Download: INVERTEC ® V450-PRO SERVICE MANUAL SVM199-A | Issue D ate 10-Jul

INVERTEC ® V450-PRO

For use with machines having Code Numbers:

SERVICE MANUAL SVM199-A | Issue D ate 10-Jul

© Lincoln Global, Inc. All Rights Reserved. View Safety Info View Safety Info View Safety Info View Safety Info, i SAFETY i

WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains

are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. FOR ENGINE 1.h. To avoid scalding, do not remove the

powered equipment. radiator pressure cap when the engine ishot. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. _ 1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

ELECTRIC AND MAGNETIC FIELDS

_ 1.c. Do not add the fuel near an open flame weld- may be dangerous ing arc or when the engine is running. Stop the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and not spill fuel when filling tank. If fuel is spilled, welding machines wipe it up and do not start engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and _ welders having a pacemaker should consult their physician 1.d. Keep all equipment safety guards, covers and devices in posi- before welding. tion and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health when starting, operating or repairing equipment. effects which are now not known. _ 1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit: guards only when necessary and replace them when the maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure Always use the greatest care when working near moving them with tape when possible. parts. _ 2.d.2. Never coil the electrode lead around your body. 1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and idler by pushing on the throttle control rods work cables. If the electrode cable is on your right while the engine is running. side, the work cable should also be on your right side. 2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded. _ 1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source. turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate., ii SAFETY ii

ELECTRIC SHOCK can kill. ARC RAYS can burn.

3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from area of physical contact with work and ground. the arc rays. In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal. clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or FUMES AND GASES accidental contact with the workpiece or ground) use the following equipment: can be dangerous. • Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases • DC Manual (Stick) Welder. hazardous to health. Avoid breathing these • AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep your head out of the fume. Use enough 3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When welding gun are also electrically “hot”. welding with electrodes which require special ventilation such as stainless or hard facing (see 3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or connection with the metal being welded. The connection cadmium plated steel and other metals or coatings should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and 3.e. Ground the work or metal to be welded to a good electrical ACGIH TLV limits using local exhaust or mechanical ven- (earth) ground. tilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional pre- 3.f. Maintain the electrode holder, work clamp, welding cable and cautions are also required when welding on galvanized welding machine in good, safe operating condition. Replace steel. damaged insulation. 5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the 3.g. Never dip the electrode in water for cooling. equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker expo- 3.h. Never simultaneously touch electrically “hot” parts of sure level should be checked upon installation and periodi- electrode holders connected to two welders because voltage cally thereafter to be certain it is within applicable OSHA PEL between the two can be the total of the open circuit voltage and ACGIH TLV limits. of both welders. 5.c. Do not weld in locations near chlorinated hydrocarbon vapors 3.i. When working above floor level, use a safety belt to protect coming from degreasing, cleaning or spraying operations. yourself from a fall should you get a shock. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating prod- 3.j. Also see Items 6.c. and 8. ucts. 5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe. 5.e. Read and understand the manufacturer’s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 5.f. Also see item 1.b., iii SAFETY iii

WELDING and CUTTING CYLINDER may explode SPARKS can if damaged.

cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for materials from welding can easily go through small cracks the application and maintained in good condition. and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support. 6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous 7.c. Cylinders should be located: situations. Refer to “Safety in Welding and Cutting” (ANSI • Away from areas where they may be struck or subjected to Standard Z49.1) and the operating information for the physical damage. equipment being used. • A safe distance from arc welding or cutting operations and 6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame. circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder. 6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet will not cause flammable or toxic vapors from substances when opening the cylinder valve. inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for Containers and Piping That Have Held Hazardous use. Substances”, AWS F4.1 from the American Welding Society (see address above). 7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, 6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in welding. They may explode. Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202. 6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear FOR ELECTRICALLY ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a powered equipment. welding area. 8.a. Turn off input power using the disconnect 6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on area as practical. Work cables connected to the building the equipment. framework or other locations away from the welding area increase the possibility of the welding current passing 8.b. Install equipment in accordance with the U.S. National through lifting chains, crane cables or other alternate circuits. Electrical Code, all local codes and the manufacturer’s This can create fire hazards or overheat lifting chains or recommendations. cables until they fail. 8.c. Ground the equipment in accordance with the U.S. National 6.h. Also see item 1.c. Electrical Code and the manufacturer’s recommendations. 6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101. 6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

, iv SAFETY iv

PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de

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

PRÉCAUTIONS DE SÛRETÉ POUR

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais LES MACHINES À SOUDER À enrouler le câble-électrode autour de n’importe quelle partie du TRANSFORMATEUR ET À corps.

REDRESSEUR

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc: a. Utiliser un bon masque avec un verre filtrant approprié ainsi 1. Relier à la terre le chassis du poste conformement au code de qu’un verre blanc afin de se protéger les yeux du rayon- l’électricité et aux recommendations du fabricant. Le dispositif nement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une quand on regarde l’arc. bonne mise à la terre. b. Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié. soudage à l’aide d’écrans appropriés et non-inflammables. 3. Avant de faires des travaux à l’interieur de poste, la debranch- 4. Des gouttes de laitier en fusion sont émises de l’arc de er 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, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur place. talons sans revers, et chaussures montantes. 5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier., v SAFETY v

Electromagnetic Compatibility (EMC)

Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment. Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work com- plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome. Note: The welding circuit may or may not be earthed for safety reasons according to national codes. Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equip- ment. Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob- lems in the surrounding area. The following shall be taken into account: a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment; b) radio and television transmitters and receivers; c) computer and other control equipment; d) safety critical equipment, e.g., guarding of industrial equipment; e) the health of the people around, e.g., the use of pacemakers and hearing aids; f) equipment used for calibration or measurement g) the immunity of other equipment in the environment. The user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures; h) the time of day that welding or other activities are to be carried out., vi SAFETY vi

Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommen- dations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure. Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equip- ment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations. Welding Cables The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level. Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components. Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con- nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capaci- tance, selected according to national regulations. Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applica- tions. 1_1Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.”, I - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - I Page Safety ..i-iv Installation ..Section A Operation ..Section B Accessories ..Section C Maintenance ..Section D Theory of Operation ..Section E Troubleshooting and Repair ..Section F Electrical Diagrams ..Section G Parts Manual ..P-525, A-1 TABLE OF CONTENTS - INSTALLATION SECTION A-1 Installation ..A-1 Technical Specifications ..A-2 Safety Precautions ..A-3 Location ..A-3 Lifting, Stacking & Machine Grounding ..A-3 High Frequency Protection ..A-3 Input Connection ..A-3 Input Fuse and Supply Wire Considerations ..A-4 Negative Electrode Polarity ..A-5 Connections of Wire Feeders ..A-6 Parallel Operation ..A-7, A-2 INSTALLATION A-2

TECHNICAL SPECIFICATIONS - INVERTEC® V450-PRO INPUT AT RATED OUTPUT - THREE PHASE ONLY

INPUT VOLTS- OUTPUT INPUT IDLE POWER FACTOR EFFICIENCY FREQUENCY CONDITIONS CURRENT POWER @ RATED OUTPUT @ RATED AMPS / VOLTS / DUTY CYCLE AMPS OUTPUT 208/230/460/575V - 60HZ. 450A@38V.100% 58/53/25/22 570A@43V. 60% 82/78/37/31 400 Watts .95 MIN. 88% 400A@36V.100% 49/45/23/18 Max. 200/220/440/575V - 50HZ. 500A@40V. 60% 67/61/31/25

OUTPUT

PULSE PULSE PULSE AND AUXILIARY POWER FREQUENCY VOLTAGE BACKGROUND (CIRCUIT BREAKER PROTECTED) RANGE TIME RANGE 0.15 - 1000 Hz 5 - 55 VDC 100 MICRO SEC. -3.3 24VAC SEC. 42VAC AT 10 AMPS 115VAC AT 15* AMPS

OPEN CIRCUIT VOLTAGE PROCESS CURRENT RANGE (DC) CURRENT

30-76 MIG/MAG 50-570 Average Amps 76 FCAW 40-570 Average Amps 76 SMAW 55-570 Average Amps 18-76 GTAW 5-570 Average Amps 76 Pulse 5-750 Peak Amps

RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT

INPUT TYPE 75°C TYPE 75°C TYPE 75°C VOLTAGE / COPPER WIRE IN GROUND WIRE IN (SUPER LAG) FREQUENCY CONDUIT AWG(MM2) CONDUIT AWG(MM2) OR BREAKER SIZES SIZES SIZE (AMPS) 208/50/60HZ 4(25) 8(10) 100 230/50/60HZ 4(25) 8(10) 100 460/50/60HZ 8(10) 10(6) 50 575/50/60HZ 10(6) 10(6) 40

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT 26.10 in 19.86 in 32.88 in 293 lbs. 663 mm 505 mm 835 mm 133 kg.

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE -20°C to +40°C -40°C to +40°C * Earlier models used 10 amps circuit breaker., A-3 INSTALLATION A-3

SAFETY PRECAUTIONS LIFTING Read this entire installation section before you Lift the machine by the lift bail only. The lift bail is

start installation. designed to lift the power source only. Do not attempt to lift the V450-PRO with accessories attached to it.

WARNING STACKING

V450-PRO machines can be stacked to a maximum of ELECTRIC SHOCK can kill. 3 high. • Only qualified personnel should perform this installation. • Turn the input power OFF at the CAUTION disconnect switch or fuse box before working on this equipment. Turn off the input The bottom machine must always be placed on a power to any other equipment connected to the firm, secure, level surface. There is a danger of welding system at the disconnect switch or fuse machines toppling over if this precaution is not box before working on the equipment. taken. • Do not touch electrically hot parts. • Always connect the V450-PRO grounding lug (located inside the reconnect input access door) MACHINE GROUNDING to a proper safety (Earth) ground. The frame of the welder must be grounded. A ground -

SELECT SUITABLE LOCATION terminal marked with the symbol is located inside

the reconnect/input access door for this purpose. See Do not use the Invertec® in outdoor environments with- your local and national electrical codes for proper out appropriate protection. The V450-PRO power grounding methods. source should not be subjected to falling water, nor should any parts of it be submerged in water. Doing so HIGH FREQUENCY PROTECTION may cause improper operation as well as pose a safe- Locate the V450-PRO away from radio controlled ty hazard. The best practice is to keep the machine in a machinery. dry, sheltered area.

WARNING CAUTION

The normal operation of the V450-PRO may Do not mount the V450-PRO over combustible sur- adversely affect the operation of RF controlled faces. Where there is a combustible surface direct- equipment, which may result in bodily injury or ly under stationary or fixed electrical equipment, damage to the equipment. that surface shall be covered with a steel plate at least .060" (1.6mm) thick, which shall extend not less than 5.90" (150mm) beyond the equipment on all sides. INPUT CONNECTION -

WARNING

Place the welder where clean cooling air can freely cir- culate in through the rear louvers and out through the Only a qualified electrician should connect the case sides and bottom. Water, Dirt, dust, or any foreign input leads to the V450-PRO. Connections should material that can be drawn into the welder should be be made in accordance with all local and national kept at a minimum. Failure to observe these precau- electrical codes and the connection diagram locat- tions can result in excessive operating temperatures ed on the inside of the reconnect/input access and nuisance shutdowns. door of the machine. Failure to do so may result in bodily injury or death. Machines are equipped with F.A.N. (fan as needed) cir- cuitry. The fan runs whenever the output is enabled, - whether under loaded or open circuit conditions. The fan also runs for a period of time (approximately 5 min- Use a three-phase supply line. A 1.75 inch (45 mm) utes) after the output is disabled, to ensure all compo- diameter access hole for the input supply is located on nents are properly cooled. the upper left case back next to the input access door. Connect L1, L2, L3 and ground according to the Input If desired, the F.A.N. feature can be disabled (causing Supply Connection Diagram decal located on the the fan to run whenever the power source is on). To dis- inside of the input access door or refer to Figure A.1 on able F.A.N., connect leads 444 and X3A together at the the following page. output of the solid state fan control relay, located on the back of the Control PC board enclosure. (See Wiring Diagram), A-4 INSTALLATION A-4 FIGURE A.1 - CONNECTION DIAGRAM ON CONNECTION/INPUT ACCESS DOOR

