedback) sig- primary reason that Lincoln’s Invertec
nals are taken at the output terminals and design uses FETs instead of Silicone
fed to the Control Board. The Control Board Controlled Rectifiers (SCRs) or bipolar tran-
also monitors the panel controls to deter- sistors for power switching. This high-fre-
mine which weld process is being employed quency switching is not detectable to the
and how the output should be controlled to human ear. Annoying switching sounds that
optimize welding results. The Control Board are typical to lower frequency inverter
controls the FET switching through pulse power supplies are not present in the
width modulation circuitry. See FET discus- Lincoln high frequency inverter design.
sions Figures E.5 and E.6. Unlike conventional transformers, this
design is small, lightweight, and capable of
Excessive output current, the thermal pro- operating at high frequencies without over-
tection signal, and the overvoltage signal heating. Future designs will also use newer
are monitored by the Control Board for the high-speed IGBTs in place of FETs.
trigger disable function.
INVERTEC V300-I
FIELD EFFECT TRANSISTOR (FET) OPERATION
FIGURE E.5 — FIELD EFFECT TRANSISTOR OPERATION.

GATE
SOURCE TERMINAL DRAIN
TERMINAL (0 VOLTS) TERMINAL
SOURCE (N) DRAIN (N)
SUBSTRATE (P) N CHANNEL

A. PASSIVE
GATE
TERMINAL
(+ 6 VOLTS)
SOURCE (N) DRAIN (N)
ELECTRONS
B. ACTIVE
An FET is a type of transistor. FETs are Drawing B above shows the FET in an
semiconductors well suited for high-fre- active mode. When the gate signal, a posi-
quency switching. tive DC voltage relative to the source, is
applied to the gate terminal of the FET, it is
Drawing A above shows an FET in a pas- capable of conducting current. A voltage
sive mode. There is no gate signal, zero supply connected to the drain terminal will
volts relative to the source and, therefore, allow the FET to conduct and henceforth
no current flow. The drain terminal of the supply current to downstream components.
FET may be connected to a voltage supply; Current will flow through the conducting
but since there is no conduction, the circuit FET to downstream components as long as
will not supply current to downstream com- the gate signal is present. This is similar to
ponents connected to the source. The cir- turning on a light switch.
cuit is turned off like a light switch in the
OFF position.
11 / 94
INVERTEC V300-I
PULSE WIDTH MODULATION

FIGURE E.6 — TYPICAL FET OUTPUTS.
sec 48 sec sec

50 sec
MINIMUM OUTPUT
24 sec
2 sec 24 sec
50 sec
MAXIMUM OUTPUT
The term PULSE WIDTH MODULATION is ond. The negative portion is the other FET
used to describe how much time is devoted group 1 . The dwell time (off time) is 48
to conduction in the positive and negative microseconds (both FET groups off). Since
portions of the cycle. Changing the pulse only 2 microseconds of the 50-microsecond
width is known as MODULATION. Pulse time period is devoted to conducting, the
Width Modulation (PWM) is the varying of output power is minimized.
the pulse width over the allowed range of a
cycle to affect the output of the machine. MAXIMUM OUTPUT
MINIMUM OUTPUT By holding the gate signals on for 24

By controlling the duration of the gate sig- microseconds each and allowing only 2
nal, the FET is turned on and off for differ- microseconds of dwell time (off time) during
ent durations during a cycle. The top draw- the 50-microsecond cycle, the output is
ing above shows the minimum output signal maximized. The darkened area under the
possible over a 50-microsecond time peri- top curve can be compared to the area
od. under the bottom curve. The more dark
area under the curve, the more power is
The positive portion of the signal represents present.
one FET group1 conducting for 1 microsec-
1 A FET group consists of the sets of FET modules

grouped onto one switch board.
INVERTEC V300-I
PROTECTIVE CIRCUITS THERMAL PROTECTION
Protective circuits are designed into the Thermostats protect the machine from
Invertec machine to sense trouble and shut excessive operating temperatures.
down the machine before the trouble dam- Excessive temperatures may be caused by
ages the internal machine components. a lack of cooling air or operating the
Both overload and thermal protection cir- machine beyond the duty cycle and output
cuits are included. rating. If excessive operating temperature
should occur, the thermostat will prevent
output voltage or current. The meter will
OVERLOAD PROTECTION remain on during this time.
The machine is electrically protected from Thermostats are self-resetting once the
producing high output currents. Should the machine cools sufficiently. If the thermostat
output current exceed 340 to 360 amps, an shutdown was caused by excessive output
electronic protection circuit will reduce the or duty cycle and the fan is operating nor-
current to approximately 150 amps. Lincoln mally, the Power Switch may be left on and
Electric refers to this current reduction as the reset should occur within a 15-minute
“Fold Back.” The machine will continue to period. If the fan is not turning or the air
produce this low current until the protection intake louvers were obstructed, then the
circuit is reset. Reset occurs when the out- power must be switched off for 15 minutes
put load is removed. in order to reset. The fan problem or air
obstruction must also be corrected.
A protection circuit is included to monitor
the voltage across input filter capacitors. In
the event that the capacitor voltage is too
high, the protection circuit will prevent out-
put. The protection circuit may prevent out-
put, if any of these circumstances occur:
1. Capacitor conditioning is required

(Required if machine has been off for

prolonged periods of time.)
2. Line surges over 500 VAC
3. Internal Component damage
4. Improper connections
INVERTEC V300-I
TABLE OF CONTENTS Section F
- TROUBLESHOOTING & REPAIR SECTION -
Troubleshooting & Repair Section .................................................................Section F

How To Use Troubleshooting Guide.....................................................................F-1
PC Board Troubleshooting Procedures ................................................................F-2
Matched Parts.......................................................................................................F-2
Troubleshooting Guide .........................................................................................F-3
Test Procedures
Output Pilot Circuit Test ...............................................................................F-8
Protection PC Board Output Test...............................................................F-11
Static Capacitor Balance Test....................................................................F-15
Dynamic Capacitor Balance Test...............................................................F-18
Switch PC Board Test ................................................................................F-20
Snubber Resistors Test..............................................................................F-24
Output Diodes Test ....................................................................................F-26

Input Rectifier Test .....................................................................................F-28
Overcurrent Protection Current Trigger Circuit Test ..................................F-30
Overvoltage Protection DC Trigger Circuit Test.........................................F-35
Thermal Protection AC Trigger Circuit Test ...............................................F-41
Control Board Test .....................................................................................F-46
Power Board Test ......................................................................................F-47
Capacitor Replacement ......................................................................................F-50
Switch PC Board Replacement ..........................................................................F-54
Test After Repair of Switch Boards and/or Capacitors .......................................F-56
Output Diode Replacement ................................................................................F-58
Input Filter Capacitor Conditioning .....................................................................F-59
Environmental Protection....................................................................................F-59
Retest After Repair .............................................................................................F-60
WARNING
Never work on the inside of the machine without turning off the input power and discharging the
input capacitors. You can receive a life-threatening electrical shock if you fail to do this. Only qual-
ified technicians should perform installation, maintenance, and troubleshooting work on the
machine.
__________________________________________________________________________
INVERTEC V300-I
F-1 TROUBLESHOOTING & REPAIR
How to Use Troubleshooting Guide

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to Step 3. PERFORM COMPONENT TESTS.
help you locate and repair possible machine The last column labeled “Recommended
malfunctions. Simply follow the three-step Course of Action” lists the most likely com-
procedure listed below. ponents that may have failed in your
machine. It also specifies the appropriate
Step 1. LOCATE PROBLEM (SYMPTOM). test procedure to verify that the subject
Look under the column labeled “PROBLEM component is either good or bad. If there
(SYMPTOMS)”. This column describes are a number of possible components,
possible symptoms that the machine may check the components in the order listed to
exhibit. Find the listing that best describes eliminate one possibility at a time until you
the symptom that the machine is exhibiting. locate the cause of your problem.
Symptoms are grouped according to: output
problems and welding problems. All the needed test specifications and repair
procedures are described in detail on the
Step 2. PERFORM EXTERNAL TESTS. referenced pages. All the needed electrical
The second column labeled “POSSIBLE test points, terminal strips, junctions, etc.,
AREAS OF MISADJUSTMENT(S)” lists the can be found on the referenced electrical
obvious external possibilities that may con- wiring diagrams and schematics. See
tribute to the machine symptom. Perform Electrical Diagram.
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed call 216-383-2531 or 1-800-833-9353.
OSCILLOSCOPE WARNING
WARNING
Do not use oscilloscopes and other test equipment which are powered by 115 VAC.
This equipment should not be used with inverter-type machines, such as Invertec
V300-I. There are high voltages present, which are “floating” off case ground (floating
ground). Connecting the ground lead of a test probe (which may be connected to the
case of the test equipment) to a high voltage potential presents a shock hazard as well
as the possibility of damage to the equipment in question.
_____________________________________________________________________
INVERTEC V300-I
TROUBLESHOOTING & REPAIR F-2
PC BOARD TROUBLESHOOTING PROCEDURES

4. Test the machine to determine if the fail-

WARNING ure symptom has been corrected by the
ELECTRIC SHOCK can replacement PC board.
kill.
Have an electrician install and ser- NOTE: Allow the machine to heat up so
vice this equipment. Turn the input that all electrical components can reach
power OFF at the fuse box before
working on equipment. Do not their operating temperature.
touch electrically hot parts.
5. Remove the replacement PC board and
CAUTION: Sometimes machine failures substitute it with the original PC board to
appear to be due to PC board failures. recreate the original problem.
These problems can sometimes be traced
to poor electrical connections. To avoid a. If the original problem does not reap-
problems when troubleshooting and replac- pear by substituting the original board,
ing PC boards, please use the following then the PC board was not the prob-
procedure: lem. Continue to look for bad connec-
tions in the control wiring harness,
1. Determine to the best of your technical junction blocks, and terminal strips.
ability that the PC board is the most like-
ly component causing the failure symp- b. If the original problem is recreated by
tom. the substitution of the original board,
then the PC board was the problem.
2. Check for loose connections at the PC Reinstall the replacement PC board
board to assure that the PC board is and test the machine.
properly connected.
6. Always indicate that this procedure was
3. If the problem persists, replace the sus- followed when warranty reports are to be
pect PC board using standard practices submitted.
to avoid static electrical damage and
electrical shock. (Read the warning NOTE: Following this procedure and writ-
inside the static resistant bag.) ing on the warranty report, “INSTALLED
AND SWITCHED PC BOARDS TO VERIFY
NOTE: It is desirable to have a spare PROBLEM,” will help avoid denial of legiti-
(known good) PC board available for PC mate PC board warranty claims.
board troubleshooting.
MATCHED PARTS
The following machine parts must be • Capacitor Bleeder Resistors: R1 and R9.
replaced in matched sets If, for example,
Capacitor C1 is found to be defective, both • Capacitors: C1 and C2.
Capacitors C1 and C2 must be replaced at

the same time: • Capacitors: C1, C2, C14, and C15
(575 VAC models only).
• Output Diodes: D1, D2, D3, D4, and D5.
• Output Diodes: D7, D8, D9, D10, and

D11.
INVERTEC V300-I
Troubleshooting Guide — See Wiring Diagrams for location of specified Observe Safety Guidelines
components. See Schematic Diagram for troubleshooting of specific circuits. detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF POSSIBLE AREAS OF

(SYMPTOMS) MISADJUSTMENT(S) MALFUNCTION(S)
OUTPUT PROBLEMS
Major physical or electrical damage Contact Lincoln Electric Service
is observed when cover wrap- Department (216-383-2531) or
around is removed. 1-800-833-9353 (WELD)
Machine is dead — no output — Power Switch must in ON position. 1. Power Switch (S1).
no fan — no display.
Check input voltage. 2. Loose or broken wires between
Power Switch and Input
If machine is set for single-phase Rectifier (component D13).
operation, inspect to assure that
WHITE and BLACK leads are 3. Broken leads to primary of

connected properly and RED lead Auxiliary Transformer T1.
is not connected and is insulated.
4. Open primary coil of Auxiliary
Check that input voltage set-up Transformer T1.
switch and jumper A (the recon-
nect, auxiliary jumper) are in proper
position for input voltage being
used.
Check continuity of 3-amp slow

blow fuse located on reconnect
panel.
No output but fan operates and the Output Terminal Switch or Remote 1. See Output Pilot Circuit test.
meter display is on. Trigger MUST be in ON position.
2. See Thermal Protection AC

Local/Remote Switch must be in Trigger Circuit test.
LOCAL position unless remote
control device is attached to remote 3. See Overvoltage Protection DC
receptacle. Trigger Circuit test.
If machine has not been used for a 4. See Static Capacitor Balance/
long time and is connected for Dynamic Capacitor Balance
380 VAC or higher, Capacitors may tests.
need “conditioning.” See Input Filter
Capacitor Conditioning section. 5. See Switch PC Board test.
6. Broken or loose connections on

high current-carrying parts of
machine (i.e., choke, output
bridges, output studes, main
transformer.
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 216-383-2531 or 1-800-833-9353.
INVERTEC V300-I

OUTPUT PROBLEMS (continued)
No output or reduced output the Check input voltages, fuses, and Check continuity of 3-amp slow
first time power is applied to input voltage reconnect proce- blow fuse located on reconnect
machine. dures. See Installation section. panel.
If high input (380 VAC or higher)

voltage is applied. Capacitors may
need conditioning.
Output turns on momentarily, then Check input voltages and recon- 1. See Thermal Protection AC
switches off and repeats cycle. nection procedures. See Instal- Trigger Circuit test.
lation section.
2. See Overvoltage Protection DC
Check output terminal switch S4 Trigger Circuit test.
and/or Remote Trigger Options
(i.e., wire feeders, guns, cables, 3. See Static Capacitor
etc.). Balance/Dynamic Capacitor
Balance test. NOTE: This test
is necessary only if machine is
connected for 380 VAC or high-
er.
4. See Switch PC Board test.
5. See Snubber Resistor test.
Remote output control not function- Test or replace Output Remote 1. Test Local/Remote Switch S3
ing. Machine performs well on Control Device. with ohmmeter. See schematic
LOCAL control. drawing in Electrical Diagram
Section.
2. Check continuity of
local/remote circuit. See
schematic drawing in Electrical
Diagram Section.
CAUTION
INVERTEC V300-I

No ouput. Main fuses open, indicat- Inspect input leads for possible Inspect interior of machine for
ing excessive current draw. shorts or grounds or misconnec- physical signs of electrical and heat
tions. damage. Replace any damaged
components after conducting the
Install new fuses and reapply tests below:
power. If fuses open again, go to
next column of this Guide. 1. Input Rectifier (component
D13). Perform Input Rectifier
test.
2. See Switch Board test.
3. See Static Capacitor

Balance/Dynamic Capacitor
Balance tests.
Machine does not produce more Check input voltages, fuses, and 1. See Protection Board Output.
than 250 amps on meter (while input voltage reconnect proce- Voltage test.
welding) when connected to dures. See Installation section of
3-phase supply. this manual.. 2. See Control Board test.
3. See Input Rectifier test (com-

ponent D13).
Machine does not produce more Normal operation. No test necessary. This single-
than 250 amps on meter (while phase operation is determined by
welding) while connected to single- Nothing is wrong. the Protection Board.
phase supply.
Machine operates okay at 230 VAC Check input voltage and input volt- 1. See Protection Board Output
or lower. No output at 380 VAC or age reconnect procedures. See test.
higher. Installation section of this manual.
2. See Static Capacitor
Balance/Dynamic Capacitor
Balance tests.
4. See Switch PC Board test.

CAUTION
INVERTEC V300-I

Meter reads low voltage (1-2 VDC), Local/Remote Switch must be in 1. See Output Diodes test.
and output is extremely low or no LOCAL position unless Remote
output. Control device is attached to 2. See Static Capacitor
remote receptacle. Balance/Dynamic Capacitor
Balance tests.
3. See Switch Board test.
4. See Power Board test.

5. See Control Board test.

CAUTION
INVERTEC V300-I
Troubleshooting Guide Observe Safety Guidelines
— See Wiring Diagrams for location of specified


WELDING PERFORMANCE PROBLEMS
Poor welding, weld settings drift, or Check welding procedures and 1. Check Mode Switch S2 for
output power is low. weld cable connections. damage and continuity.
Check with machine on local con- 2. Check for continuity between

trol. Mode Switch S2 and Control
Board. See schematic drawing.
Check input voltages and input volt-
age reconnect procedures. See 3. Check for loose or faulty con-
Installation section of this manual. nections in heavy current-carry-
ing leads (i.e., choke, shunt,
output bridge, and output

studs). See wiring diagram.
4. Check overcurrent protection

on Control Board. Refer to
Overcurrent Protection Current
Trigger Circuit tests. Also refer
to Control Board test.
Poor stick electrode performance. Check output welding cables. 1. Check for loose or burned con-
Arc pops out. nections at choke, shunt, and
Is electrode DRY? Try welding with output studs. See wiring dia-
another electrode from a different gram.
container.
2. Test and inspect D6, D12, L1
Make sure you have the correct and L2. See schematic draw-
electrode for your application. ing.
Machine makes “squealing” noise Check input lines and connections. 1. See Switch Board test.
while under load when welding.
Output power is low (less than 20 Check input voltage and reconnec- 2. See Snubber Resistor test.
VDC on meter @ 100 amps). Input tion procedures.
voltage 230 VAC or lower.
CAUTION
INVERTEC V300-I
OUTPUT PILOT CIRCUIT TEST

WARNING
Observe all safety precautions detailed
throughout this manual.
– Perform input filter capacitor discharge

procedure
TEST DESCRIPTION TEST PROCEDURE
The Output Pilot Circuit Test determines if 1. Turn main power OFF.
the Fan Thermostat, Choke Thermostat,
Transformer T1, and Output Terminal 2. Perform Input Filter Capacitor
Switch S4 are functioning properly. Discharge procedure detailed in

Maintenance chapter.
MATERIALS NEEDED 3. Remove the four screws that attach the

Control Panel to the frame.
• Analog voltmeter/ohmmeter (multimeter)
• V300-I wiring diagrams in Electrical

Diagrams section of this manual.
FIGURE F.1 — REMOVING CONTROL PANEL.

INVERTEC V300-I
OUTPUT PILOT CIRCUIT TEST (continued)
210 223A
J5 G2527 CONTROL J1 J2 J4 J3
FIGURE F.2 — CONTROL BOARD TEST POINTS.
4. Position the Control Panel so you have 7. Test for 24 VAC between leads 223A
access to the Control Board by pulling and 210.
the Control Panel away from the
machine and moving it to the left. a. If 24 VAC is measured, test is OK for

Carefully let the Control Panel hang from Fan Thermostat, Choke Thermostat,
the machine. Transformer T1, and Output Terminal
Switch S4. Go to step 8.
5. Move Terminal Output Switch S4 to the
ON position. b. If 0 VAC is measured, test is not OK.
Test each of the following compo-
6. Turn the main power ON. nents: Fan Thermostat, Choke
Thermostat, Transformer T1, and
Output Terminal Switch S4.

OUTPUT PILOT CIRCUIT TEST (continued)

302
275D
8. Test for 15 VDC between leads 302 (+)

and 275D (–).
a. If 15 VDC is measured, test is OK for

15 VDC Power Supply and Trans-
former T1. Go to Protection Board
Output Test.
b. If 0 VDC is measured, test is not OK.

Test Power Board and Transformer
T1.
INVERTEC V300-I
PROTECTION BOARD OUTPUT TEST
WARNING
– Perform input filter capaciter discharge

procedure.
TEST PROCEDURE 4. Slide the through bolts toward the

Control Panel until the brackets are dis-
1. Turn main power OFF. connected and resistors are loose. Be
careful when loosening these through
2. Perform Input Filter Capacitor bolts, as they secure the two resistors.
As the through bolts are removed, care-

Discharge procedure detailed in

Maintenance section. fully place the resistors and the connect-
ed wires to the side.
3. Remove the two through bolts that attach
the Power/Drive Board bracket to
Protection/Input Rectifier bracket. Each
through bolt also supports a resistor.
FIGURE F.4 — REMOVING THROUGH BOLTS.

INVERTEC V300-I
PROTECTION BOARD OUTPUT TEST (continued)

FIGURE F.5 — REMOVING BRACKET SCREWS.

5. Remove the two screws attaching the

Protection Board/Input Rectifier bracket
to main assembly bracket.
6. Tilt the top of the Protection Board brack-

et toward the Power Panel to gain
access to test points on the Protection
Board.
INVERTEC V300-I
FIGURE F.6 — INSERTING PROBES.

7. With power OFF, disconnect J8 and 8. Turn main power ON.

attach voltage probes into back of wire
harness lead junction block (J8). See 9. Move Output Terminal Switch S4 to ON
Figure F.7. position on Control Panel.
Insert probes into back of the connec-

tion cavities for leads 313 (-) and 311
(+) of Protection Board. Make sure
contact is made with conductor materi-
al.
NOTE: Right-angle, thin-gauge probes

are best for this test.
With probes attached, plug the (J8)

block into the PC board.
INVERTEC V300-I

FIGURE F.7 — INSERTING PROBES.
L7915 PROTECTION
313
J8 J15
311
10. Test for less than 1 VDC between leads 11. Repeat steps 1 thru 8, but measure
313 (-) and 311 (+). voltage between leads 306 (+) and 275
(-). If voltage is less than 1 VDC,
a. If less than 1 VDC is measured, test Protection Board is OK. If voltage is
is OK and Protection Board is func- greater than 14 VDC, Protection Board
tioning properly. is faulty. See Figure F.28.
b. If more than 5 VDC is measured, go
to Static Capacitor Balance Test.
NOTE:. During voltage test, be cautious

to avoid positioning loose components

to avoid shorts and damage to equip-
ment.
INVERTEC V300-I
STATIC CAPACITOR BALANCE TEST
WARNING
NOTE: This test should only be conducted TEST PROCEDURE

when the machine reconnect switch and 1. Move Output Terminal Switch S4 to
jumper are set for high voltage (above 380 REMOTE (OFF) position.
VAC) and the proper line voltage is applied.
FIGURE F.8 — OUTPUT TERMINAL SWITCH IN OFF POSITION.
OUTPUT TERMINAL SWITCH S4

REMOTE (OFF)
LINCOLN
- +
INVERTEC V300-I
STATIC CAPACITOR BALANCE TEST (continued)

FIGURE F.9 — SWITCH BOARD TEST POINTS.
9 12
L8604-1 SWITCH
2. Test VDC across terminals 9 and 12 of

one Switch Board and repeat the test for
the other Switch Board. See Table F.1
in this procedure for expected voltage
readings.
NOTE: For 575 VAC only, compare volt-

age across 9A and 13 and 13 and 12A;
then 9B and 15 and 15 and 12B.
INVERTEC V300-I
STATIC CAPACITOR BALANCE TEST (continued)
3. Record VDC measured for each Switch Replace Protection Board and go to
Board and determine the difference in Dynamic Capacitor Balance Test.
VDC.
b. If more than 25 VDC difference is
NOTE: The following measurements measured between each Switch
should result based on VAC input. Board, test each of the following
components:
TABLE F.1 — EXPECTED VOLTAGE
READINGS. • Capacitors C1 and C2 and
Resistors R1 and R9.
VDC at terminals 9
and 12 should be • (575 VAC only machines —
If VAC Input is: approximately: Capacitors C1, C2, C14, and
575VAC 407 VDC C15; and Resistors R1 and R9.)
460 VAC 325 VDC

440 VAC 311 VDC
415 VAC 293 VDC
380 VAC 269 VDC
a. If less than 25 VDC difference is

measured between each Switch
Board, then capacitive balance is OK.
• This indicates that Capacitors C1

and C2, Resistors R1 and R9 are
functioning properly.
• (575 VAC only machines —

Capacitors C1, C2, C14, and

C15; Resistors R1 and R9.)
INVERTEC V300-I
DYNAMIC CAPACITOR BALANCE TEST

WARNING
NOTE: This test should only be conducted TEST PROCEDURE

when the machine reconnect switch and
jumper are set for high voltage (above 380 1. Move Output Terminal Switch S4 to ON
VAC) and the proper line voltage is applied. position.
Adjust the output control to the minimum

setting. Place the mode control at the
SMAW (soft) position.
FIGURE F.10 — OUTPUT TERMINAL SWITCH IN ON POSITION.
OUTPUT TERMINAL SWITCH S4

(ON) POSITION
LINCOLN
- +
INVERTEC V300-I
DYNAMIC CAPACITOR BALANCE TEST (continued)
9 12
L8604-1 SWITCH
2. Test VDC across terminals 9 and 12 of TABLE F.2 — EXPECTED VOLTAGE

one Switch Board and repeat the test for READINGS.

the other Switch Board.
VDC at terminals 9
and 12 should be
NOTE: For 575 VAC ONLY, compare
If VAC Input is: approximately:
voltage across 9A and 13 and 13 and
12A; then 9B and 15 and 15 and 12B. 575VAC 407 VDC
460 VAC 325 VDC
3. Record VDC measured for each Switch 440 VAC 311 VDC
Board and determine the difference in 415 VAC 293 VDC
VDC. (See Table F.2.) 380 VAC 269 VDC
NOTE: The following measurements a. If less than 15 VDC difference is

should result based on VAC input. measured between each Switch
Board, test is OK.
b. If more than 15 VDC difference is

measured between each Switch
Board, Power Board or Switch
Board is damaged. Test these PC
boards and replace if needed.
INVERTEC V300-I
SWITCH BOARD TEST

WARNING
– Perform input filter capaciter discharge

procedure.
LOCATION. There are two Switch Boards. the Capacitor(s), Main Transformer primary
One is located on each side of the machine. windings, Input Rectifier, and Reconnect
Switches.
FUNCTION. The Switch Boards are
designed to receive gate (turn-on) signals TEST DESCRIPTION. The Switch Board
from the Driver Board (pulse transformer Test determines if the switch boards are
secondaries). The internal board circuitry operating properly. This Resistance Test is
processes the signals and outputs them to preferable to a Voltage Test with the
the FETs. The switch board circuitry con- machine energized because these boards
tains snubber circuitry to protect the FETs. can be damaged easily. In addition, it is
This protection is supplemented by off- dangerous to work on these boards with
board resistors. The Switch Board design machine power ON.
accommodates the connection point(s) for
INVERTEC V300-I
SWITCH BOARD TEST (continued)
FIGURE F.12 — SWITCH BOARD RESISTANCE TEST.

TEST PROCEDURE 4. Using an ohmmeter, perform the

Resistance Tests detailed in Table F.3

1. Disconnect power to the machine and and shown in Figure F.12. If any test
discharge Capacitors as described on fails, replace both Switch Boards. See
Maintenance section. Switch Board replacement procedure.
2. Disconnect all wiring harness leads 5. If the Switch Boards appear to be burned
(401/403, 1/8, 9, 12, 4/5, 402/404) from or overheated, or if the machine was
the PC board. supplied by a 380 VAC or higher voltage
supply when the failure occurred, replace
3. Fold the leads up so they do not interfere the Capacitors and the Switch Boards.
with the exposed PC board terminals.
See Figure F.12.
INVERTEC V300-I

WARNING
TABLE F.3 — SWITCH BOARD RESISTANCE TEST.
Apply Positive Apply Negative

Test Prove to Test Probe to
Terminal Terminal Test Result Conclusion Repair Action Next Procedure Notes
1/8 12 Greater than OK None Continue
1K ohm
Less than Shorted Replace both Snubber Test
100 ohms Switch Boards
12 1/8 Less than OK None Continue

100 ohms
Greater than Open Replace both Snubber Test
1K ohm Switch Boards
9 4/5 Greater than OK None Continue

1K ohm
4/5 9 Less than OK None Continue

100 ohms


100 ohms

1K ohm

100 ohms

1K ohm
NOTE: K ohm = ohm reading multiplied by 1000.

NOTE: Always make shure that Switch Boards are changed in matched pairs. Never mix an old style (different part
number) Switch
INVERTEC V300-I
WARNING
TABLE F.3 — SWITCH BOARD RESISTANCE TEST.( continued)
Apply Positive Apply Negative

Test Prove to Test Probe to
Terminal Terminal Test Result Conclusion Repair Action Next Procedure Notes
1K ohm

100 ohms

100 ohms

1K ohm

NOTE: K ohm = ohm reading multiplied by 1000.

NOTE: Always make shure that Switch Boards are changed in matched pairs. Never mix an old style (different part
number) Switch

SNUBBER RESISTORS TEST

WARNING

procedure.
MATERIALS NEEDED TEST PROCEDURE
• Analog voltmeter/ohmmeter (multimeter) 1. Turn main power OFF.
• V300-I wiring diagrams. 2. Perform Input Filter Capacitor Discharge

procedure detailed in Maintenance sec-

tion.
3. Locate and gain access to the Switch

Board.
4. Remove leads from terminals 401, 402,

403, and 404 on Switch Board.
FIGURE F.13 — REMOVING LEADS.

INVERTEC V300-I
SNUBBER RESISTORS TEST (continued)
401 12
L8604-1 SWITCH
5. Test for 25 ohms resistance from lead c. If 20 ohms or less is measured,

401 to terminal 12 on Switch Board. Resistor R4 is faulty and must be
replaced.
a. If 25 ohms is measured, Resistor R4

is OK. 6. Repeat same procedures to test R5, R6,
and R7 per Table F.4.
b. If 30 ohms or more is measured,
Resistor R4 is faulty and must be
replaced.
TABLE F.4 — SNUBBER RESISTORS TEST.
Check Test Result Conclusion Next Test Step Repair Action

Lead 401 to 25 ohms OK Continue
Terminal 12 >30 ohms R4 open Replace R4
<20 ohms R4 faulty
<20 ohms R5 faulty

<20 ohms R6 faulty
<20 ohms R7 faulty
> = GREATER THAN < = LESS THAN
INVERTEC V300-I
OUTPUT DIODES TEST

WARNING

procedure.
TEST PROCEDURE
1. Perform Input Filter Capacitor Discharge 2. Locate the Output Terminals on front
procedure detailed in Maintenace sec- panel.
tion..
FIGURE F.15 — LOCATION OF OUTPUT STUDS.

LINCOLN
- +
OUTPUT
OUTPUTTERMINALS
STUDS
INVERTEC V300-I
OUTPUT DIODES TEST (continued)
FIGURE F.16 — TESTING OUTPUT DIODES.

LINCOLN
- +
- PROBE
+ PROBE
3. Remove any output load. a. If more than 200 ohms measured,

Output Diodes are OK.
4. Test for more than 200 ohms resistance
between positive and negative Output b. If less than 100 ohms measured, an
Terminals: positive test lead to positive Output Diode is shorted. Test all
terminal, negative test lead to negative Output Diodes (D-1 thru D-12) indi-
terminal. vidually.
NOTE: Polarity of test leads is impor-

tant.
INVERTEC V300-I
INPUT RECTIFIER TEST

WARNING

procedure.
MATERIALS NEEDED
• Analog voltmeter/ohmmeter (multimeter) 2. Locate Input Rectifier (Component D-

13).
• V300-I wiring diagrams
3. Locate leads needed to perform tests

shown in Figure F.17.
TEST PROCEDURE
4. Use ohmmeter to perform tests shown in
1. Perform Input Filter Capacitor Discharge Table F.5.
tion.
FIGURE F.17 — INPUT RECTIFIER LOCATION.