ET545 H

400-547650VV 545400-547650VV 545400-547650VV ICO NL

AX

220-230V 'A' 220-230V 'A' 220-230V 'A' LE NL

CAN KILVLOLT

usAeG oE 0=0 2-22008-2V30V VOLTAG2E0=0 -424008-V460V VOLTAG2E0=0 -525008-V575V CTEC IOCR

E SLHECOTCRKIC .O.. DrDeoo

nm ly nno oo qrtustaoervice tvte odp. luicehdera te p ele hecirsst roe withic nqasu col ilspyh mloiveuenl dtp. ainrststa. ll, . inspecting o vers 545400-575V

CL

. Disconnect -460V

E

'A' AEDNVL

INPUT SUPPLY CONW

irn spAeurtv picoinwge rm bacehfoinree. U / L1 CR1 220-230V ,OHNECRTINOINN DGIAGRAM WV // LL32 VOLTAG2E0=0 -220008-V208V . A..SU

OI 95S218 INPUT SUPPLY CONNECTION DIAGRAM VOLTAGE = 200-208V W / L3 WARNING V / L2 CR1 200-208V. Disconnect input power before

220-230V inspecting or servicing machine. U / L1 . 'A'Do not operate with covers 440-460V removed.550-575VELECTRIC Do not touch electrically live parts.

SHOCK Only qualied persons should install, CAN KILL use or s ervice this equipment. VOLTAGE= 220-230V VOLTAGE = 440-460V VOLTAGE= 550-575V

200-208V 200-208V 200-208V 220-230V 220-230V 220-230V 'A' 'A' 'A' 440-460V 440-460V 440-460V 550-575V 550-575V 550-575V NOTE: Turn main input power to the machine OFF before performing connection procedure. Failure to do so will result in damage to the machine. INPUT FUSE AND SUPPLY WIRE ELECTRODE AND WORK CABLE CONSIDERATIONS CONNECTIONS Refer to the Technical Specifications at the beginning Connect a work lead of sufficient size and length (Per of this Installation section for recommended fuse and Table 1) between the proper output terminal on the wire sizes. Fuse the input circuit with the recommend- power source and the work. Be sure the connection to ed super lag fuse or delay type breakers (also called the work makes tight metal-to-metal electrical contact. “inverse time” or “thermal/magnetic” circuit breakers). To avoid interference problems with other equipment Choose an input and grounding wire size according to and to achieve the best possible operation, route all local or national electrical codes. Using fuses or circuit cables directly to the work and wire feeder. Avoid breakers smaller than recommended may result in excessive lengths and do not coil excess cable. “nuisance” shut-offs from welder inrush currents, even if the machine is not being used at high currents. Minimum work and electrode cable sizes are as follows: TABLE A.1 INPUT VOLTAGE CHANGE OVER (FOR (Current (60% Duty Cycle) MINIMUM COPPER MULTIPLE INPUT VOLTAGE WORK CABLE SIZE AWG MACHINES ONLY) Up To-100 Ft. Length (30 m) 400 Amps 2/0 (67 mm2) Welders are shipped connected for the highest input 500 Amps 3/0 (85 mm2) voltage listed on the rating plate. To move this connec- 600 Amps 3/0 (85 mm2) tion to a different input voltage, see the diagram locat- ed on the inside of the input access door. If the main reconnect switch or link position is placed in the wrong NOTE: K1796 coaxial welding cable is recommended position, the welder will not produce output power. to reduce the cable inductance in long cable lengths. This is especially important when Pulse welding up to If the Auxiliary (A) lead is placed in the wrong position, 350 amps. there are two possible results. If the lead is placed in a CAUTION position higher than the applied line voltage, the welder may not come on at all. If the Auxiliary (A) lead is When using inverter type power sources like the placed in a position lower than the applied line voltage, V450-PRO, use the largest welding (electrode and the welder will not come on, and the two circuit break- work) cables that are practical. At least 2/0 (67 ers or fuses in the reconnect area will open. If this mm2) copper wire - even if the average output cur- occurs, turn off the input voltage, properly connect the rent would not normally require it. When pulsing, (A) lead, reset the breakers, and try again. For the pulse current can reach very high levels. machines equipped with a fuse in the reconnect area, Voltage drops can become excessive, leading to turn off the input voltage and replace the fuse with the poor welding characteristics, if undersized welding spare fuse that is attached to the reconnect switch pin. cables are used. -

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. XA S25198

., A-5 INSTALLATION A-5 CABLE INDUCTANCE, AND ITS EFFECTS For additional Safety information regarding the elec- ON PULSE WELDING trode and work cable set-up, See the standard "SAFE- TY INFORMATION" located in the front of the For Pulse Welding processes, cable inductance will Instruction Manuals. cause the welding performance to degrade. For the total welding loop length less than 50 ft.(15.24m), tradi- CAUTION tional welding cables may be used without any effects on welding performance. For the total welding loop Excessive voltage drops caused by poor work length greater than 50 ft. (15.24m), the K1796 Coaxial piece connections often result in unsatisfactory Welding Cables are recommended. The welding loop welding performance. length is defined as the total of electrode cable length - (A) + work cable length (B) + work length (C) (See Figure A.2). NEGATIVE ELECTRODE POLARITY

B WORK C V450-PRO A FIGURE A.2 FIGURE A.2 When negative electrode polarity is required, such as in

some Innershield applications, switch the output con-

V450-PRO

nections at the power source (electrode cable to the

A

negative (-) stud, and work cable to the positive (+)

C stud. WORK B

For long work piece lengths, a sliding ground should be considered to keep the total welding loop length less than 50 ft.(15.24m). (See Figure A.3.)