INVERTEC V300-I
INPUT RECTIFIER TESTS (continued)
TABLE F.5
INPUT RECTIFIER TEST
Test Points
Steps + Probe – Probe Acceptable Meter Reading
A 9 H1 Greater than 100K ohms
B 9 A Greater than 100K ohms
C 9 H5 Greater than 100K ohms
D H1 9 Less than 100 ohms
E A 9 Less than 100 ohms
F H5 9 Less than 100 ohms
G 12 H1 Greater than 100 ohms
H 12 A Greater than 100 ohms

I 12 H5 Greater than 100 ohms
J H1 12 Less than 100 ohms
K A 12 Less than 100 ohms
L H5 12 Less than 100 ohms
5. Replace Input Rectifier Component D13 7. Test Capacitors C1 and C2 and replace
when any of tests A-L are not OK. both Capacitors if either is faulty.
NOTE: When installing new Input NOTE: Faulty Capacitors could be the rea-
Rectifier, torque mounting nuts (in a son for Component D13 (Rectifier) failure.
cross tightening pattern) to 6 inch-
pounds (.7 Nm). Torque terminals to 26 Visually inspect Capacitors for leakage,
inch-pounds (3 Nm). ALWAYS GO TO damage, etc., and use appropriate test

STEP 6 TO CHECK RELATED COMPO- equipment to determine component integrity
NENTS. (also check/test Switch Boards for damage).
6. Inspect Main Power Switch S1 and

replace if faulty. Go to step 7.
INVERTEC V300-I
OVERCURRENT PROTECTION CURRENT TRIGGER CIRCUIT TEST

WARNING

procedure.
CIRCUIT DESCRIPTION
One of the functions of the Control Board is MATERIALS NEEDED

to limit the output loading to 370-400 amps
for three-phase operation (225-275 amps • Analog voltmeter/ohmmeter (multimeter)
for single-phase).
• V300-I wiring diagrams
The functioning circuit will reduce the output
amperage to approximately 200 amps in • NOTE: See Figure F.22 for Overcurrent
three-phase operation (100-190 amps sin- Protection Current Trigger Circuit.
gle-phase) when overcurrent loading is
detected.
INVERTEC V300-I
(continued)
FIGURE F.18 — GETTING ACCESS TO CONTROL BOARD.
TEST PROCEDURE
1. Perform Input Filter Capacitor Discharge


tion.
2. Remove front panel from machine to

access Control Board.
3. Arrange wires so there is ample room to

work on the board.
INVERTEC V300-I

(continued)
302
275D
4. Turn main power ON.
5. Test for 15 VDC between leads 302 and

275D.
a. If 15 VDC is present, test is OK. Go

to step 6.
b. If 15 VDC is not present, check

Power Board and leads 302 and
275D for continuity and wire break-
age.
INVERTEC V300-I
(continued)
J5 J3
G2527 CONTROL J1 J2 J4
1J3
6. Turn main power OFF.

tion.
Test resistance between pin 1J3 and

black lead from Control Board to shunt.
See Figure F.22.
a. If zero ohms resistance (continuity)

is shown, test is OK. Go to step 8.
b. If resistance of any value is shown,

check wire and connections.
INVERTEC V300-I

(continued)
2J3
8. Test resistance between pin 2J3 to white NOTE: If tests for steps 5, 7, and 8 are OK
lead from Control Board to shunt. and the machine continues to experience
the problem, the Control Board should be
a. If zero ohms resistance (continuity) replaced.
is shown, test is OK. See note
below.
b. If resistance of any value is shown,

check wire and connections.
FIGURE F.22 — OVERCURRENT PROTECTION CURRENT TRIGGER CIRCUIT.
302 275D
6J1 1J1
CONTROL
BOARD
1J3 2J3
BLACK WHITE
L3
400 AMP (-) OUTPUT

CHOKE SHUNT TERMINAL
INVERTEC V300-I
OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST
WARNING

procedure.
CAUTION
Always turn off power to the machine to change the position of the reconnect switch. Never
change the reconnect switch with the main line switch in the on position. this will severely dam-
age the machine.
CIRCUIT DESCRIPTION auxiliary in the Reconnect Panel. Pre-

charge sampling of the Capacitor(s) also
Overvoltage protection occurs through two controls for overvoltage via the Driver
circuits. The Protection Board monitors the Board.
voltage applied to the Input Filter
Capacitors. If an overvoltage is sensed
from conditions such as misconnections or MATERIALS NEEDED
line surges, the Output Trigger Circuit and
the Input Power Relays are opened, caus- • Analog voltmeter/ohmmeter (multimeter)
ing the machine to shut down. In the event
that line surges occur, the circuit will reset • V300-I wiring diagrams
when the line voltage returns to normal.
NOTE: Figure F.28 shows the Overvoltage

Misconnection protection includes the Protection DC Trigger Circuit.
Protection Board function along with a fused
INVERTEC V300-I
OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT TEST (continued)

FIGURE F.23 — PC BOARDS REMOVED.

TEST PROCEDURE 4. Arrange the PC boards and wiring so

you can easily perform the tests.

NOTE: Do not allow live connections to
2. Perform Input Filter Capacitor Discharge touch each other.
tion. 5. Turn main power ON.
3. Detach the following PC boards so you 6. Move the Output Terminal Switch S4 to
can gain access to and have ample room the ON position (closed).
to perform the tests: (Do not disconnect
from wiring harness.)
• Control Board
• Protection Board
• Power Board
NOTE: Do not disconnect any wires.

The machine must be functional to per-
form tests.
INVERTEC V300-I
FIGURE F.24 — PROTECTION BOARD TEST POINT.
L7915 PROTECTION
313
J8 J15
311
7. Test for 0 VDC between leads 311 and

313 on Protection Board.
a. If 0-1 VDC is present, the Protection

Board is OK. Go to step 8.
b. If 15 VDC is present, go to step 11.

INVERTEC V300-I

FIGURE F.25 — POWER BOARD TEST POINTS.
302
POWER BOARD
L8033
J14
J7 J6 275D
501
504
8. Test for 15 VDC supply voltage between 9. Test for 0-1 VDC (DC trigger circuit)
leads 302 and 275D on Power Board. between leads 305 and 275D on Power
Board.
a. If 15 VDC is present, test is OK. Go
to step 9. a. If 0-1 VDC is present, DC trigger cir-
cuit is operating properly.
b. If 15 VDC is not present, the Power
Board may be faulty. Check for 18 b. If 15 VDC is present, go to step 10.
VAC input voltage at lead 501 and
504 (J7).
If 18 VAC is present the Power

Board is faulty and must be
replaced.
POWER BOARD
L8033
J14 J6
J7
305 275D
INVERTEC V300-I
301
POWER BOARD
L8033
J14 J6
J7
275D
10. Test for 0-1 VDC between leads 301

and 275D on Power Board.
a. If 0-1 VDC is present, AC trigger,

Control Board, and Power Board
are operating properly.
b. If 15 VDC is present, go to Thermal

Protection AC Trigger Circuit Test .
INVERTEC V300-I

FIGURE F.28 — OVERVOLTAGE PROTECTION DC TRIGGER CIRCUIT.
1J8 #311 1J14 #302 (+)

52 6J6
THESE LEADS
ARE USED FOR #313 2J14 #275D (-)
14 3J8 1J6
MONITORING
CAPACITOR 53
VOLTAGES POWER
51 BOARD
SEE TABLE 1 PROTECTION

BELOW BOARD
OPTOCOUPLER #301 #305

DEPENDENT ON
PROTECTION BOARD
TABLE 1:INPUT VOLTS FOR
460 VOLTS AC
IF AC TRIGGER 5J1 4J1
LEADS NORMAL CIRCUIT IS GOOD,
52-53 325 VDC #301 LEAD
IS TAKEN TO +15 VDC
51-53 325 VDC
CIRCUIT COMMON
14-53 14-15 VDC #275D CONTROL
14-52 315 VDC BOARD
11. If 15 VDC is present at step 7, test

Capacitor voltages using leads shown
in Figure F.28.
If voltage does not match table, check

reconnect for proper position for voltage

applied. Also test Capacitor balance.

Refer to Static and Dynamic Capacitor
Balance Tests.
INVERTEC V300-I
THERMAL PROTECTION AC TRIGGER CIRCUIT TEST

WARNING

procedure.
CIRCUIT DESCRIPTION MATERIALS NEEDED
The choke thermostat will open the normally • Analog voltmeter/ohmmeter (multimeter)
closed output trigger circuit if overheating
occurs due to excessive output loading • V300-I wiring diagrams
and/or excessive duty cycle.

NOTE: Figure F.30 shows the Thermal
The fan thermostat will open the normally Protection AC Trigger Circuit.
closed output trigger circuit if air flow is
blocked, the fan motor fails, or if the fan
blade breaks. This protection is necessary
to avoid overheating of machine compo-
nents during idle conditions.
INVERTEC V300-I
THERMAL PROTECTION AC TRIGGER CIRCUIT TEST (continued)

FIGURE F.29 — PC BOARDS REMOVED.

TEST PROCEDURE


tion.
3. Detach the following PC boards so you

can gain access to and have ample room
to perform the tests. (Do not disconnect
from wiring harness.)
• Power Board
• Control Board
NOTE: Do not disconnect any wires. The

machine must be functional to perform
tests.
INVERTEC V300-I
FIGURE F.30 — THERMAL PROTECTION AC TRIGGER CIRCUIT.
CHOKE FAN
THERMOSTAT THERMOSTAT
#503 #503A #224
24
T1 VOLTS
AC NORMALLY CLOSED
NOTE:
WHEN THERMOSTATS
10J6 TRIP, THE CIRCUIT
#212D
POWER WILL BE OPENED
EXTERNAL BOARD
#212B
TRIGGER 9J6
#212C #212A
2 C S4 OUTPUT
TERMINAL
4 D SWITCH
#223B
#223A CONTROL #210
11J4 4J2
BOARD
PART OF 14 PIN
AMPHENOL
4. Locate the Auxiliary Transformer T1 and

leads used for test. See Figure F.30.

INVERTEC V300-I

CHOKE FAN
#503 #503A #224
24
T1 VOLTS
A.C. NORMALLY CLOSED
NOTE:
WHEN THERMOSTATS
#212D
WILL BE OPENED
EXTERNAL POWER
#212B
TRIGGER 9J6 BOARD
#212C #212A
2 C S4 OUTPUT
TERMINAL
4 D SWITCH
#223B
#223A CONTROL #210
11J4 4J2
BOARD
PART OF 14 PIN
AMPHENOL
6. Test Auxiliary Transformer voltage for 24 7. Check that Output Terminal Switch S4 is
VAC between leads 503 and 212D. See in the ON position (closed).
Figure F.31.
a. If 24 VAC is present, transformer is

OK. Go to step 7.
b. If 0 VAC is present, test input voltage

to Auxiliary Transformer.
c. If input voltage to Auxiliary Transfor-

mer is correct, replace Auxiliary
Transformer.
d. If input voltage to Auxiliary Transfor-

mer is not correct, check Line Switch
S12 and connecting leads.
INVERTEC V300-I
CHOKE FAN
#503 #503A #224
24
T1 VOLTS
A.C. NORMALLY CLOSED
NOTE:
WHEN THERMOSTATS
#212D
EXTERNAL BOARD
#212B
TRIGGER 9J6
#212C #212A
2 C S4 OUTPUT
TERMINAL
4 D SWITCH
#223B
#223A CONTROL #210
11J4 4J2
BOARD
PART OF 14 PIN
AMPHENOL
8. Test for 24 VAC between leads 223A b. If 0 VAC is present, check Choke
and 210. Thermostat and Fan Thermostat.
a. If 24 VAC is present, then AC Trigger

Circuit is functioning normally.
CHOKE FAN
#503 #503A #224
24
T1 VOLTS
AC NORMALLY CLOSED
NOTE:
WHEN THERMOSTATS
#212D
EXTERNAL BOARD
#212B
TRIGGER 9J6
#212C #212A
2 C S4 OUTPUT
TERMINAL
4 D SWITCH
#223B
#223A CONTROL #210
11J4 4J2
BOARD
PART OF 14 PIN
AMPHENOL
INVERTEC V300-I
CONTROL BOARD TEST

WARNING

procedure.
FUNCTION: The Control Board monitors 6. Obtain new (functioning) Control Board.
the panel controls to determine which weld
process is being employed and how the out- NOTE: Repeat steps 1-3 before
put should be controlled to optimize welding attempting to change the Control Board.
results. The Control Board controls the FET
switching through pulse width modulation 7. Remove Control Panel by removing the
circuitry. four mounting screws.
The Control Board monitors excessive out- 8. Locate the Control Board.
put current, the thermal protection signal,
and the overvoltage signal for the trigger 9. Disconnect all Control Board wiring con-
disable function. See Theory of Operation nections and remove old Control Board.
section for details.
10. Reconnect all Control Board wiring con-
nections and attach new (functioning)
TEST PROCEDURE Control Board.
1. Turn main power OFF. 11. Reinstall Control Panel.
2. Remove wrap-around cover. 12. Turn main power ON.

3. Perform Input Filter Discharge proce- 13. Verify machine operates correctly.
dure detailed in Maintenance section..
a. If machine operates correctly, the
4. Check that all wiring connections are old Control Board was faulty.
secure and all potentiometers and Discard the old Control Board.
switches are functioning properly.
b. If machine does not operate correct-
a. If all components check OK, go to ly, the old Control Board was not
step 6. faulty. Replace the old Control
Board and continue to look for wiring
b. If any connection is loose or any and connection problems.
component is faulty, fix it. Go to
step 5.
5. Reassemble and operate machine and

verify it operates correctly.
a. If machine does not operate correct-

ly, go to step 6.
INVERTEC V300-I
POWER BOARD TEST
WARNING
NOTE: Use Test A before disassembling 4. Listen for control relays CR1, CR2,
the unit. CR3, and CR4 to operate (audible click
of contacts closing) after a 5-second
delay.
TEST PROCEDURE
a. If audible click of control relay con-

Test A tacts closing is heard, Power Board

is probably OK.
NOTE: If there is still a possibility
2. Position yourself at Switch Board area that the Power Board is faulty, go to
of the machine (near Case Back) to lis- Test B.
ten to control relays CR1, CR2, CR3,
and CR4 operate (audible click of con- b. If audible click of control relay con-
tacts closing). tacts closing is not heard, Power
Board could be faulty. Go to Test B.
INVERTEC V300-I
POWER BOARD TEST (continued)

FIGURE F.34 — REMOVING CONTROL PANEL.

Test B 4. Detach Control Panel by removing the

four mounting screws. Move the panel
1. Turn main power OFF. to the left to gain access to the Power
Board.
2. Remove wrap-around cover.
3. Perform Input Filter Capacitor Dis-
charge procedure.
INVERTEC V300-I
POWER BOARD TEST (continued)
POWER BOARD
L8033
J14
J7 J6
501
504
6. Test for 18 VAC input from Auxiliary 7. Test for 15 VDC output between leads
Transformer between leads 504 and 275D (-) and 302 (+) (J6) on Power
501 (J7) on Power Board. Board.
a. If 18 VAC is measured, input power a. If 15 VDC output is measured,

from Auxiliary Transformer is OK. Power Board is OK.
Go to step 7.
b. If 15 VDC output is not measured,
b. If 18 VAC input power from Auxiliary replace Power Board.
Transformer is not measured, test
Auxiliary Transformer.
302
POWER BOARD
L8033
J14 J6
J7
275D
11 / 94
INVERTEC V300-I
CAPACITOR REPLACEMENT
WARNING
throughout this manual. Turn off input power to
machine. Discharge input capacitors. Only
qualified technicians should perform installa-
tions, maintenance, and troubleshooting work
on the machine.
Capacitors must always be replaced in during reassembly so that all parts are rein-
matched sets (C1 and C2 as a set or C1, stalled properly.
C2, C14, and C15 as a set on 575 VAC
machines).
TEST PROCEDURE
When replacing Capacitors, remove the
entire FET heat sink assembly, including 1. Remove the two 3/8” hex head nuts
Capacitors and Switch Board, as a unit. from the top of the through bolts. The
hex nuts are located on top of the fan
Disassemble and reassemble only one unit shroud. See Figure F.37.
at a time. Use the other unit as a model
FIGURE F.37 — REMOVING HEX HEAD NUTS OF THROUGH BOLTS.

INVERTEC V300-I
CAPACITOR REPLACEMENT (continued)
FIGURE F.38 — REMOVING THROUGH BOLTS.

2. Place the machine on its side as shown

in Figure F.38. Slide the plastic insula-
tors that go through the base of the
machine to one side. Pull the through
bolts out of the machine, being careful

to save all the insulation and standoff
material. Set aside for reassembly.
INVERTEC V300-I

FIGURE F.39 — REMOVING CAPACITOR NUTS.

3. Remove the two 7/16” hex nuts that 4. Loosen the set screw of the Capacitor
hold the Capacitor to the PC board. clamp ring and remove the Capacitor
See Figure F.39. from the clamp ring. See Figure F.40.
FIGURE F.40 — LOOSENING THE CLAMP RING SET SCREW.

INVERTEC V300-I
FIGURE F.41 — COMPLETE SWITCH BOARD ASSEMBLY READY FOR INSTALLATION.

5. Install the new Capacitor and tighten NOTE: Proper capacitor polarity must be
the two 7/16” hex nuts to a torque of 55 noted when attaching the capacitor to the
inch-pounds (6 Nm). Tighten these Switch Board assembly.
nuts in increments of 10 inch-pounds,
alternating between the two nuts. See
Figure F.41.
6. Perform the “Test After Repair of Switch

Boards and/or Capacitors”.

SWITCH BOARD REPLACEMENT

WARNING
throughout manual. Turn off input power to
on the machine.
If a test indicates that a Switch Board is b. Burned areas are visible on the Switch
defective, both Switch Boards must be Boards.
replaced at the same time.In addition to
replacing the Switch Boards, Capacitors C1
and C2 (plus C14 and C15 on 575 VAC TEST PROCEDURE

models) must also be replaced if the follow-
ing conditions exist: 1. Carefully disconnect the leads at the top
of the Switch Board.
a. Machine was operating from 380 VAC
or higher when the failure occurred. 2. Remove the four 3/16” socket head cap
screws as shown in Figure F.42.
FIGURE F.42 — REMOVING THE SOCKET HEAD CAP SCREWS

FROM THE SWITCH BOARD.
INVERTEC V300-I
SWITCH BOARD REPLACEMENT (continued)
3. Remove the two 7/16” head Capacitor 9. Insert each of the two hex head screws
screws located in the center of the into the Capacitor terminal holes and
Switch Board. Hold the PC board firmly thread finger tight. Be careful not to
while doing this. cross thread the screws.
4. Remove the Switch Board carefully. 10. Torque both sets of screws in 10 inch-
pound increments using a diagonal
5. Clean the heat sink surfaces thoroughly tightening sequence. Torque the four
to remove all the heat sink compound. socket head screws to 44 inch-pounds
During machine operation, this com- (5 Nm). Torque the two hex head
pound helps conduct heat from the PC screws to 55 inch-pounds (6 Nm).
board to the heat sinks.
11. Reconnect all the leads to the PC
6. Apply a thin layer (.002”) of Dow 340 board. Double check that each lead is
Heat Sink Compound to the mounting connected to the correct terminal.

surfaces of the new PC board and to Failure to reconnect the leads correctly
the Capacitor terminals. DO NOT allow can result in machine damage when the
the compound to enter the mounting power is applied.
screw holes because it can distort the
torque values. 12. Perform the “Test After Repair of Switch
Boards and/or Capacitors”.
7. Prepare to mount the new PC board on
the heat sink by first lining up the NOTE: Always make sure that Switch
mounting holes. Then press the PC Boards are changed in matched pairs.
board into place. Never mix an old style (different part num-
ber) Switch Board with a new style (new
8. Insert each of the four socket head part number).
screws into the mounting heads and
thread finger tight. The threads are soft
— be careful not to cross thread the

screws.
INVERTEC V300-I
TEST AFTER REPAIR OF SWITCH BOARDS AND/OR CAPACITORS

The following test must be performed after

the Switch Boards and/or the Capacitors 5. Test the other Switch Board the same
have been replaced. way.
NOTE: Repeat the Filter Capacitor Dis-

TEST PROCEDURE charge procedure.
1. Turn main power OFF. NOTE: Always make sure that Switch
Boards are changed in matched pairs.
2. Perform Input Filter Capacitor Dis- Never mix an old style (different part num-
charge procedure detailed in Mainten- ber) Switch Board with a new style (new
ance section.. part number).
3. Connect a shorting conductor across 6. Remove the shorting conductor set up

terminals 14 and 53 of Protection in step 3.

Board.
7. Install 5-amp fuses in the input supply
4. Set an ohmmeter to X1000 range and fuse holders.
place probes on terminals 9 (+) and 12
(-) of one Switch Board. The meter will NOTE: These fuses should be installed
show the Capacitors charging up and to protect against excessive current flow
may take a minute or so to stabilize. caused by a short circuit during the pro-
The final meter reading should not cedure.
exceed 8600 ohms (8.6 on the scale).
FIGURE F.43 — SHORTING TERMINALS 14 AND 53 OF PROTECTION BOARD.

INVERTEC V300-I
TEST AFTER REPAIR OF SWITCH BOARDS AND/OR CAPACITORS
(continued)
8. Turn on the machine. 12. Remove the 5-amp fuse from the input
supply fuse holders.
9. With the output free of a load, check the
open circuit voltages of the output. 13. Install 20-amp fuses and test under
load.
10. Connect the machine for 440- or 575-
volt operation. NOTE: A resistive-type grid load bank
is recommended.
11. With the output free of a load, check
open circuit voltages of the output. 14. Perform Retest After Repair.
Voltage should be 70 VDC.
INVERTEC V300-I
OUTPUT DIODE REPLACEMENT

WARNING
throughout manual. Turn off input power to
on the machine.

7. Before mounting the new diode sets,
2. Perform Input Filter Capacitor Discharge clean and brighten the mounting sur-
procedure detailed in Maintenance sec- faces of both the diode sets and the heat
tion.. sink with fine steel
3. Detach and remove both Switch Boards 8. Apply an even coating of DOW 340 Heat
and attached capacitors as a unit. Sink Compound to the mounting sur-
faces of the diodes that contact the heat
4. Detach the fan shroud to gain access to sink. This compound layer should be
the diode heat sink and mounting brack- less than .001 inch thick. DO NOT apply
et. When the fan shroud is lifted, the the compound to the diode studs or
tabs securing the heat sink mounting mounting nut threads.
bracket will release.
9. Insert the diode sets into the mounting
5. Move the diode heat sink and mounting hole and tighten the diode mounting nuts
bracket away from the Case Back. to a torque of 25 inch-pounds (3 Nm).
6. Remove the nut that secures each diode

to the heat sink and mounting bracket.

NOTE: The Output Diodes must be

replaced in matched sets.
INVERTEC V300-I
INPUT FILTER CAPACITOR CONDITIONING
If the machine will not produce output when To condition the Input Filter Capacitors:
turned on and the following two conditions
exist: 1. Turn main power OFF.
The machine is connected to operate at 2. Remove any load and do not load
an input voltage of 380 VAC or higher machine until conditioning procedure is
and complete.
Power has not been applied to the 3. Turn main power ON.
machine for a long period of time (many
months). Then. . . 4. Let the unloaded machine sit for 30 min-
utes.
The Input Filter Capacitor Protection Circuit
could have been activated and prevented 5. Turn main power OFF.
output. This means the Input Filter

Capacitors must be conditioned. 6. Turn main power ON.
The Input Filter Capacitor Protection Circuit NOTE: The machine should be ready to
monitors the voltage across Input Filter operate, and the protection circuit should
Capacitors C1 and C2. When it senses an have automatically reset once the
overvoltage condition, the protection circuit Capacitors have been conditioned and
will prevent the machine from operating. capacitor voltage has reached the accept-
able operating level.
ENVIRONMENTAL PROTECTION
If the machine will not produce output when as Dow Corning 3140, 3145, or 738;
turned on and the following two conditions Columbus Adhesives 0172; or GE RTV-162
High voltage connections are covered with is recommended. Sealant may also be pur-
an RTV sealant to prevent malfunction in chased from Lincoln Electric (order E2519
severe environments. Sealant must be Silicone Rubber RTV Coating). Apply
applied to connections which have been sealant after machine is repaired and test-
opened or otherwise lost their protection. A ed. All five terminals of Input Rectifier D13
noncorrosive, electronic grade sealant such require this type of sealant.
INVERTEC V300-I
RETEST AFTER REPAIR

Should a machine under test be rejected for NOTE: 50 Hz machines may be tested
any reason requiring the removal of any using 60 Hz power.
mechanical part that could affect the
machine’s electrical characteristics, or if any
electrical components are repaired or
replaced, the machine must be retested.
INPUT IDLE AMPS AND IDLE WATTS
Input Single Phase Three Phase

Volts/Hertz Max. Amps Max. Watts Max. Amps Max. Watts
220/50 or 60 2.75 425 2.75 425
230/60 3.00 450 3.00 450

440/50 or 60 1.38 425

460/60 1.50 450
380/50 or 60 1.67 425
575/60 — —
OCV at rated INPUT: V300-PRO, V300-I 60-75V

MAXIMUM ACCEPTABLE OUTPUT AMPS (AT MINIMUM OUTPUT SETTINGS)
Output
Min. (Max. acceptable), all machines:
CC modes 12A @ 10V. (GTAW, SOFT, CRISP)
CV modes 20A @ 19V. (FCAW, GMAW)
OUTPUTMINIMUM ACCEPTABLE VOLTS (AT MAXIMUM OUTPUT SETTINGS,

WITH FULL LOAD)
Min. Acceptable,
Max. — All Modes V300-I V300-PRO
1 phase @ 200A 380V 220/440V 208V 230/460V 575V
— 38V — 38V 36V
3 phase @ 300A 32V 36V 34V 38V 36V
AUXILIARY TRANSFORMER — 50 Hz or 60 Hz
TEST POINTS RANGE

18 VAC winding to Power Board J9 pins 1 and 2 Welding 17-20 VAC
terminals sw. remote

24 VAC winding to Control Board J2 pin 4 to lead 212 23-26.5 VAC
STANDARD CODES: (Test at Amphenol)
24 VAC with load, measure across pins C and D 22-25 VAC
42 VAC with load, measure across pins I and K 39-44 VAC
115 VAC with load, measure across pins A and J 109-120 VAC
INVERTEC V300-I
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-61
INVERTEC V300-I
NOTES
TABLE OF CONTENTS Section G
- ELECTRICAL DIAGRAMS SECTION -
Electrical Diagrams .....................................................................................Section G

PC Board Component Diagrams — Invertec V300-I ................................................G-2
Protection Board ................................................................................................G-2
Control Board .....................................................................................................G-4
Switch Board ......................................................................................................G-8
Power Board ....................................................................................................G-10
Driver Board (L8660-1) ...................................................................................G-12
Driver Board (L9134-1) ...................................................................................G-13
Wiring Diagrams — Code 9826..............................................................................G-14
Code 9827 .......................................................................................................G-15
Code 10036 .....................................................................................................G-16
Code 10037 .....................................................................................................G-17
Code 10132 .....................................................................................................G-18
Code 10133 .....................................................................................................G-19

Schematic Diagrams — Invertec V300-I ................................................................G-20
Driver Board (L8660-1) ...................................................................................G-21
Driver Board (L9134-1) ...................................................................................G-22
Switch Board ....................................................................................................G-23
Control Board ...................................................................................................G-24
Protection Board ..............................................................................................G-25
Power Board ....................................................................................................G-26
INVERTEC V300-I
G-2 ELECTRICAL DIAGRAMS
PROTECTION BOARD
51
H5
52
53
14
NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board
repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail-
able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages
board level troubleshooting and repair since it may compromise the quality of the design and may result in
danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
INVERTEC V300-I
ELECTRICAL DIAGRAMS G-3
PROTECTION BOARD
Item Identification
B5, B14, B51, B52, B53 CONNECTOR, tab 1/4”

C1, C3, C4, C5, C6 CAPACITOR, ceramic
C2 CAPACITOR, tantlm etc.
27µf 35VDC
D1, D3, D4, D5, D6, D7 DIODE, 1A 400V
D8 DIODE, 1A 1000V
DZ1 DIODE, IN4740 Zener 10V 1W
J8 RECEPTACLE, Molex mini 4 pin
J15 RECEPTACLE, Molex mini 6 pin
OCI1, OCI2, OCI3, OCI4 OPTO, Isolator CNY17-3
P8 (plugs into J8) PLUG HOUSING, Molex mini 4 pin
P15 (plugs into J15) PLUG HOUSING, Molex mini 6 pin
R1, R2 RESISTOR, MF .25W 1% 681K

ohm
R3, R13, R16 RESISTOR, MF .25W 1% 1.82K
ohm.
R4, R5, R11, R12 RESISTOR, MF .25W 1% 150K
ohm
R6, R8, R9, R10, R27 RESISTOR, MF .25W 1% 56.2K
ohm
R7, R20 POTENTIOMETER, Cermet trmr
.25W 1% 5K ohm
R14 RESISTOR, MF .25W 1% 100K
ohm
R15 RESISTOR, MF .25W 1% 475
ohm
R18, R26, R28, R32 RESISTOR, MF .25W 1% 10K
ohm
R19 RESISTOR, MF .25W 1% 3.32K

ohm
R21, R23, R24, R25, RESISTOR, MF.25W 1% 15K
R29, R30, R31, R33 ohm
R22 RESISTOR, MF .25W 1% 332K
ohm
ohm
R35, R37 RESISTOR, MF .25W 1% 332
ohm
TERMINALS (P8, P15) TERMINALS, Molex mini
X1 QUAD OP-AMP
X2 VOLTAGE REGULATOR, linear
7805 5VDC
NOTE: Individual parts listed are not available from Lincoln Electric.
machine.
INVERTEC V300-I
CONTROL BOARD (G2527)
PRO
INVERTEC-300
G2527
CONTROL
machine.
INVERTEC V300-I
CONTROL BOARD (G2527)
Item Identification Item Identification
C1, C2, C3, C6, C8, C14, CAPACITOR, CEMO .022 50V 20% DZ2, DZ7 DIODE, Zener 1W 10V 5%
C15, C16, C17, C20, C24, 1N4740A
C27, C30, C32, C35, C36, DZ4, DZ6, DZ9, DZ10, DIODE, Zener 1W 5.1V 5%
C38, C44, C45, C47, C49, DZ13, DZ14 1N4733A
C50, C51, C52, C53, C54, DZ5 DIODE, Zener 1W 6.2V 5%
C55, C56, C57, C58, C60, 1N4735A
C61, C63, C64, C66, C67, DZ11, DZ12 DIODE, Zener 1W 43V 5%
C69, C70, C74 1N4755A
C4, C23, C75 CAPACITOR, CEMO 150P J1 RECEPTACLE, Molex mini 8 pin
100V 5% J2 RECEPTACLE, Molex mini 4 pin
C5 CAPACITOR, PEMF 0.33 J3 RECEPTACLE, Molex mini 2 pin
200V 10% J4 RECEPTACLE, Molex mini 12 pin

C10, C29, C33 CAPACITOR, TAEL 1.8 20V 10% J5 RECEPTACLE, Molex mini 14 pin
C11 CAPACITOR, ALEL 20 50V OCI1 OPTOCOUPLER, Photo Q 70V
+75/-10% CNY17-3
C12 CAPACITOR, PFC .018 50V 2% P1 (plugs into J1) PLUG HOUSING, Molex 8 pin
C13, C22, C25 CAPACITOR, CEMO 330P P2 (plugs into J2) PLUG HOUSING, Molex 4 pin
100V 5% P3 (plugs into J3) PLUG HOUSING, Molex 2 pin
C18 CAPACITOR, CEMO 4700P P4 (plugs into J4) PLUG HOUSING, Molex 12 pin
50V 10% P5 (plugs into J5) PLUG HOUSING, Molex 14 pin
C19, C39, C42, C48, C65 CAPACITOR, TAEL 4.7 35V 10% Q1, Q2 TRANSISTOR-N, T226 0.5A 40V
C25 CAPACITOR, CEMO 47P 100V 2N4401
5% R2, R4, R8, R20, R23, RESISTOR-MF, .25W 1% 10.0K
C26, C41, C46, C59, C73 CAPACITOR, CEMO 0.1 50V 10% R32, R38, R43, R45, R46,
C28, C62 CAPACITOR, TAEL 1.0 35V 10% R51, R57, R64, R68, R87,
C31, C40 CAPACITOR, TAEL 0.33 50V 10% R109, R125, R139, R141,
C34, C37 CAPACITOR, CEMO 2700P R143, R151
R3, R10, R26, R42, R129 RESISTOR-MF, .25W 1% 475K
50V 5%
R5, R6 RESISTOR-CC, .50W 5% 1

C43, C68 CAPACITOR, TAEL 2.7 50V 10%
R7, R9, R30, R47, R71, RESISTOR-MF, .25W 1% 47.5K
C71 CAPACITOR, TAEL 39 20V 10%
R11 RESISTOR-MF, .25W 1% 267
C72 CAPACITOR, TAEL 100 20V 10%
R12, R25, R75, R98, RESISTOR-MF, .25W 1% 22.1K
D1, D2, D3, D7 DIODE, AXLDS 1A 400V FR
R127, R133, R149
1N4936
R13, R34, R40, R48, R50, RESISTOR-MF, .25W 1% 100K
D4, D5, D8, D9, D10, D11, DIODE, AXLDS 1A 400V
R60, R81, R94, R105, .
D12, D13, D14, D15, R114, R118, R123, R124
D17, D18, D20, D21, R14 TRIMMER-ST, .50W 10% 5K linear
D22, D25, D26, D27, D28, R15, R100, R103, R104 THERMISTOR-PT, 56 ohms 9 oma
D29, D30, D31, D33, D34, R16, R19, R28, R41, R113, RESISTOR-MF, .25W 1% 332K
D35, D36, D37, D38, D39, R17 THERMISTOR-PTC,.08-0.19 ohms
D40, D41, D42, D45, D46, 1.85A
D47, D48, D50, D51, D52 R18 RESISTOR-CC, 2W 5% 680
D16, D19, D24 DIODE, AXLDS 0.15A 75V 1N914 R21, R73, R102, R119, RESISTOR-MF, .25W 1% 2.67K
D23 DIODE, AXLDS 1A 30V Schottky R144
DZ1, DZ3, DZ8 DIODE, Zener 0.5W 3.0V 5% R22, R70, R126, R132, RESISTOR-MF, .25W 1% 26.7K
1N5225B R137, R140