OCAFB OLUETER JACKET OF K1796 COAXIAL CABLMEEASURE FROM END BSLIDING WORK B C WORK C V450-PRO FIGURE A.3 A A FIGURE A.3 V450-PRO A A C WORK C B B SLIDING WORK K1796 COAXIAL CABLE MEASURE FROM END OF OUTER JACKET OF CABLE

Output connections on some V450-PRO are made via 1/2-13 threaded output studs located beneath the spring-loaded output cover at the bottom of the case front. Most welding applications run with the electrode being positive (+). For those applications, connect the elec- trode cable between the wire feeder and the positive (+) output stud on the power source (located beneath the spring loaded output cover near the bottom of the case front). Connect the other end of the electrode cable to the wire drive feed plate. The electrode cable lug must be against the feed plate. Be sure the con- nection to the feed plate makes tight metal-to-metal electrical contact. The electrode cable should be sized according to the specifications given in the work cable connections section. Connect a work lead from the negative (-) power source output stud to the work piece. The work piece connection must be firm and secure, especially if pulse welding is planned., A-6 INSTALLATION A-6 CONNECTIONS OF WIRE FEEDERS TO V450-PRO LN-15 Connection Instructions (See Figure A.4) LF-72, 74 Connection Instructions • Turn the Invertec® power switch "off". • Turn the Invertec® power switch "off". • Connect the electrode cable to the output terminal of polar- • Connect the K1797-[ ] control cable from the LF-72, 74 ity required by electrode. (See Figures below) to the 14-pin MS-style connector. • Set the meter polarity switch on the front of the Invertec® • Connect the electrode cable to the output terminal of the to coincide with wire feeder polarity used. polarity required by electrode. Connect the work lead to the other terminal. LN-25 Connection Instructions • If a remote control such as K857 is to be used with the • Turn the Invertec® power switch "off". LF-72, 74 the remote can be connected directly to the 6- • Connect the electrode cable to the output terminal of polar- pin MS-style connector on the front of the Invertec® or ity required by electrode. Connect the work lead to the use a K864 adapter to connect the LF-72, 74 and the other terminal. remote to the 14-pin MS-style connector. • LN-25 with Remote Control 6-Pin (K444-1) and 14-pin (K444-2) remotes can be connected directly to the 6-pin & LN-10, DH-10 Connection Instructions 14-pin MS-style connectors. The 42 Volt Remote Voltage • Turn the Invertec® power switch "off" and Output Control (K624-1) Kit can be connected to the • Connect the K1505 control cable from the LN-10 to the V450’s 14-pin MS-style connector using Remote Control 14-pin MS-style connector. Cable assembly K627- [ ]. LN-25s with a K431-1 remote kit • Connect the electrode cable to the output terminal of can be connected to the V450’s 14-pin MS-style connector polarity required by the electrode. Connect the work lead using a K432 cable and K876 adapter. (See connection to the other terminal. diagram S19899). Or the K432 cable could be modified • Set the meter polarity switch on the front of the Invertec® with a K867 Universal Adapter Plug (See connection dia- to coincide with wire feeder polarity used. gram S19405) to connect it to the V450’s 14-pin MS-style • See the LN-10 manual for details on accessing Control connector. DIP Switch. Dip Switches for the V350 and the same set- tings may be used for the V450. FIGURE A.4 14-SPTINUD ELECTRODE CABLE K1871-1 MODEL

V450-PRO CK1O8N1T9R-1O0L CABLE LSWNEIR-M1EI5A FUETEODMEARTIC AACONROL CABLE MODEL M SNASDGE NCMUABMBLL YGEUN

14-SPTINUD SK“OW8E4NLI8T”E C JPCTRODE CABLE

WORK CLAMP V450-PRO AOPLUOWTWPAEUYRHUO M KW1S IR T SMSTHOPEIOUTEURSTIORRM.T NC IPBN ELOEA UCR LIGNO SU NKTSTHIETAE. AC TOR LSNE-M1

7EI50A F-U1ETEODMEARTIC MAANSASDGE CMABBLLYEACROSS THE ARC MODEL NUM GUN

ACROSS THE ARC MODEL V450-PRO OUTPUT TERMINALS ALWAYS HOT. POWER SOURCE CONTACTOR SWITCH MUST BE IN THE MAGNUM GUN

“ON” POSITION OR USE A LN-15 AND CABLE

K848 JUMPER PLUG KIT. SEMIAUTOMATIC ASSEMBLY

14-PIN WIRE FEEDER

K1870-1 STUD ELECTRODE CABLE WORK CLAMP CONROL CABLE MODEL V450-PRO MAGNUM GUN LN-15 AND CABLE K1819-10 SEMIAUTOMATIC ASSEMBLY CONTROL CABLE

14-PIN WIRE FEEDER

K1871-1 MODEL STUD ELECTRODE CABLE

, A-7 INSTALLATION A-7 LN-742 Connection Instructions General Instructions for Connection of Wire • Turn the Invertec® power switch "off" Feeders to V450-Pro • A K1819-1 Input cable assembly is required to con- Wire feeders other than those listed above may be nect the LN-742 to the Invertec®. used provided that the auxiliary power supply rating of • Connect the control cable from the LN-742 to the the V450-Pro is not exceeded and the V450-PRO out- 14-pin MS-style connector. put is not actively controlled by the wire feeder. (Like • Connect the electrode cable to the output terminal an LN-9). K867 universal adapter plug is required. See of the polarity required by electrode. Connect the connection diagram S24985 in Operator Manual. work lead to the other terminal. • Set the meter polarity switch on the front of the REMOTE CONTROL OF INVERTEC® Invertec® to coincide with wire feeder polarity used. Remote Control K857, Hand Amptrol K963 and Foot The wire feeder will now display the welding volt- Amptrol K870 may be used. age. • If a remote control such as K857 is to be used with the PARALLEL OPERATION LN-742, the remote can be connected directly to the 6-pin The V450-Pro are operable in parallel in CC mode. For MS-style connector on the front of the Invertec® or use a best results, the currents of each machine should be K864 adapter to connect the LN-742 and the remote to reasonably equally balanced. As an example, with two the 14-pin MS-style connector. machines set up in parallel for a 800 amps procedure, each machine should be set to deliver approximately Cobramatic Connection Instructions 400 amps, not 450 amps from one and 350 amps from • Turn the Invertec® power switch "off" the other. This will minimize nuisance shutdown condi- • Connect the control cable from the Cobramatic to tions. In general, more than two machines in parallel the 14-pin MS-style connector. will not be effective due to the voltage requirements of • Connect the electrode cable to the output terminal procedures in that power range. of the polarity required by electrode. Connect the work lead to the other terminal. To set machine outputs, start with output control pots • Set the meter polarity switch on the front of the and arc control pots in identical positions. Use the out- Invertec® to coincide with wire feeder polarity used. put control pots to balance the currents and maintain • If a remote control such as K857 is to be used with the desired current. The arc control pots should be the Cobramatic, the remote can be connected kept identical on the two machines. directly to the 6-pin MS-style connector on the front of the Invertec® or use a K864 adapter to connect the cobramatic and the remote to the 14-pin MS- style connector. TIG Module K930-2 The TIG Module connects to the Factory and Advanced Process V450-Pro versions with a K936-1 (9-14 pin) control cable. Connect the K936-1 to the 14-Pin MS- style connector., A-8 NOTES A-8, B-1 TABLE OF CONTENTS - OPERATION SECTION B-1 Operation ..B-1 Safety Precautions ..B-2 General Description ..B-2 Case Front Controls ..B-2 Hidden Middle Control Panel ..B-3 TIG GTAW ..B-4 CV-Innershield ..B-4 Weld Mode Select ..B-5 Memory Selections ..B-6 Weld Mode Details ..B-7 Pulse Programs ..B-8 Remote Control Selection ..B-9 Limitations ..B-10, B-2 OPERATION B-2