(continued on next page)
machine.
INVERTEC V300-I
CONTROL BOARD (G2527) – cont’d
Item Identification
R24, R130 RESISTOR-MF, .25W 1% 56.2K

R27, R37, R53, R55, RESISTOR-MF, .25W 1% 33.2K
R58, R92, R115, R136
R29 RESISTOR-MF, .25W 1% 392K
R31, R79, R88, R90, R93, RESISTOR-MF, 25W 1% 4.75K
R97, R99, R121, R135,
R142
R33 RESISTOR-MF, .25W 1% 3.32K
R35 RESISTOR-CC, 1W 5% 390
R36, R66, R85, R91, R110 RESISTOR-MF, .25W 1% 150K
R39, R52, R72, R86 RESISTOR-MF, .25W 1% 221K
R44, R101 RESISTOR-MF, 25W 1% 100
R49, R67, R80, R107, RESISTOR-MF, .25W 1% 681K

R61, R147, R148 RESISTOR-MF, .25W 1% 10.0
R65, R77 RESISTOR-MF, .25W 1% 475
R82, R120, R128 RESISTOR-MF, .25W 1% 301
R83 RESISTOR-MF, .25W 1% 267K
R95 TRIMMER-ST, .50W 10% 10K
linear
R96 RESISTOR-MF, .25W1 825 %
R152, R153, R154, R155 RESISTOR-MF,.25W 1% 26.7K
TERMINALS (P1, P2, P3, TERMINALS, Molex mini

P4, P5)
X1, X3, X11 QUAD, IC-OP-AMP. gen. purpose
224J
X2 CONTROLLER, IC-PWM I-mode
3847
X4 QUAD, IC-OP-AMP high-perf 1014
X5, X6, X8, X9, X10 SWITCH, IC-CMOS analog quad
4066
X7 INVERTER,IC-CMOS Schmitt h
ex 4584
machine.
INVERTEC V300-I
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES
INVERTEC V300-I
G-7
SWITCH BOARD (L8441)
machine.
INVERTEC V300-I
SWITCH BOARD (L8441)

Item Identification
A1 ELECTRONIC MODULE ASSEMBLY

A2 ELECTRONIC MODULE ASSEMBLY
B1, B2, B3, B4, B5, B6, CONNECTOR, tab QC edge offset
B7, B8, B9, B10, B11, 1/4”
B12
C1, C5, C6, C7 CAPACITOR,CEMO .022 50V 20%
C2, C8 CAPACITOR, CEMO 2700P 50V 5%
C3, C4 CAPACITOR-PPF, .047 1200V 5%
D1, D2, D3, D4, D5, D6, DIODE, AXLDS 1A 400V FR 1N4936
D7, D8, D9, D10
DZ1, DZ2, DZ3, DZ12 DIODE, Zener 1W 10V 5% 1N4740A
DZ4, DZ7 DIODE, Zener 1W 15V 5% 1N4744A
DZ5, DZ6, DZ8, DZ9 DIODE, Zener 1W 6.2V 5% 1N4735A

Q1, Q2, Q3, Q10 TRANSISTOR-NMF, 4PDIP 1A 100V
RFD110
Q4, Q12 TRANSISTOR-N, T226 0.5A 40V
2N4401
Q5, Q6, Q7, Q8, Q9, Q11 TRANSISTOR-P, T226 0.5A 40V
2N4403
R1, R3, R5, R24 RESISTOR-MF, .25W 1% 100 ohm
R2, R4 RESISTOR-MF, .25W 1% 221 ohm
R6, R8, R9, R17, R19, RESISTOR-MF, .25W 1% 10.0 ohm
R25, R26, R27, R33, R34
R7, R30 RESISTOR-MF, .25W 1% 1.50K ohm
R11, R15, R22, R28 RESISTOR-CC, .50W 5% 1 ohm
R12, R14, R20, R21 RESISTOR-MF, .25W 1% 1.00K ohm
R13, R31 RESISTOR-MF, .25W 1% 20.0 ohm

R18, R29, R37, R42 RESISTOR-MF, .25W 1% 475 ohm
R35, R36 RESISTOR-MF, .25W 1% 47.5 ohm
R38, R39, R40, R41 RESISTOR-MF, .25W 1% 39.2K ohm
machine.
INVERTEC V300-I
POWER BOARD (L8033)
E
F
L8033-4
C
A
B
D
POWER BOARD
machine.
INVERTEC V300-I
POWER BOARD (L8033)

Item Identification
X1 REGULATOR ASBLY
C2,C7,C11 .022/50
J7 CONNECTOR
X5 VOLT. REG. & HEAT SINK ASBLY.
C3 150/50
D1,D2,D3,D4,D5,D8,D9, 1N4004
D10,D11,D12,D13
C6 1.8/20
C4 4.7/35
C5 39uF/20VDC
C1 3300/50
OCI1 OPTO ISOLATOR
X2,X3 8 PIN I.C. (SS)
C8,C9,C12,C13 .1/50
J6 HEADER
C10 500/50
DZ1 1N4744A
DZ2,DZ3 1N4746A
Q1,Q3 3A/60V. TRANSISTOR
Q2,Q4 3A ,60V. PNP TRANSISTOR
Q5 3.5A. 60V. MOSFET (SS)
D6,D7 1N5822 SCHOTTKY BARRIER
DIODE
R1 .0 OHM, 5W RESISTOR
TP1,TP2 15J
R11,R19,R26,R27 10K 1/4W
R5,R6,R10,R22 100K 1/4W
R4 1.5K 1/4W
R14,R41 15K 1/4W
R9 1150K 1/4W
R21 2.21K 1/4W
R3 243 1/4W
R7,R8,R24 267 1/4W
R2 2.67K 1/4W
R18 26.7K 1/4W
R20 267K 1/4W

R13,R15,R16,R17 33.2K 1/4W
R23 4.75K
R12 475K 1/4W
R25 5.11K 1/4W
X4 LM224 OP-AMP
J14 HEADER
Q40 2N4401
R42,R43 100 1/4W
DZ4,DZ5 1N4742A
R28,R29 10 1/4W
D14 1N4936
R44 THERMISTOR
machine.
INVERTEC V300-I
DRIVER BOARD (L8660)
DZ1
Q1
R13
R14
DZ2 J16
Q2
Item Description
CR1, CR2, CR3, CR4 RELAY, SPNO 24VDC 6000 ohms

AG-CDO
D1 DIODE, AXLDS 1A 400V
DZ1, DZ2 DIODE, Zener 1W 12V 5%

1N4742A
J9, J10, J16 CONNECTOR, Molex mini PCB
6 pin
J11 CONNECTOR, Molex mini PCB
4 pin
P9, P10, P16 (plugs into PLUG, Molex mini 6 pin
J9, J10, J16)
P11 (plugs into J11) PLUG, Molex mini 4 pin
Q1, Q2 TRANSISTOR, NMFT247 4A 900V
R1, R2, R13, R14 RESISTOR, WW 20W 5% 250K
R3, R4, R5, R6, R8, R9, RESISTOR, MF .25W 1% 150K
T1 TRANSFORMER, PCB
machine.
INVERTEC V300-I
DRIVER BOARD (L9134)

XXXX XXXX XXXX XXXX DRIVER L9134
XXXX
XXXXX
XXXXXXX
XXXXXXX
XXXX XXXX XXXX XXXX XXXXX
XXXX
Item Description
J11 HEADER
J9,J10 HEADER
T1 TRANSFORMER
J16 HEADER
R1,R2,R13,R14 20 WATT 250 OHM RESISTOR
DZ1,DZ2 1N4742A
Q1,Q2 FET (SS)
R7,R12 100 1/4W
R3,R4,R5,R6,R8,R9, 150K 1/4W
R10,R11
machine.
INVERTEC V300-I
Wiring Diagram — Invertec V300-I — Code 9826

311 313
275F 306
+ ARC
N.G.
9A 9 L2 229
52 52 T2 229
N.F. 9A RIGHT
8657
14 14 4, 5 4 TP5 229
1 2 3 4 R7 MAIN D12 400A
53 53 402, 404 250 C5
(208/230/460V.)
R8
52 TRANSFORMER S SHUNT
J8
51 51
25
+ F
10
C7 25W
TP6
H5 H5 7500 25W C2 + SWITCH R13
R1
L
F 2W
4 L3
PROTECTION 1 314 25W 25 BOARD F BOTTOM .001/400 286
- ARC
2200 F TOP .001/400
BOARD 2
- (LEFT) AUX 10
14 25W 450V
9-11-92
OUTSIDE R3
3 316 S 2W CHOKE 285
J15 R6 401, 403 S
INVERTER WELDERS
C4 B W
4 315
5
53 12A R W R W 1, 8 1
S F D11
6 12A 12 BOTTOM BOTTOM
317 D10 C6 S5
INSIDE
TP4
WIRING DIAGRAM
D9 204C METER
F S V
1
D8 220 FUNCTION
A
INPUT D7 SWITCH
S1 RECTIFIER 9C 9D
POWER D13 214 +5
9D CR1(N0)
6 3 2 5 1 4 275B GND
OFF ON 9A CR2(N0)
AC1 + 225 DPC
W 12B CR3(N0) N.E.
U H1 TP1 DRIVER J10
CHOKE 226 DP1
METER
12D CR4(N0)
H1 BOARD THERMOSTAT
}
227 IN(+)
}
S7 J16 J11
J9 275C
} R AC2 IN(-)
INPUT RECONNECT 12 3 4 5 6 1 3 2 4
V 3 6 2 5 4 1 224 503A
H5 9B
PER TP3
N.A. 9C 9B
TP2 203
B 12A
-
W AC3 12C T3
A 12A CC GTAW
314 315 307 309 215
CURRENT N.E. 1 CC SOFT
G 9B 12A 317 316 308 310
TRANSFORMER 206 S2
I 2
204A CC CRISP MODE
12C 12D N.H. D1 3 SWITCH
9B 9 204B CV FCAW
4
}
N.G. 4, 5 5 5 D2
}
S
N.F. 9B W W F 220 1 2 W 213
R R D3 J3 5 CV GMAW
Y Y I BOTTOM
1
A R5 402, 404 204A 10 B 218
OUTSIDE TOP D4
3 AMP
25
+ SWITCH S F D5
76 5
25W C1 + 3 77B
}}
7500 203
R9
C3 CW (MAX)
SLOW 25W 25
BOARD S
10 206 4 1 77A R11
2200 F
R11
BLOW TOP S R2 10K
51 25W 450V - (RIGHT) INSIDE
TOP 2W
.001/400 211A 12 2 502 276 OUTPUT
A J4 2W
R4 401, 403 AUX .001/400 223A 11 8 229 275C CONTROL
F F 10
12B 1, 8 8 8 R10 227 2 13 228 275B
REMOTE 2W
12B 12 S F
C8
213 9 12 207 275A
OUTPUT
D6 214 6 7 208
CONTROL
H1 H3 J13 J12 L1 225 8 3 276 LOCAL
MIN H1 J5 S3
H1 1 1 504 LEFT 226 7 6 218 228
75 G 75 200- LOCAL/REMOTE
14 75 204B REMOTE
208V H2 SWITCH
FAN 18V
H2 4 4 77A 204C
76 F 76 MOTOR
H3 H3 11 215
77 E 77B H3 2 4 501
}}
CB2 220- 110V 275F 2 10 207 CW (MAX)
31 J 212 6 32A 307 7 2 305 R12
110/115 2AMP 5 306
230V POWER 3 ARC FORCE
VAC 308 8 301 10K
R12
7
BOARD 275D 1 9 208 /INDUCTANCE
32 A 32 H4 309 2 6 302 2W
H4 3 301 5 CONTROL
42 32A
{
42V
41 I 212 N.D. 380- 310 4 3 303 J1
}
VAC 5 42A J7 302 6 1 Y
42 K 42 CB1 415V 501 5 8 304
6AMP J6 305 4 3 Y 212A
2 C 212 504 6 1 275D

24V
3 503 J2
A 6 303 7 4 210 212B S4
212C 42A H6 1 4 211A ON
TRIGGER H5 304 8 OUTPUT
440- 0V 2 275A
4 D 223B 2 212D FAN 3 5 211B
460V 223B TERMINAL
9 212B REMOTE
THERMOSTAT CONTROL SWITCH
}
311 1 223A
81 M T1 10 212D BOARD
313 2
82 L + S6 AUXILIARY 224
3
J14 502
21 H 21 TRANSFORMER THERMAL
4
N.C. GND B GND - WIRE FEEDER
Y OVERLOAD
SPARE N 285 WELDING 212C
211B INDICATOR
POLARITY
}
}
212A 150 5W 210 (V300-I ONLY)

229 SWITCH 503
WIRE REMOTE 503A
FEEDER CONTROL
RECEPTACLE
NOTES:
S2
N.A. MODE SWITCH
1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO)
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. S4
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT. OUTPUT TERMINAL SWITCH
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. S5
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. S3
METER FUNCTION SWITCH
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. J2, J8 J9, J10, J12 LOCAL/REMOTE SWITCH
J3 J11, J14 J13, J15, J16 J1, J7
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I)
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. R11
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT. OUTPUT CONTROL
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.
J6 J4 J5 R12
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THERMAL ARC FORCE/INDUCTANCE CONTROL
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. OVERLOAD
N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "I". INDICATOR
(V300-I ONLY)
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION. COLOR CODE: CONNECTOR CAVITY NUMBERING SEQUENCE
B = BLACK (VIEWED FROM COMPONENT SIDE OF BOARD)
N.E. D1 THRU D5 OUTPUT DIODES ARE A MATCHED SET.
G = GREEN
D7 THRU D11 OUTPUT DIODES ARE A MATCHED SET.
R = RED
N.F. R1, R9 BLEEDER RESISTORS ARE A MATCHED SET.
W = WHITE
ELECTRICAL SYMBOLS PER E1537 CONTROL PANEL
N.G. C1, C2 CAPACITORS ARE A MATCHED SET. Y = YELLOW LAYOUT
N.H. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 380-460V OPERATION.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific
diagram for a particular code is pasted inside the machine on one of the enclosure panels.
INVERTEC V300-I

311 313
275F 306
+ ARC
N.G.
9A 9 L2 229
52 52 T2 229
N.F. 9A RIGHT
14 14 4, 5 4 TP5 229
8938
1 2 3 4 R7 MAIN D12 400A
53 53 402, 404 250 C5
R8
J8
51 51
25
+ F
10
C7 25W
TP6
H5 H5 7500 25W C2 + SWITCH R13
R1
L
F 2W
4 L3
- ARC
2200 F TOP .001/400
BOARD 2
- (LEFT) AUX 10
25W 450V
9-11-92
14 OUTSIDE R3
3 316 S 2W CHOKE 285
J15 R6 401, 403 S
INVERTER WELDERS
C4 B W
4 315
5
53 12A R W R W 1, 8 1
S F D11
317 D10 C6 S5
INSIDE
TP4
WIRING DIAGRAM
D9 204C METER
F S V
1
D8 220 FUNCTION
A
INPUT D7 SWITCH
S1 RECTIFIER 9C 9D
POWER D13 214 +5
9D CR1(N0)
6 3 2 5 1 4 275B GND
OFF ON 9A CR2(N0)
AC1 + 225 DPC
W 12B CR3(N0) N.E.
U H1 TP1 DRIVER J10
CHOKE 226 DP1
METER
12D CR4(N0)
H1 BOARD THERMOSTAT
}
227 IN(+)
}
S7 J16 J11
J9 275C
} R AC2 IN(-)
INPUT RECONNECT 12 3 4 5 6 1 3 2 4
V 3 6 2 5 4 1 224 503A
H5 9B
PER
TP3
N.A. 9C 9B
TP2 203
B 12A
-
W AC3 12C T3
A 12A CC GTAW
314 315 307 309 215
CURRENT N.E. 1 CC SOFT
G 9B 12A 317 316 308 310
TRANSFORMER 206 S2
I 2
204A CC CRISP MODE
12C 12D N.H. D1 3 SWITCH
9B 9 204B CV FCAW
4
}
N.G. 4, 5 5 5 D2
}
S
N.F. 9B W W F 220 1 2 W 213
R R D3 J3 5 CV GMAW
Y Y I BOTTOM
1
A R5 402, 404 204A 10 B 218
OUTSIDE TOP D4
3 AMP
25
+ SWITCH S F D5
76 5
25W C1 + 3 77B
}}
7500 203
R9
C3 CW (MAX)
SLOW 25W 25
BOARD S
10 206 4 1 77A R11
2200 F
R11
BLOW TOP S R2 10K
TOP 2W
.001/400 211B 12 2 502 276 OUTPUT
A J4 2W
R4 401, 403 AUX .001/400 223A 11 8 229 275C CONTROL
F F 10
12B 1, 8 8 8 R10 227 2 13 228 275B
REMOTE 2W
12B 12 S F
C8
213 9 12 207 275A
OUTPUT
D6 214 6 7 208
CONTROL
H1 H3 J13 J12 L1 225 8 3 276 LOCAL
MIN H1 J5 S3
H1 1 1 504 LEFT 226 7 6 218 228
14 75 204B REMOTE
208V H2 SWITCH
FAN 18V
H2 4 4 77A 204C
76 F 76 MOTOR
H3 H3 11 215
77 E 77B H3 2 4 501
}}
220- 275F 2 10 207 CW (MAX)
31 J 6 307 7 2 305 R12
230V POWER 3 5 306
8 ARC FORCE
308 301 10K
R12
CB1 7
32 A 6AMP H4 309 2 6 302 2W
H4 3 301 5 CONTROL
42
{
42V
41 I 212 N.D. 380- 310 4 3 303 J1
}
VAC 5 42A J7 302 6 1 Y
42 K 42 415V 501 5 8 304
J6 305 4 3 Y 212A
2
C 212 24V 504 6 1 275D

3 503 J2
42A A 6 303 7 4 210 212B S4
212C H6 1 4 ON
440- 0V 2 275A
4 D 223B 2 212B FAN 3 5 230
460V 223B TERMINAL
9 REMOTE
}
311 1 223A
81 M 10 231 BOARD
2 230 313 2
82 L + S6 24V
224
3
J14 502
21 H 21 THERMAL
4
N.C. GND B GND - WIRE FEEDER 3 231 Y OVERLOAD
211B J17 INDICATOR
POLARITY T1
}
}
212A 150 5W 210 (V300-I ONLY)

229 SWITCH AUXILIARY 503
WIRE REMOTE TRANSFORMER 503A
FEEDER CONTROL
RECEPTACLE
NOTES:
S2
N.A. MODE SWITCH
1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO)
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. S4
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT. OUTPUT TERMINAL SWITCH
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. S5
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. S3
METER FUNCTION SWITCH
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. J2, J8 J9, J10, J12 LOCAL/REMOTE SWITCH
J3 J11, J14, J17 J13, J15, J16 J1, J7
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I)
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. R11
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT. OUTPUT CONTROL
J6 J4 J5 R12
THERMAL ARC FORCE/INDUCTANCE CONTROL
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
OVERLOAD
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

INDICATOR
N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "C".
(V300-I ONLY)
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION. COLOR CODE: CONNECTOR CAVITY NUMBERING SEQUENCE
B = BLACK (VIEWED FROM COMPONENT SIDE OF BOARD)
G = GREEN
R = RED
W = WHITE
ELECTRICAL SYMBOLS PER E1537 CONTROL PANEL
N.G. C1, C2 CAPACITORS ARE A MATCHED SET. Y = YELLOW LAYOUT
INVERTEC V300-I

WIRING DIAGRAM (208/230/460V.)
311 313
275F 306
+ ARC
N.G.
9A 9 L2 229
52 52 T2 229
N.F. 9A RIGHT
14 14 4, 5 4 TP5 229
1 2 3 4 R7 MAIN D12 400A
53 53 402, 404 250 C5
R8
J8
51 51
25
+ F
10
C7 25W
TP6
H5 H5 7500 25W C2 + SWITCH R13
R1
F 2W
4 L3
- ARC
2200 F TOP .001/400
BOARD 2
- (LEFT) AUX 10
14 25W 450V OUTSIDE
3 S 2W R3 CHOKE
J15 316 R6 401, 403 285
S C4
4 315 B W
5
53 12A R W R W 1, 8 1
S F D11
317 D10
C6 S5
INSIDE
TP4 204C METER
F S D9 V
1
220 FUNCTION
INPUT 9C 309 310 309 310
S1 9D D8 A
RECTIFIER 9D SWITCH
307 308
POWER D13 D7
CR1 CR2
9A 214 +5
OFF ON
A D + 6 3 2 5 1 4 1 2 3 4 275B GND
W
}
U 225 DPC
H1 TP1
9D 12B DRIVER J10 J11
N.E. METER
H1 CHOKE 226 DP1
BOARD
12D THERMOSTAT 227 IN(+)

INPUT
} R B J16 J9
}
V S7 275C IN(-)
PER H5 TP3 RECONNECT 1 2 3 7 8 12 13 14 3 6 2 5 4 1 224 503A
N.A. 9B
TP2 9C 9B
B 203
W C F - 12A 314 52 9D 317
A 12C
12A 315 12B 12D 316 T3 N.E. CC GTAW
G 215
CURRENT 1 CC SOFT
9B 12A
TRANSFORMER 206 S2
12D I D1 2
204A CC CRISP MODE
12C 12D N.H.
D2 3 SWITCH
9B 9 204B CV FCAW
4
}
N.G. 4,5 5 5
}
S
N.F. 9B 1 2 213
YB
R
M
A IC
B
O
6
1
(2 2
8
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9
-29
4
0
3
13
0
4
8 R
O
5NH
TK
A A
O
SR
IN #
D2
R
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NH
TO
RYO
LT
A NH
,O4
IO4
B
INR
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SAD
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E S
R
U IR
,H G
IN
N
T
LA
P SR
,TE
V
ALIN
B
OC
T
JE E
IV
:
U
D
EA
CTN
IO
:
R
A
CRE
E
E E
P
X C
N
IE
R E
:
P
E
SE
T
:
E
IN
TS
E
RS
T
:
C
DD
E
RN
T
E LS
IA:
A
V
A O
P
LEU
B
ILA R
NU
Q
E
M
P
E M
Y
LON
T
E
E
RE
R
FEC
NEN
SA
W R W R
F D3 220 CV GMAW
I BOTTOM J3 5
R5 402, 404 Y Y 204A 10 1 B 218
A OUTSIDE TOP D4
3 AMP
25
+ SWITCH S F D5
76 5
25W C1 + 3 77B
}}
7500 203
R9
CW (MAX)
SLOW 25W 25
BOARD S
10
C3
206 4 1 77A R11
2200 F
R11
BLOW TOP S R2 10K
TOP 2W
.001/400 211A 12 2 502 276 OUTPUT
A J4 2W
R4 401, 403 AUX .001/400 223A 11 8 229 275C CONTROL
F F 10
12B 1, 8 8 8 R10 227 2 13 228 275B
2W
12B 12 S F
C8
213 9 12 207 275A
D6 214 6 7 208
H1 H3 J13 J12 L1 225 8 3 276
REMOTE LOCAL
MIN H1 J5 S3
H1 1 1 504 LEFT 226 7 6 218 228
OUTPUT 200-
75 G 75 REMOTE LOCAL/REMOTE
CONTROL 14 75 204B
208V H2 SWITCH
FAN 18V
H2 4 4 77A 204C
76 F 76 MOTOR
H3 H3 11 215
77 E 77B H3 2 4 501
}}
CB2 220- 110V 275F 2 10 207 CW (MAX)
31 J 212 6 32A 307 7 2 305 R12
110/115 2AMP 5 306
VAC 308 8 301 10K
R12
7
32 A 32 H4 309 2 6 302 2W
H4 3 301 5 CONTROL
42 32A
{
42V
41 I 212 N.D. 380- 310 4 3 303 J1
}
VAC 5 42A J7 302 6 1 Y
42 K 42 CB1 415V 501 5 8 304
6AMP J6 305 4 3 Y 212A
2 C 212 24V 504 6 1 275D J2
3 503 303 7 4 210 212B S4
A 6
212C 42A H6 1 4 211A ON


440- 0V 2 275A
4 D 223B 2 212D FAN 3 5 211B
460V 223B TERMINAL
9 212B REMOTE
}
311 1 223A
81 M T1 10 212D BOARD
313 2
3
J14 502
4
Y OVERLOAD
211B INDICATOR
POLARITY
}
}
212A 150 5W 210 (V300-I ONLY)

229 SWITCH 503
WIRE REMOTE 503A
FEEDER CONTROL
RECEPTACLE
NOTES:
N.A.
S4
1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO) OUTPUT TERMINAL S2
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. J2, J8 J9, J10, J12 SWITCH MODE SWITCH
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT. J3 J11, J14 J13, J15 J1, J7
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
COLOR CODE: S3
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
B = BLACK LOCAL/REMOTE
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. S5
G = GREEN SWITCH METER FUNCTION
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I) R = RED
SWITCH
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. W = WHITE J6 J4 J5, J16
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT. Y = YELLOW R11
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. OUTPUT CONTROL
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT CONNECTOR CAVITY NUMBERING SEQUENCE
R12
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. THERMAL
(VIEWED FROM COMPONENT SIDE OF BOARD) ARC FORCE/INDUCTANCE
N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "I". OVERLOAD
CONTROL
N.D. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. INDICATOR
ELECTRICAL SYMBOLS PER E1537 (V300-I ONLY)

N.G. C1, C2 CAPACITORS ARE A MATCHED SET.
CONTROL PANEL
CONNECTION SHOWN IS FOR 380-460V OPERATION. LAYOUT
R 12-2-93L
L9299
INVERTEC V300-I

311 313
275F 306
+ ARC
N.G.
9A 9 L2 229
52 52 T2 229
N.F. 9A RIGHT
14 14 4, 5 4 TP5 229
1 2 3 4 R7 MAIN D12 400A
53 53 402, 404 250 C5
R8
J8
51 51
25
+ F
10
C7 25W
TP6
H5 H5 7500 25W C2 + SWITCH R13
R1
F 2W
4 L3
- ARC
2200 F TOP .001/400
BOARD 2
- (LEFT) AUX 10
14 25W 450V OUTSIDE
3 S 2W R3 CHOKE
J15 316 R6 401, 403 285
S C4
4 315 B W
5
53 12A R W R W 1, 8 1
S F D11
317 D10 C6 S5
INSIDE
TP4 204C METER
F S
D9 V
1
220 FUNCTION
309 310 309 310
S1 9C 9D D8 A
9D SWITCH
307 308
D7
POWER CR1 CR2
9A 214 +5
OFF ON
A D + 6 3 2 5 1 4 1 2 3 4 275B GND
W
}
U N.E. 225 DPC
H1 TP1
METER
H1 226 DP1
BOARD
12D 227 IN(+)

} R B J16 J9
}
INPUT S7
V 275C IN(-)
PER H5 TP3 CHOKE
RECONNECT 1 2 3 7 8 12 13 14 3 6 2 5 4 1
N.A. 9B THERMOSTAT
TP2 9C 9B
B 203
W C F - 12A 314 52 9D 317 224 503A
A 12C
12A 315 12B 12D 316 T3 CC GTAW
N.E.
G 215
CURRENT 1 CC SOFT
9B 12A
TRANSFORMER 206 S2
12D I D1 2
204A CC CRISP MODE
12C 12D N.H.
D2 3 SWITCH
9B 9 204B CV FCAW
4
}
N.G. 4,5 5 5
}
S
N.F. 9B W F D3 220 1 2 W 213
R W R J3 5 CV GMAW
YB
R
M
A IC
B
O
6
1
(2 2
8
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9
-29
O
SR
IN D
A2
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0
4
43
3
1
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4
8 O
5NH
T
RK
A
NT
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H
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DN
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9
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INE
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8 R
HUPS
E
R
S
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RO
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NIBILIT
IN
M
ATIN
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PE
P
ORINN
E
V
M
P
E E
Y
LOEO
SHS
R
U IR
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IND
N
A
N
T
LA
P R
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S E
V
A G
LIND
N
AWK
R
O
V
AA O
P
LEU
B
ILA R
NQ
E
B
OC
T
JE E
IV
:
U
D
EA
CTN
IO
:
R
A
CRE
E
E E
P
X C
N
IE
R E
:
M
P
E M
Y
LON
T
E:
E
IN
TS
E
RS
T
:
E
RE
R
FEC
NEN
SAC
DD
E
RN
T
E LS
IA:
Y Y I BOTTOM
1
A R5 402, 404 D4 204A 10 B 218
OUTSIDE TOP
3 AMP
25
+ SWITCH S F D5
76 5
25W C1 + 3 77B
}}
7500 203
R9
C3 CW (MAX)
SLOW 25W 25
BOARD S
10 206 4 1 77A R11
2200 F
R11
BLOW TOP S R2 10K
TOP 2W
.001/400 211A 12 2 502 276 OUTPUT
A J4 2W
R4 401, 403 AUX .001/400 223A 11 8 229 275C CONTROL
F F 10
12B 1, 8 8 8 R10 227 2 13 228 275B
2W
12B 12 S F
C8
213 9 12 207 275A
D6 214 6 7 208
REMOTE
H1 H3 J13 J12 L1 225 8 3 276
OUTPUT LOCAL
MIN H1 J5 S3
CONTROL H1 1 1 504 LEFT 226 7 6 218 228
14 75 204B REMOTE
208V H2 SWITCH
FAN 18V
H2 4 4 77A 204C
76 F 76 MOTOR
H3 H3 11 215
77 E 77B H3 2 4 501
}}
220- 275F 2 10 207 CW (MAX)
31 J 212 307 7 2 305 R12
230V POWER 3 5 306
8 ARC FORCE
308 301 10K
R12
7
32 A 32 H4 309 2 6 302 2W
H4 3 301 5 CONTROL
42
{
41 I 212 CB1 N.D. 42V
310 4 3 303
380- J1
}
VAC 5 42A J7 302 6 1 Y
42 K 42 6AMP 415V 501 5 8 304
J6 305 4 3 Y 212A
2 C 212 24V 504 6 1 275D J2
3 503 303 7 4 210 212B S4
212C 42A A H6 6 1 4 211A ON
H5
TRIGGER 440- 0V 304 8 2 275A OUTPUT

4 D 223B 2 212D FAN 3 5 211B
460V 223B TERMINAL
9 212B REMOTE
}
311 1 223A
81 M 10 212D BOARD
T1 313 2
82 L + S6 AUXILIARY
224
3
J14 502
21 H 21 THERMAL
TRANSFORMER 4
Y OVERLOAD
211B INDICATOR
POLARITY
}
}
212A 150 5W 210 503 (V300-I ONLY)

229 SWITCH
WIRE REMOTE 503A
FEEDER CONTROL
RECEPTACLE
NOTES:
N.A. S4
J2, J8 J9, J10, J12
1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO) OUTPUT TERMINAL
J3 J11, J14 J13, J15 J1, J7
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. SWITCH
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.