SAFETY PRECAUTIONS • After welding, the meter holds the actual current

value for 5 seconds. Output adjustment while in the

WARNING "hold" period results in the "prior to operation" char-

ELECTRIC SHOCK can kill. acteristics stated above. The displays blink indicat- • Do not touch electrically live parts or ing that the machine is in the "Hold" period. electrode with skin or wet clothing. • Insulate yourself from work and 3. VOLT METER ground. • Prior to CV operation (current flow), the meter dis- • Always wear dry insulating gloves. plays desired preset voltage value (+/- .5V). - • Prior to STICK or TIG operation, the meter displays FUMES AND GASES can be dangerous. the Open Circuit Voltage of the Power Source or four • Keep your head out of fumes. dashes if the output has not been turned on. • Use ventilation or exhaust to remove • During welding, this meter displays actual average fumes from breathing zone. volts. - • After welding, the meter holds the actual voltage - value for 5 seconds. The displays blink indicating WELDING SPARKS can cause fire or that the machine is in the "Hold" period. explosion. • Output adjustment while in the "hold" period results • Keep flammable material away. in the "prior to operation" characteristics stated • Do not weld on closed containers. above. - 4. OUTPUT CONTROL ARC RAYS can burn eyes and skin. • Output control is conducted via a single turn poten- • Wear eye, ear and body tiometer. protection. • Adjustment is indicated by the meters as stated above. - • When in TIG modes, this control sets the maximum welding current. Full depression of a foot or hand

See additional warning information at Amptrol results in the preset level of current.

front of this operator’s manual. - 5. WELD TERMINALS-REMOTE / ON • Two status lights indicate the location of trigger con-

GENERAL DESCRIPTION trol as determined by the "WELD TERMINALS" push

The Invertec® V450-Pro offers multi-process CV, CC, button. and DC welding and is rated 570 amps, 43 volts at a • If trigger control is local "weld terminals on", the ON 60% duty cycle. display will be lit. DUTY CYCLE • If trigger control is remote "weld terminals remotely controlled", the REMOTE display will be lit. The V450-Pro is rated at 570 amps, 60% duty cycle • The unit will power up in "pre-determined preferred" (based on a 10 minute cycle). It is also rated at 450 trigger modes. amps, 100% duty cycle. STICK = ON OPERATIONAL FEATURES and CONTROLS: CV = REMOTE UPPER CONTROL PANEL TIG = REMOTE if remote output controls are attached 1. ON, OFF- SWITCH to the machine. 2. AMPS Meter TIG = ON if remote output controls are not attached to the machine. • Prior to STICK or TIG operation (current flow), the meter displays preset current value (either +/- 2 For all versions, these trigger modes can be over-ridden amps or +/- 3% (e.g. 3 amps on 100), whichever is (switched) with the WELD TERMINALS push button. When greater). changed, the unit will power up in the configuration it was in • Prior to CV operation, the meter displays four dash- es indicating AMPS unable to be preset. • During welding, this meter displays actual average amps., B-3 OPERATION B-3 6. THERMAL CC-STICK SOFT: The Stick Soft process features contin- • This status light indicates when the power source has been uous control ranging from 5 to 570 amps. This mode was driven into thermal overload. If the output terminals were intended for most SMAW applications, and Arc Gouging. "ON", the "ON" light will blink indicating that the output will be turned back on once the unit cools down to an accept- • Arc Gouging: Setting the output of the Stick Soft able temperature level. If the unit was operating in the mode to 570 amps or setting the arc control to maxi- "REMOTE" mode, the trigger will need to be opened mum will enable the arc-gouging mode. The actual out- before or after the thermal has cleared and closed after the put current will depend on the size of carbon used. The machine has cooled down to an acceptable temperature to recommended maximum size carbon is 3/8"(9.5mm). establish output. • The Hot Start control regulates the starting current at arc initiation. Hot Start can be adjusted from minimum 7. CONTROL-REMOTE / LOCAL (0), with no additional current added at arc start, to • Two status lights indicate the location of output control as maximum (10), with double the preset current or 570 pre-determined by the power sources auto-configure sys- amps (max of machine) added for the first second after tem. arc initiation. • The LOCAL display will be lit when control is at the power • The Arc Control regulates the Arc Force to adjust the source. short circuit current. The minimum setting (-10) will pro- • The REMOTE display will be lit when a remote pot/control duce a "soft" arc and will produce minimal spatter. The is detected. maximum setting (+10) will produce a "crisp" arc and These Output Control configurations can be overridden will minimize electrode sticking. (switched) with the CONTROL push button. When changed, the unit will power up in the configuration it was in when it CC-STICK CRISP:The Stick Crisp mode features contin- was last powered down. uous control from 5 to 570 amps with a crisp shorting response optimized for E6010 type electrodes. Hidden Middle Control Panel – Process Set Up • Arc Gouging: Setting the output of the Crisp mode to Panel 570 amps or setting the arc control to maximum will enable the arc-gouging mode. The actual output cur- The middle control panel is removable to allow for rent will depend on the size of carbon used. The rec- upgrades (see Field Installed Options/Accessories). ommended maximum size carbon is 3/8"(9.5mm). Additionally, this panel is hidden by an access door to provide protection to the controls. • The Hot Start control regulates the starting current at arc initiation. Hot Start can adjust starting current up or 8. WELD MODE SELECT - STANDARD (See down by 25% of the preset value. The recommended Figure B.1) setting for Hot Start is 5 where the initial current is The Mode Control button selects from the following equal to the preset current. welding modes.

FIGURE B.1 CSOELECT

TSTOITGAURCTH TIGLOCAL HI-FREQ SOFT CRIP NTROLREMOTE AMPS OUTPVUTOLTS

AMPS VOLTS

CONTROL OUTPUT

REMOTE

LOCAL 1

SELECT

8 TOUCHSTART HI-FREQTIG TIG SOFT CRIP 13 12 14 11, B-4 OPERATION B-4 • The Arc Control regulates the Arc Force to adjust the CV-WIRE: The CV-WIRE mode features continuous short circuit current. The minimum setting (-10) will control from 10 to 40 volts. This mode was intended for produce a "soft" arc and will produce minimal spat- most GMAW, FCAW, and MCAW applications. ter. The maximum setting (+10) will produce a "crisp" arc and will minimize electrode sticking. • The Hot Start control is not used in the CV-WIRE mode. TIG GTAW: The TIG mode features continuous control from 5 to 570 amps. The TIG mode can be run in either • The Arc Control regulates pinch effect. At the mini- the TIG touch start or high frequency (optional equip- mum setting (-10), minimizes pinch and results in a ment required) assisted start mode. soft arc. Low pinch settings are preferable for weld- • The Hot Start control selects the starting mode ing with gas mixes containing mostly inert gases. At desired. A setting of less than 5, the TIG lift start the maximum setting (+10), maximizes pinch effect mode is selected. The OCV is controlled below 10v and results in a crisp arc. High pinch settings are and the short circuit "TIG touch" current is main- preferable for welding FCAW and GMAW with CO2. tained at 25 amps independent of the preset current. CV-INNERSHIELD: The CV-INNERSHIELD mode When the tungsten is lifted, an arc is initiated and features continuous control from 10 to 45 volts. This the output is regulated at the preset value. Hot start mode was designed for self-shielded flux cored wires settings between 0 and 5 regulate the arc initiation that require tight voltage control. current. A setting of 5 results in the most positive arc initiation. A setting of 0 reduces hot start. • The Hot Start control is not used in the CV-INNER- SHIELD mode. • Hot Start settings between 5 and 10, select high fre- quency assisted starting TIG mode. In this range, the OCV of the machine is controlled between 50 • The Arc Control regulates pinch effect. At the mini- and 70 volts. If using the Lincoln K930-1 TIG mum setting (-10), minimizes pinch and results in a Module, set the Hot start to 10 for maximum OCV. soft arc. At the maximum setting (+10), maximizes pinch effect and results in a crisp arc. Most self-shield- • The Arc Control is not used in the TIG mode. ed wires work well at an Arc Control setting of 5.,

B-5 OPERATION B-5

8A. WELD MODE SELECT-FOR • Gouge Mode

MACHINES EQUIPPED WITH OPTIONAL The gouging mode is specifically designed for car- ADVANCED PROCESS PANEL bon arc gouging with electrodes up to 3/8”.

(See Figure B.2 UPPER AND MIDDLE SECTION) • Pulsed Modes

See (WELD MODE DETAILS) in this section. In Pulse Modes; The work point will be in the Amps window and To program welding modes, the SELECT knob is used should be set close to the wire feed speed of the

to Scroll through all welding modes. The MEMORY wire feeder in inches per minute. The Volts window button is used to store and access welding modes into will have SPd displayed indicating Wire Feed locations M1 thru M8. Speed. Once current starts flowing and during the 5 second “Hold” feature the displays will show amps

Modes: and volts. In addition to the 5 welding modes described in SEC- TION 7, the Advance Process Panel allows you to Pulse Mode features that are displayed while selecting

select the Following additional modes. a Welding pulse mode are listed below:

Steel - .030”, .035”, .045”, .052”, 1/16” – Argon Blends

• Constant Power mode Stainless Steel - .030”, .035”, .045” – Argon Blends &

In the Power Mode; Helium/Argon Blends The work point will be in the Volts window. The Amp Aluminum - .035”, 3/64”, 1/16” – 4043 & 5356

window will have CP displayed indicating Constant Metal Core - .045”, .052”, 1/16” – Argon Blends

Power. Once current starts flowing and during the 5 Nickel - .035”, .045” – Argon/Helium blends

second “Hold” feature the displays will show Volts and Amps respectively.

FIGURE B.2

(SCOALDVANCE PROCESS PANEL- MIDDLE SECTION OF WELDER (OPTIONAL) M(ME1MTOHRRLSUWM SE8E)LLDEICNG PROCESSES) (SHEOLTE CSTT ABRUTT T OORN ARC CONTROL) Y BUTTONT KNOB ( - 10THRU( 00TAHNARDDU J 0+U 1TS0HT R KHUNO +OT1B S0 T AARRTC) CONTROL) MEMORY SELECT SELECT ADJUST OUTPUT KNOB CSOENLTERCOTLRLEOMCOATLE REOMNOTE SELECTAMPS VOLTS WELD TERMINALS AMPS VOLTS OUTPUT KNOB CONTROL WELD TERMINALS REMOTE REMOTE LOCAL ON

SELECT SELECT

MEMORY SELECT SELECT ADJUST ADJUST KNOB MEMORY BUTTON (0 THRU +10 HOT START) (M1 THRU M8) (-10 THRU 0 AND 0 THRU +10 ARC CONTROL) SELECT KNOB (SCOLLS WELDING PROCESSES) SELECT BUTTON (HOT START OR ARC CONTROL) ADVANCE PROCESS PANEL- MIDDLE SECTION OF WELDER (OPTIONAL), B-6 OPERATION B-6

MEMORY SELECTIONS:

(See Figure B.2 for location of controls) The MEMORY button and SELECT knob are used 4. Start welding. If the arc length is too short, turn the together to select a welding process and store it in Output knob up. If the arc length is too long, turn memory (M1 thru M8). The SELECT knob scrolls the Output knob down. through the welding process modes and memory M1 thru M8. The MEMORY button stores the welding The Arc Control, which is displayed in the right digi- process in memory. tal window, can be used to fine-tune the arc length and characteristics. • SELECT button" (The right button) selects between the "Hot Start" or "Arc Control". The < will indicate the 5. After all adjustments have been made press and active feature shown below. hold the MEMORY button until the display changes. Right Digital Window The right and the left window will display a memory "Hot Start" (-10 to 0 +10) position, for example M1 (or turn knob to select "Arc Control" (0 to 10) < memory of your choice). To store in M1, push the • The ADJUST knob adjusts the desired settings for MEMORY button again to save the Pulse Mig mode the Hot Start or Arc Control feature that is active. to memory M1. WELDING PROCESS MODES AVAILABLE 6. The display in the digital windows read as follows: M1 Pulse MIG Argon Blends Stick SMAW, TIG GTAW Steel .035 Arc Cntrl 1.2 Gouge CAG, CV MIG GMAW CV Flux Core, Pulse MIG 7. To save a second welding mode to a memory posi- tion of your choice, turn the SELECT knob until the ELECTRODE MATERIAL desired welding process mode is displayed in right digital window. Then follow steps 2 thru 6. Steel, Metal Core, Stainless, Aluminum, Nickel 8. Adjust the output control to the correct wire feed set- EXAMPLE OF SAVING WELDING MODES TO MEM- ting and the V450-PRO is ready to weld again. ORY (NOTE: The wire feed speed setting is not stored in memory and will need to be reset.) The following example is how to select Pulse MIG using .035 steel and store it into memory. 9. Adjust the Arc Control and note that the M1 goes away indicating that the V450-PRO settings no 1. Turn the SELECT knob until welding process is dis- longer match what is stored in memory. Going back played. to the original settings will not bring the M1 back. RIGHT WINDOW LEFT WINDOW You will need to push the MEMORY button to recall Pulse MIG Argon Blends the original settings in M1. Steel .035 NOTE: After all memory; M1 thru M8, are used and the 2. Wait two seconds and the right window will display welder needs to store another welding process, a new Arc Control on the second line on the right side. welding process will overwrite what was originally in Pulse MIG Argon Blends the memory and will read: Steel .035 Arc Cntrl ### < Save to MEM M1 Overwrite 3. SPd is displayed in the upper right Volts window. M1, which previously stored Pulse Mig, is now over- The left Amps window matches the desired wire written with the new welding process. feed speed that is set on the wire feeder. Adjust the OUTPUT knob until desired number is displayed., B-7 OPERATION B-7

WELD MODE DETAILS:

Mode Range Comments Stick Soft 55 - 570 amps The stick soft mode is the best selection for general stick applications. Arc Control = Arc Force Hot Start = Initial hot start current (min = start a match set amps, Max. = greatest hot start current) During hot start, arc force is set at high and is fast response. For gouging applications: Turn current up to 570 amps. Stick Crisp 55 - 570 amps The stick crisp mode features an aggressive arc force routine well suit- ed for Exx10, Exx11 series electrodes. Arc Control = Arc Force Hot Start = Initial hot start current (Mid range = welding current and will vary up and down with knob control.) During hot start, arc force is set at high and is fast response. For gouging applications: Turn current up to 570 amps. GTAW (Tig mode) 5 - 570 amps The tig mode produces a soft, steady constant current waveform for either touch start or high frequency assisted start DC GTAW applica- tions. Hot Start = Min to Mid range = Touch start with low OCV Mid to Max range = High frequency assisted starting with adjustable OCV up to 70 volts. GMAW - CV 10 - 45 volts The GMAW - CV mode is the best selection for general MIG welding, Metal core, and gas shielded applications. Arc Control = Pinch (Min = min pinch, softest arc), (Max = max pinch, crispest arc) FCAW-SS 10 - 45 volts The FCAW-SS mode is designed for Self Shielded Innershield products that require tight voltage control. For example; the NR 203 series or NR 207) Arc Control = Pinch (Min = min pinch, softest arc), (Max = max pinch, crispest arc) ADVANCED PULSE PANEL WELDING PROGRAMS Gouging 60 - 570 amps The gouging mode is specifically designed for carbon arc gouging with electrodes up to 3/8”. GMAW - Power 0.1 - 20 KW The GMAW - power mode is similar in operation to other GMAW modes. The power mode features a very stable short arc performance, which is especially good when welding small diameter (.025 and .030 steel and stainless) wires for low procedures. The short arc steel and stainless applications, a fast response for spray applications, and a drooper type spray mode characteristic for Aluminum., B-8 OPERATION B-8

PULSE PROGRAMS:

MODE IPM* COMMENTS .030 Steel 75 - 800 The V450 pulse programs are non-synergic and allow independent .035 Steel 50 - 800 control of the wire feed speed and the arc length. The Output .045 Steel 60 - 800 Control Knob on the V450, adjusts an "SPD" value. Similar to trim, .052 Steel 60 - 750 the "SPD" value indicates the relative arc length setting. The value 1/16 Steel 60 - 600 of "SPD" is meant to be a starting point at which to set the arc .045 Metal Core 60 - 700 length relative to the wire feed speed. Depending on the applica- .052 Metal Core 60 - 500 tion, the "SPD" value can be adjusted to obtain the desired arc 1/16 Metal Core 60 - 500 length. .030 Stainless Ar Blends 100 - 800 .030 Stainless He Ar CO2 100 - 800 The "SPD" value displayed on the V450 may not match the .035 Stainless Ar Blends 70 - 800 actual wire feed speed! .035 Stainless He Ar CO2 70 - 700 .045 Stainless Ar Blends 50 - 700 The operation of the Arc Control knob on the V450 is similar to the .045 Stainless He Ar CO 60 - 700 Power Wave series. As Arc Control is increased, the frequency is2 increased and the background reduced. Decreasing Arc Control will .035 Aluminum 4043 125 - 700 reduce frequency and increase background current. Arc Control .035 Aluminum 5356 130 - 750 acts to fine tune the arc plasma to the specific application. 3/64 Aluminum 4043 85 - 600 Preferred gas selections: 3/64 Aluminum 5356 85 - 700 1/16 Aluminum 4043 55 - 300 Steel Argon Blends = Argon with CO2 additions from 2 to 201/16 Aluminum 5356 65 - 400 % or Oxygen additions from 2 to 5%. Stainless Argon Blends = Argon with Oxygen additions up to 2%. Stainless He Ar CO2 = ~ 90% Helium, 7 1/2 % Argon 2 1/2 CO2 Aluminum 100% Argon The Nickel Alloy pulse programs are non adaptive. The operator sets the output control knob to deliver the correct arc length at the desired wire feed speed and stick out. While welding, the operator .035 Nickel Alloys (Non Adaptive) 60 - 700 manipulates the stick out to maintain the correct arc length. This .045 Nickel Alloys (Non Adaptive) 60 - 600 method of operation produces very stable arc performance consid- ering the nature of nickel alloys. Preferred gas: Argon/Helium Blends = for the best results add helium to the argon base from 0-25%.