S2
MODE SWITCH
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. COLOR CODE: S3
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. B = BLACK LOCAL/REMOTE
J6 J4 J5, J16
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I) G = GREEN SWITCH
R = RED S5
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
W = WHITE METER FUNCTION
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.
Y = YELLOW SWITCH
R11
CONNECTOR CAVITY NUMBERING SEQUENCE OUTPUT CONTROL
(VIEWED FROM COMPONENT SIDE OF BOARD)
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT R12
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. ARC FORCE/INDUCTANCE
THERMAL
N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "C". ELECTRICAL SYMBOLS PER E1537 CONTROL
OVERLOAD

(V300-I ONLY)
CONTROL PANEL
LAYOUT
R 12-2-93L
L9300
INVERTEC V300-I

WIRING DIAGRAM - (CODE 10132)
311 313
275F 306
+ ARC
N.G.
9A 9 L2 229
52 52 T2 229
N.F. 9A RIGHT
14 14 4, 5 4 TP5 229
1 2 3 4 R7 MAIN D12 400A
53 53 402, 404 250 C5
R8
J8
51 51
25
+ F
10
C7 25W
TP6
H5 H5 7500 25W C2 + SWITCH R13
R1
F 2W
4 L3
- ARC
2200 F TOP .001/400
BOARD 2
- (LEFT) AUX 10
14 25W 450V OUTSIDE
3 S 2W R3 CHOKE
J15 316 R6 401, 403 285
S C4 S5
4 315 B W
5
53 12A R W R W 1, 8 1
S F D11
METER PANEL
6 12A 12 BOTTOM BOTTOM FUNCTION METER
317 D10
C6
INSIDE SWITCH
TP4 204C
F S D9 V
1 1 1
220
INPUT 9C 309 310 309 310 2 2
S1 9D D8 A
RECTIFIER 9D
307 308 3 3
POWER D13 D7
CR1 CR2 214
4 4
OFF ON 9A
A D + 6 3 2 5 1 4 1 2 3 4 5 5
W 6 6
U H1 TP1
N.E.
H1 CHOKE 226
BOARD
12D THERMOSTAT
INPUT
} R
V H5
B
S7
J16 J9 227
PER TP3 RECONNECT 1 224 503A 275C
2 3 7 8 12 13 14 3 6 2 5 4 1
N.A. 9B
TP2 9C 9B
B 203
W C F - 12A 314 52 9D 317
A 12C
12A 315 12B 12D 316 T3 N.E. CC GTAW
G 215
CURRENT 1 CC SOFT
9B 12A
TRANSFORMER 206 S2
12D I D1 2
204A CC CRISP MODE
12C 12D N.H.
D2 3 SWITCH
9B 9 204B CV FCAW
N.G. 4,5 5 5 S 4
N.F. 9B W W F D3 220 1 2 W 213
R R J3 5 CV GMAW
Y Y I BOTTOM
1
A R5 402, 404 D4 204A 10 B 218
OUTSIDE TOP
3 AMP
25
+ SWITCH S F D5
76 5
7500 25W C1 + 203 3 77B
R9
CW (MAX)
SLOW 25W 25
BOARD S
10
C3
206 4 1 77A R11
2200 F
R11
BLOW TOP S R2 10K
51 25W 450V - (RIGHT) TOP 2W
.001/400 211A 12
J4
2 502 276 OUTPUT
INSIDE 2W
A 223A 8 229
R4 401, 403 AUX .001/400 11 275C CONTROL
F F 10
12B 1, 8 8 8 R10 227 2 13 228 275B
2W
12B 12 S F
C8
213 9 12 207 275A
D6 214 6 7 208
H1 H3 J13 J12 L1 275B 8 3 276
REMOTE LOCAL
MIN H1 J5 S3
H1 1 1 504 LEFT 226 7 6 218 228
OUTPUT 200-
75 G 75 REMOTE LOCAL/REMOTE
CONTROL 14 75 204B
208V H2 SWITCH
FAN 18V
H2 4 4 77A 204C
76 F 76 MOTOR
H3 H3 11 215
77 E 77B H3 2 4 501
CB2 220- 110V 275F 2 10 207 CW (MAX)
31 J 212 6 32A 307 7 2 305 R12
110/115 2AMP 5 306
VAC 308 8 301 10K
R12
7
32 A 32 H4 309 2 6 302 2W
H4 3 301 5 CONTROL
42 41 I 212 32A N.D. 42V
310 4 3 303
380- J1
VAC 5 42A J7 302 6 1 Y
42 K 42 CB1 415V 501 5 8 304
6AMP J6 305 4 3 Y 212A
2 C 212 24V 504 6 1 275D J2
3 503 303 7 210 212B S4
A 6 4
212C 42A H6 1 4 211A ON

440- 0V 2 275A
4 D 223B 2 212D FAN 3 5 211B
460V 223B TERMINAL
9 212B REMOTE
311 1 223A
81 M T1 10 212D BOARD
313 2
3
J14 502
4
Y OVERLOAD
211B INDICATOR
POLARITY
212A 150 5W 210 (V300-I ONLY)
229 SWITCH 503
WIRE REMOTE 503A
FEEDER CONTROL
RECEPTACLE
NOTES:
N.A.
S4
1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO) OUTPUT TERMINAL S2
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. J2, J8 J9, J10, J12 SWITCH MODE SWITCH
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT. J3 J11, J14 J13, J15 J1, J7
COLOR CODE: S3
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
B = BLACK LOCAL/REMOTE
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. S5
G = GREEN SWITCH METER FUNCTION
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I) R = RED
SWITCH
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. W = WHITE J6 J4 J5, J16
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT. Y = YELLOW R11
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. OUTPUT CONTROL
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT CONNECTOR CAVITY NUMBERING SEQUENCE
R12
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. THERMAL
(VIEWED FROM COMPONENT SIDE OF BOARD) ARC FORCE/INDUCTANCE
N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "I". OVERLOAD
CONTROL
ELECTRICAL SYMBOLS PER E1537 (V300-I ONLY)


CONTROL PANEL
CONNECTION SHOWN IS FOR 380-460V OPERATION. LAYOUT
R 2-11-94F
L9567
INVERTEC V300-I

WIRING DIAGRAM - (CODE 10133)

311 313
275F 306
+ ARC
N.G.
9A 9 L2 229
52 52 T2 229
N.F. 9A RIGHT
14 14 4, 5 4 TP5 229
1 2 3 4 R7 MAIN D12 400A
53 53 402, 404 250 C5
R8
J8
51 51
25
+ F
10
C7 25W
TP6
H5 H5 7500 25W C2 + SWITCH R13
R1
F 2W
4 L3
- ARC
2200 F TOP .001/400
BOARD 2
- (LEFT) AUX 10
14 25W 450V OUTSIDE
3 S 2W R3 CHOKE
J15 316 R6 401, 403 285
S C4
4 315 B W S5
5
53 12A R W R W 1, 8 1
S F D11 METER
6 12A 12 BOTTOM BOTTOM PANEL
317 D10 C6 FUNCTION
INSIDE METER
TP4 204C SWITCH
F S
D9 V
1
220
309 310 309 310 1 1
S1 9C 9D D8 A
9D 2 2
307 308
D7
POWER CR1 CR2 3 3
9A 214
OFF ON 4 4
A D + 6 3 2 5 1 4 1 2 3 4
W 5 5
U N.E.
H1 TP1
9D 12B DRIVER J10 J11 6 6
H1 226
BOARD
12D
INPUT
} R
V H5
B
S7
J16 J9
227
PER TP3 RECONNECT CHOKE
1 2 3 7 8 12 13 14 3 6 2 5 4 1 275C
N.A. 9B THERMOSTAT
TP2 9C 9B
B 203
W C F - 12A 314 52 9D 317 224 503A
A 12C
12A 315 12B 12D 316 T3 CC GTAW
N.E.
G 215
CURRENT 1 CC SOFT
9B 12A
TRANSFORMER 206 S2
12D I D1 2
204A CC CRISP MODE
12C 12D N.H.
D2 3 SWITCH
9B 9 204B CV FCAW
N.G. 4,5 5 5 S 4
N.F. 9B W F D3 220 1 2 W 213
R W R J3 5 CV GMAW
Y Y I BOTTOM
1
A R5 402, 404 D4 204A 10 B 218
OUTSIDE TOP
3 AMP
25
+ SWITCH S F D5
76 5
7500 25W C1 + 203 3 77B
R9
C3 CW (MAX)
SLOW 25W 25
BOARD S
10 206 4 1 77A R11
2200 F
R11
BLOW TOP S R2 10K
TOP 2W
.001/400 211A 12 2 502 276 OUTPUT
A J4 2W
R4 401, 403 AUX .001/400 223A 11 8 229 275C CONTROL
F F 10
12B 1, 8 8 8 R10 227 2 13 228 275B
2W
12B 12 S F
C8
213 9 12 207 275A
D6 214 6 7 208
REMOTE
H1 H3 J13 J12 L1 275B 8 3 276
OUTPUT LOCAL
MIN H1 J5 S3
CONTROL H1 1 1 504 LEFT 226 7 6 218 228
14 75 204B REMOTE
208V H2 SWITCH
FAN 18V
H2 4 4 77A 204C
76 F 76 MOTOR
H3 H3 11 215
77 E 77B H3 2 4 501
220- 275F 2 10 207 CW (MAX)
31 J 212 307 7 2 305 R12
230V POWER 3 5 306
8 ARC FORCE
308 301 10K
R12
7
32 A 32 H4 309 2 6 302 2W
H4 3 301 5 CONTROL
42 41 I 212 CB1 N.D. 42V
310 4 3 303
380- J1
VAC 5 42A J7 302 6 1 Y
42 K 42 6AMP 415V 501 5 8 304
J6 305 4 3 Y 212A
2 C 212 24V 504 6 1 275D J2
3 503 303 7 4 210 212B S4
212C 42A A H6 6 1 4 211A ON
H5
TRIGGER 440- 0V 304 8 2 275A OUTPUT

4 D 223B 2 212D FAN 3 5 211B
460V 223B TERMINAL
9 212B REMOTE
311 1 223A
81 M 10 212D BOARD
T1 313 2
82 L + S6 AUXILIARY
224
3
J14 502
21 H 21 THERMAL
TRANSFORMER 4
Y OVERLOAD
211B INDICATOR
POLARITY
212A 150 5W 210 503 (V300-I ONLY)
229 SWITCH
WIRE REMOTE 503A
FEEDER CONTROL
RECEPTACLE
NOTES:
N.A. S4
J2, J8 J9, J10, J12
1. FOR MACHINES SUPPLIED WITH INPUT CABLE (V300-PRO) OUTPUT TERMINAL
J3 J11, J14 J13, J15 J1, J7
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. SWITCH
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.

S2
MODE SWITCH
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. COLOR CODE: S3
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. B = BLACK LOCAL/REMOTE
J6 J4 J5, J16
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE (V300-I) G = GREEN SWITCH
R = RED S5
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
W = WHITE METER FUNCTION
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.
Y = YELLOW SWITCH
R11
CONNECTOR CAVITY NUMBERING SEQUENCE OUTPUT CONTROL
(VIEWED FROM COMPONENT SIDE OF BOARD)
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT R12
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. ARC FORCE/INDUCTANCE
THERMAL
N.C. WIRE FEEDERS REQUIRING 24VAC, USE PINS "N" & "C". ELECTRICAL SYMBOLS PER E1537 CONTROL
OVERLOAD

(V300-I ONLY)
CONTROL PANEL
LAYOUT
R 2-11-94F
L9568
INVERTEC V300-I
Schematic Diagram For Troubleshooting Invertec V300-I

SCHEMATIC DIAGRAM FOR TROUBLESHOOTING INVERTEC V300-I (FOR CODES 9826, 9827, SPLC6792)
S7 T2 L2
J2, J8 J9, J10, J12 COLOR CODE:
9 MAIN RIGHT
RECONNECT 9A
D12
SWITCH 9A TRANSFORMER J3 J11, J14 J13, J15, J16 J1, J7 B = BLACK R = RED
4, 5 4 S F
9B R7 402, 404 W = WHITE
10 G = GREEN
52 C7
9C 9B
SWITCH F 2W
R13 Y = YELLOW
12A
12C
25
C2
+ BOARD 4 BOTTOM
12A
7500 25W + TOP
F
10
R1
AUX R3 J4
9B 12A 25W
(LEFT) 2W
J6 J5
25 2200 F OUTSIDE S C4
S
14 25W 450V - SOLDERED CONNECTION
R6 401, 403 1, 8 1 S F
BOTTOM BOTTOM D11
53 12A R W R W
INSIDE
12A 12 F S D10
1
CONNECTOR CAVITY NUMBERING SEQUENCE
QUICK CONNECTION
D9
S1 9C 15 (VIEWED FROM COMPONENT SIDE OF BOARD)
9D
D8 ELECTRICAL SYMBOLS PER E1537
POWER
OFF ON
AC1 + D7
W
9A CR2(N0) SINGLE LINE
H1 TP1 6 3 2 5 1 4
9D CR1(N0) DRIVER
TP3
} AC2
12D CR4(N0)
J10 BOARD
+ ARC
R 229
12B CR3(N0) MULTI LINES
INPUT H5 J9
J16 J11 16
250 C5
}
229
R8
TP2
B 25W TP5 TP6
-
1 2 3 4 5 6 1 3 2 4 400A
A AC3 3 6 2 5 4 1
L3
D1 SHUNT 229 286
G D13
H1
- ARC
12D
H1 INPUT CHOKE
314 317 315 316 307 308 309 310 T3 D2
H5 RECTIFIER 12C TEST WIRE
CURRENT B W
A D3 POINT LOCATION NUMBERS VOLTAGE
TRANSFORMER C6
I 285
TP4 1 R11 175/176 0 - 4.5 V DC
D4
3 AMP 9B 9
4, 5 5 5 S 0 V AT 0 AMP
SLOW 9B F
W R W R D5
BLOW Y Y I BOTTOM 50 mV AT 400 AMP
R5 402, 404 2 1J3 & 2J3 B/W
TOP
25
+ SWITCH
OUTSIDE
F
LINEAR FEEDBACK
7500 25W C1 + S C3
R9
BOARD 3 8J5 & 2J1 229/275F OUTPUT FEEDBACK
25W 25 S R2
2200 F TOP S 10
(RIGHT)
A 51 25W 450V - INSIDE
TOP
2W
.001/400
13 V DC
R4 401, 403 .001/400
F AUX 10 NO LOAD
12B F R10 7J1 & 1J1
H5 53 52 8 FAN CHOKE 4 303/275D
1, 8 8 2W C8
FAN 51 14 12B 12 8 V DC
MOTOR 9 S F D6
L1 FULL LOAD
1 311 LEFT 224
2 275F 13 V DC
BH5 B51 B53 B14 B52 J8 J13 J12
3 313 150 5W 503A
H1 NO LOAD
4 H1 1 1 504
306 5 8J1 & 1J1 304/275D
200-
H3
208V
8 V DC
H2 12
}
PROTECTION 1 314 H2 4 18V 307 7
2 308 8 FULL LOAD
BOARD H3 13 210
3 316 H3 2 4 501 POWER 212C 212A
J15 220- 110V 309 2 6 1J2 & 3J2 Y/Y 5 V AC
4 315 6 32A
230V 310 4 BOARD
5 H3 J7 7 4J2 & 11J4 210/223A 24 V AC
504 6
6 317 H4
H4 3 501 5 10 8 6J4 & 1J1 214/275D 5 V DC
380- 42V
5 42A 1
415V 9 1J8 & 3J8 311/313 1 V DC
3
24V
3 503 J6 10 5J7 & 6J7 501/504 18 V AC
A 11
}
H6 6
311 1 14
440- H6 0V 11 6J6 & 1J6 302/275D 15 V DC
460V 2 212D 313 2
J14 10 9 2 7 6 3 8 1 4 5
3 .75 V DC
T1 4
NO LOAD
AUXILIARY 12 7J7 & 1J6 307/275D
TRANSFORMER 212D 211B 6 V DC
305 301 302 303 304 275D
212B 211A
275F FULL LOAD
} .75 V DC
1 B
CONTROL BOARD J3 NO LOAD
2 3 4 5 6 7 8 1 W
2 13 8J7 & 1J6 308/275D
J5 4 5 6 V DC
3 8 J4 J2 2
J1
FULL LOAD
5 9 7 12 3 4 10 1 2 13 6 11 14 8 11 7 8 6 2 9 4 3 10 1 5 12 2 4 1 6 3
7
14 2J6 & 7J6 305/301 1 V DC
15 SW BOARDS R/W .75 V DC

306
208 207 276 77A 502 228 218 215 75 229 223A 226 225 214 227 213 206 203 204A 220 76 211A 275A 210 NO LOAD
Y
16 2J11 & 4J11 309/310 24 V DC
CB2
2AMP
{
32A 32 A 32 110/115
CB1
212 J 31 VAC
6AMP
{
42A 42 K 42 42
212 I 41 VAC
{
223B D 4
TRIGGER
212 C 2
212C
M 81
215 L 82
213 218 204B 204A 206 1 203 21 21 WIRE
H
FEEDER
5 GND B GND
4 2 211B N SPARE
208 207 212A 212B 223B 223A CV GMAW CC GTAW
204C 220 21 502
}
275A 275B 275C 276 77A 77B 228 204B 204C 285 229 503 503A 75 G 75
REMOTE
1 MIN
CV FCAW 3 CC SOFT OUTPUT
ON REMOTE 214 275B 225 226 227 275C 76 F 76
R12
10K
R11
- Y
77B E 77
CONTROL
10K LOCAL REMOTE V A
+
CW (MAX) CW (MAX) +5 GND DPC DP1 IN(+) IN(-)
2W 2W S6
CC CRISP
R12 S4 S5 WIRE FEEDER THERMAL
ARC FORCE OUTPUT R11 S3 S2 METER WELDING OVERLOAD REMOTE

/INDUCTANCE TERMINAL OUTPUT LOCAL/REMOTE MODE FUNCTION POLARITY INDICATOR CONTROL
CONTROL SWITCH CONTROL METER SWITCH SWITCH SWITCH SWITCH (V300-I ONLY) RECEPTACLE
R DAD 5-20-94
V300-I SCH
NOTE: This machine schematic is provided for reference only and may not be totally applicable to every code covered in
this manual.
INVERTEC V300-I
Schematic Diagram — Driver Board (L8660-1)

repairs will invalidate your factory warranty. This Printed Circuit Board schematic is provided for reference only. It may not
be totally applicable to your machine’s specific PC board version. This diagram is intended to provide general information
regarding PC board function. Lincoln Electric discourages board level troubleshooting and repair since it may compromise
the quality of the design and may result in Danger to the Machine Operator or Technician. Improper PC board repairs
could result in damage to the machine.
INVERTEC V300-I
Schematic Diagram — Driver Board (L9134-1)

INVERTEC V300-I
Schematic Diagram —Switch Board

POWER SUPPLY SOURCE POINT
L 8440
EARTH GROUND CONNECTION
SWITCH BOARD SCHEMATIC

VOLTAGE NET
COMMON CONNECTION
FRAME CONNECTION
LAST NO. USED
INVERTEC V300
10-8-93A
42
10
8
C-
D-
R-
SUPPLY
D4
1N4936
LABELS
W
221
D2 Q2
R4
100
R3
1N4936 D3
1A
100V 1N4936
R35
47.5
IRFD110
UNLESS OTHERWISE SPECIFIED)

UNLESS OTHERWISE SPECIFIED)
1
22.1K Q7 1/2W
R15
R16 600mA
DZ6
40V
(UNLESS OTHERWISE SPECIFIED)

2N4403
1.00K
POSITIVE
6.2V 1W
D9 9 INPUT
R14
B
1.00K 1N4936
R12
Q6
Q3 600mA
C1 DZ1
1A 40V D1 D2 D3 D4 D5
10V
100V 2N4403 R8 G1
DZ5 1W
SNUBBER
MFD ( .022/50V
A1
ELECTRICAL SYMBOLS PER E1537

3.3V 10.0 G2
1/4W
GENERAL INFORMATION
IRFD110 A2
Q5 A2
1W DZ4 G3 IRFP460
BYT12P600
RESISTOR
600mA R17
15V
40V
Q4 1 1W G4
2N4403 10.0 C1
600mA 1/2W
1A, 400V
R11
G5
RESISTORS = Ohms (
DZ3 S1 S2 S3 S4 S5
40V R6
10V 1W 15.0K
2N4401
CAPACITORS =
10.0
R10
20
402
D5
DIODES =
475 475 ---
R42
R18
R9
1N4936
404
R13
C2 10.0
2700p
50V R33
100 C3
R7
1.50K 10.0 .047
1200V
C7
R5
4 TRANSFORMER
R -
5 PRIMARY
C2
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
A2
BYT30P600
A2
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

R38 R39 INPUT
D1
39.2K 39.2K
1N4936 FILTER
W R41 R40
CAPACITOR
39.2K 39.2K
221
D6 100
R1
Q1
R2
1N4936 D7
1A
100V 1N4936 C2
R36
47.5 A1
IRFD110
BYT30P600
1
22.1K Q11 A2
1/2W
R22
R23 600mA DZ9
40V
1 TRANSFORMER
2N4403
-
1.00K 6.2V 1W 8 PRIMARY

D10
R21
1.00K 1N4936 A
R20
Q9
NUMBER.
Q10 600mA C4
C5 DZ2
1A 40V .047
10V D1 D2 D3 D4 D5 1200V
100V 2N4403
DZ8 1W R19 G1
NOTES :
3.3V
IRFD110 Q8
10.0 G2
A1
1W DZ7
600mA IRFP460 401
N.A.
15V G3
Q12 1 40V
1W
R26 ---
1/2W
2N4403 10.0
G4
403
R28
600mA
DZ12 G5
40V S1 S2 S3 S4 S5
10V 1W 15.0K
R25
2N4401 R32
20 10.0
D8 A1
475 475 SNUBBER
R29
R37
1N4936 R27
R31
C8
A1
2700p
10.0
BYT12P600
RESISTOR
50V
C1
R34
R30
100
1.50K 10.0
R24
C6
NEGATIVE
R 12
INPUT
INVERTEC V300-I
Schematic Diagram — Control Board

+15V
TO
PROTECTION TRIGGER D28

J4 +15V
12
TRIGGER BOARD TRIGGER
CIRCUIT 5 4 INTERFACE C44 C17 C53 C49
C58
to TEMP.LED J5 DZ11
R12 R30
13
.022
C57
.022 .022 .022
.022 C47
2 R144 43V .022
J1 J1 14 14 50V 50V 50V 14 .022
14 50V 4 4 50V 50V 14 14
D51 2.67K 1W R35 R11 22.1K 47.5K C27 X3 B R81 4
50V
10K 12
R17 D12 .022
J2 390 267 1 5 100K C15
24VAC FROM
R2
DZ1 50V C55
4 1W .022 X8 X9
XFRM DZ12 X7 X1 X3 X5 X6
3V OCI1 X4 .022
+t D21 D45 50V
43V C11 D4
D11 10K 500mW CNY17-3 HEXTRGR 4066B 50V
.13 4066B LM224
1W LM224 4066B 4066B
R20
680 20 LT1014
R18
OUTPUT 60V
2W 50V 2 6 4 +15V
TERMINAL 7 11
7
7 11 7 7
D13 11
R15 R8
HOT
R135
J4
11 4.75K
10K
+t D14 47.5K
C4
TRIG
REMOTE 150p 10
C6
R7
56 47.5K 332K
R28
R9
100V
.022
50V
TEST_PT_E X3
8
+15V
9 C
9
C16
C37 8
392K .022 X11 C
R29
2700p
10
50V
50V Vref
R19
3
OCV C69
C70
4
1 5 6 .022
X1 B .022
SHUNT 332K
C60
X7 B
OCV 50V 14
50V
2 12
R84 10K R16
AMPLIFIER .022
R46 14 X11
TEST PT D
R4
47.5K 50V X11 D
332K
- J3 10K X10
1 R77
13
OPEN C45 13
LM224
.022
SHUNT 475 X4 D
14
CIRCUIT 50V
4066B
V 5K 11
2
J3
R65
12
I DETECTOR 1
J2 CW
UNUSED 7
R14 R44 R151
+ 475 C34 CURRENT D3
C3
J5
10.0 10.0 10.0 47.5K .022 100 10K 10
R147
C31
R148
2700p 1N4936
V TRANS.
R61
R71
50V
.33 50V I 1 1 J1
50V 1/2W 3
1/2W
R6
C33
R5
J2 D7 C75
TEST_PT_B 1.8
3 1N4936 150p
3 4 20V
X6 C C5 50V
R80 R50
.33 16.2K Vref
+15V 681K 18.2K 100K
+ARC 200V D2
SOFT A
R69
C29
5 D34 SHORT DZ7 1N4936
R54
R109 1.8
10V
20V
PWM
D35 1W
PRIMARY D1
R152
R153
J4 3 4
10K C51 26.7 26.7 CONTROL
5
X8 B R64 1N4936 X2 +15V
100K
.022 1 16
CURRENT
R48
CLIM SHUT
C59 50V
t 10K
o
2 15
D36 0.1 R45 Vref Vin +15V

R103
50V
5 FEEDBACK 10K
3 14
56
R23
SOFT 10K I- OUTB C19 C20
R154
4 13 .022
R155
D16 26.7 4.7
SCALING 26.7 I+ Vc
LOCAL DZ4
R102
1N914 35V 50V 2.67K
5 12
5.1V V+ GND
J5 33.2K
CURRENT
R27
1W 6 11
+5V
13
47.5K Vref V- OUTA
J4
1
X7 A
2
11
X10 D 10 CONTROL R3 Q2
7
COMP SYNC
10
J1 J1 TO 6
R138
22.1K
REMOTE C61 600mA
C13
8 9 METER
AMPLIFIER 475K
R25
330p CT RT
.022 C24 10K 40V 7
SG3847 8 C56 DZ10
R143
.022 50V
R99
4.75K 50V 12 56.2K
R137 .022 5.1V
R24
50V
C23 50V 1W
R132
10K
R68
26.7K C12 2.67K
R22
26.7K 150p C14 26.7K
R21
OUTPUT .018
13
14 Pin 6 Pin
R133
V R36
6 100V .022
50V
TO DRIVER
Remote Remote CONTROL I 50V
Control Control 3
J5 1
X8 A 2
SOFT 22.1K 150K X4 B
7 10
X9 D 11
BOARD
R43
Receptacle Receptacle C8 5
10K
N D 10K .022 +15V C32
CONTROL
12
CW J2 50V Vref D46 DZ5 .022
PROTECTION
C E 2 C52 J1
6.2V 50V
MAX 2
ARC FORCE OCV 1W

.022
SELECT BOARD
R93
D F 4.75K 50V
D31
D30
F B 4.75K D38
J5 D9
2 1
X 6A
E C
4 R142 OCV R53
t
+15V
o
C46 C73 33.2K C25

J5 R104 .1 330p
G D41 0.1 13 J1
A 14 C71 C72
56 50V 50V 100V 6
100 POWER
39
H C30 20V 20V R49
.022 OCV TRIG
t 681K BOARD
C
R94
o
L 100K 50V 1 2 J1
X9 C
R100 1
M 56
D48
C1
13 .022
B
50 V
10K
D39
GMAW C36
A R141 C10 .022
V
2
100K
R90
475K 4.75K R13 D25
R26
50V
R105
1.8
I 6 I 1
20V 100K X3 D
CRISP
3
K 42VAC 115VAC, 42VAC
OCV CRISP D10
9
X6 D 8 R40
are common
J 115VAC to 4P2
3 4 Vref 100K
R41
X7 332K D5
47.5K R113
OCV
R47
R86
OVERCURRENT 332K
6 OCV
221K VOLTAGE FOLDBACK
CONTROL
C28
X3 A
7 11 10
D27 HOLD DOWN
1.0 X7 D
C66
AMPLIFIER 35V 5
Vref
TIG J5 C41
.022
50 V
D19 DZ3
11 0.1 + ARC 6
PINCH 3V
50V R112
Q1
SOFT (CC) 1N914 7
R10 R55 22.1K
500mW X1 C R114 600mA
R108
681K
J4 CONTROL 11 10
2
C63 33.2K 5 40V
R42 X6 B R87 X4 A 475K DZ6 D29 100K
4 1 .022
5.1V 4.75K
R31
MODE 475K 10K
3 1W
50V
X7 E C42
C26 8 9
12 22.1K
1 SWITCH CRISP V C22 0.1
D18 C62 267K
4.7
R111
35V
D17
I 330p 1.0
R83
R107
50V 681K 33.2K
R115
2 9 50V
CRISP (CC) J4
D8
D40
R39 R66 R52
Vref
35V
3 J4 +15V 8
33.2K D26
3 221K X4 C
R37
150K C38 221K
10 R101
TIG 10 R74
1
X5 C 2
.022
J5 100 681K
R67
50V
D15 6 4 24.3K
5
R62
13 +15V + ARC
Vref 8.25K
6
R146 100K
FCAW (CV) D50 150K
R110
R60
D37 A 28.0K
D47 8 9
X5
J5
J4
9 Cut out for Std. C40
5
TO PROTECTION BOARD
GMAW (CV) -Pro Machines 0.33
+ ARC 50 V 1 PHASE DET.

10K
22.1K
R149
J5
J5 J5
8
12 7 R63
AMPS VOLTAGE CW
1.00K
R70 + ARC NOTES :
R73
ARC FORCE/PINCH
J4
2.67K 26.7K
SETTING 825
SHORT
R96
1
5
DZ9
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE
5.1V 301
C39
7
SHORTING
R82
4.7 C74 X11 A R117

1W INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR
VOLTS 35V 6
332K
DETECTOR
R139 12
CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER.
CAD [50,50] G1916.HSD
10K
R116
11 10
X5 B
56.2K 47.5K GENERAL INFORMATION (more notes)
R131
D23
5
R130 68.1K C43
1N5818
X7 + ARC
12 2.7
D42 DZ8 33.2K
R92
C50 50V ELECTRICAL SYMBOLS PER E-1537
3V
Vref 13
R97
GMAW
3 4
X9 4.75K .022
J4 J4 50V
500mW
CAPACITORS = f d (UNLESS OTHERWISE SPECIFIED) LABELS
A D52
R123 R121 R124 RESISTORS = Ohms (1/4W UNLESS OTHERWISE SPECIFIED)
9
7 8
100K 100K X1 D
V 4.75K C65
8 DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED) test points
I 2.67K DZ2 C18
R119
4.7 10K
DP1 DPC Vref 10V
R32
35V 10 .0047 1 1 5
3 4 1W 50V
X5 D
12
SUPPLY VOLTAGE NET
VOLTS 2
X10 A 1
R122 J3
TO 150K
J1
R85
D 10 X8 11
22.1K 5
R120
R58
METER ACTUAL
301
R75
13 22.1K
D24 2 6 10
FC 33.2K
POWER SUPPLY SOURCE POINT
FCAW C64
1N914
J4 8 9
X8 C R136 .022
2
TEST_PT_E
PRESET R59 1 7
R88
50V 4.75K 1 2
33.2K
C35 COMMON CONNECTION
6
150K TO 82.5K
R91
.022 R140 J2 J4
50V 4 3 9 8
METER
X10 B
OCV 26.7K 12 X10 C
D22
R57
Vref
R51
C2 10K FRAME CONNECTION
R118 14 3 4 8 14
C48
4.75K C67 AMPS 10K
4.7
2 10K X1 A R33
5
.022
100K X11 B 13 CC SET 50 V
R95
.022 1 3.32K DZ14

R79
C54 35V
CW DZ13
50V R125 5.1V 1 5
C68
.022 3
R38 R34 1W 6 5.1V EARTH GROUND CONNECTION
9
X9 B 8 10K 2.7 1W
50V 10K 100K J5
R127
50V
R126
22.1K
TIG 22.1K 26.7K
R98
R72
6
D33
D20 221K 6 10
R129
475K
CURRENT
R56
43.2K
OCV INVERTEC V300
R128
OCV SETTING 301

CONTROL P.C. BOARD SCHEMATIC
AUSTRALIA CANADA
6-25-93A G2525
INVERTEC V300-I
Schematic Diagram — Protection Board

INVERTEC V300-I
Schematic Diagram — Power Board

INVERTEC V300-I

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RETURN TO MAIN INDEX

Safety Depends on You

proper installation ... and thought-

NOT INSTALL, OPERATE OR

ARC WELDING can be hazardous.

ELECTRIC SHOCK can ARC RAYS can burn.

open arc welding. Headshield and filter lens

fumes and gases away from the breathing zone. When

3.e. Also see item 7b.

WELDING SPARKS can CYLINDER may explode

8.c. Exposure to EMF fields in welding may have other health

vaporizing on contact with hot engine parts

____________________________________________________ Mar. ‘93

7.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove

7.g. To prevent accidentally starting gasoline engines while

7.h. To avoid scalding, do not remove the

5. Toujours porter des lunettes de sécurité dans la zone de

2. Dans le cas de travail au dessus du niveau du sol, se pro-

RETURN TO MAIN INDEX

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Troubleshooting and Repair ............................................................................Section F

Electrical Diagram ............................................................................................Section G

Input Voltage Reconnect Procedure ...............................................................A-3

RECOMMENDED INPUT WIRE AND FUSE SIZES

(Superlag) Ampere Wire in Wire in (Superlag) Ampere Wire in Wire in

200/50-60 60 43 6 (16mm2) 10 (6mm2) 200/50-60 80 53 6 (16mm2) 10 (6mm2)

475 mm 274 mm 564 mm 29 Kg

(1) Input voltage must be within ±10% of rated value.

Read entire installation section before starting TILTING

• Always connect the V300-I INPUT CONNECTIONS

FIGURE A.1 — RATING PLATE LOCATION

SELECT SUITABLE LOCATION 14 PIN AMPHENOL

INPUT CORD 6 AMP BREAKER

causing nuisance shutdown of the machine.

1. Verify the machine will be located in an area where

• free circulation of air into the sides and out the

• dust and dirt is kept to a minimum.

fillers. Insert conductors through cord connector.

INPUT POWER CONNECTIONS To Operate at Procedure

labeled “U”, and lower terminal is labeled “W”.

sizes. 3. Move lead “A” to terminal that

FIGURE A.2 — RECONNECT PANEL

OUTPUT CONNECTIONS WORK AND ELECTRODE CABLE

NOTE: A quick disconnect system is used for welding

1. Remove 1 in. (25mm) of welding cable insulation.

2. Slide rubber boot onto cable end. Boot end may be

trimmed to match cable diameter. Soap or other

3. Slide copper tube into brass plug.

4. Insert cable into copper tube.

- + 5. Tighten set screw to collapse copper tube. Screw

and Work Cable (Copper Cable Rated at 75°C).

Length AMPHENOL RECEPTACLE

• Do not touch electrically live parts

• Insulate yourself from work and

• Always wear dry insulating

FUMES AND GASES

• Keep your head out of fumes.

• Use ventilation or exhaust to