PULSE ON PULSE

.035 4043 (4x Pulse on Pulse) 125 - 600 Arc Control = Pulse on Pulse frequency. For faster travel 3/64 4043 (4x Pulse on Pulse) 85 - 400 speed welds, the arc control should be increased. 1/16 4043 (4x Pulse on Pulse) 65 - 315 For larger puddle, slower travel speeds, the arc control .035 5356 (5x Pulse on Pulse) 140 - 700 should be decreased. 3/64 5356 (5x Pulse on Pulse) 100 - 550 1/16 5356 (5x Pulse on Pulse) 75 - 360 *IPM (INCHES PER MINUTE), B-9 OPERATION B-9 LN-10/DH-10 Wire Feeder Compatibility Note: TIG Mode The LN-10 and DH-10 feeders can be used to pulse weld and • The remote will default to the 6-pin MS-style if a in the power mode with the panel. The displays on the LN-10 remote control is connected to the 6-pin MS-style & DH-10 do not show the wire feed speed or power. and to the 14-pin MS-style connector. If a remote is not connected to the 6-pin MS-style connector, then the remote will default to the 14-pin MS-style con- 9. SERIAL PORT FOR SOFTWARE UPDATES nector if a remote is connected. • If a remote control is connected to any of the MS- 10. HOT START and ARC CONTROL features have different style connectors, the WELD TERMINAL control will default to REMOTE. If there are not any remote con- functions depending on the welding Mode that is active. Each ( trol devices attached, the WELD TERMINAL controlfeature is described under the welding mode heading. See will default to ON. Item 8 or 8A for specified Mode Operations) (See Figure B.1 or B.2) CC-Stick Modes LOWER CASE PANEL (See Figure B.1) • The remote will default to only the 6-pin MS-style The output studs, Meter Polarity switch and remote connector connector if a remote is connected to it. are located on the lower case front. • The WELD TERMINAL control will default to ON with or without a remote connected. 11. Both Output terminals are "STUD" connectors. Types of Remote OUTPUT CONTROL 12. The METER POLARITY switch is located above the out- • The Invertec® V450-Pro’s Output Control can be put connectors. The switch provides a work connection for controlled by either a potentiometer connected wire feeder voltmeters. Place the switch in the position of between 77 & 75 with the wiper connected to 76 or a the electrode polarity indicated by the decal. The switch 0V to 10V DC supply connected between 76 & 75. does not change the welding polarity. (76 needs to be positive) • 14-Pin Ms-style connector lead 75 is pin G, lead 76 13. 6-pin MS-style connector for remote control. is pin F and lead 77 is pin E. • 6-Pin Ms-style connector lead 75 is pin C, lead 76 is 14. 14-PIN MS-style connector for wire and remote control. pin B and lead 77 is pin A. 15. AUXILIARY POWER Potentiometer Control • 115VAC, 42VAC and 24VAC power is available from the • The total resistance should be between 2,000 ohms 14-pin MS-style connector. (2K) and 10,000 ohms (10K) • 42 VAC supply is rated at 10 amps. • The machine output will be at minimum when lead • 24 VAC supply is rated at 10 amps. 76 (wiper) is at the end of the potentiometer that is • 115VAC outlet rated at 15* amps. connected to 75. The machine’s output will increase as the wiper of the potentiometer is moved to the end * Earlier models used a 10 amp circuit breaker. that is connected to 77. (Note: In TIG mode, moving the lead 76 (wiper) to lead 77 would produce the cur- REMOTE CONTROL SELECTION rent that has been set by the Invertec® V450-Pro’s front panel Output Control.) The Invertec® V450-Pro has auto sensing of remote output • Remotes of this type offered by Lincoln Electric are controls. If after connecting or removing a remote, the the K857, K812 and K870. Invertec® V450-Pro did not configure the way you would like the local or remote control settings can be changed by push- Voltage Control ing the OUTPUT CONTROL or WELD TERMINAL button. (A • The supply should be an isolated supply. (Not refer- user cannot select between the 6 and 14 pin MS-style con- enced to earth ground, any auxiliary power from the nectors.) Invertec® V450-Pro or the welding output) The sup- ply should be capable of supplying at least 20mA. CV modes • 0 volts supplied to 76 will set the Invertec® V450-Pro • The remote will default to the 14-pin MS-style connector if a to minimum output for the mode that has been remote is connected. If no remote is connected to the 14-pin selected while 10 volts supplied to 76 will set the MS-style connector, then the remote will default to the 6-pin Invertec® V450-Pro to the maximum output for the MS-style connector if a remote is connected to it. mode. (NOTE: In TIG mode, 10 volts supplied to • In all of the CV modes, the WELD TERMINAL control will lead 76 would produce the current that has been set default to REMOTE. by the Invertec® V450-Pro’s front panel Output Control.), B-10 OPERATION B-10 Types of Remote WELD TERMINAL Control LIMITATIONS • The Invertec® V450-Pro’s Weld Terminals can be • The V450-Pro is not recommended for processes controlled from each of the MS-style connectors. other than those listed. The circuit has a nominal OCV of 15VDC and • The V450-Pro can only be used with the recom- requires a dry contact closure (less than 100 ohms) mended equipment and options. to activate the output of the Invertec® V450-Pro. • 14-Pin MS-style connector, the Weld Terminals are RECOMMENDED PROCESSES controlled from pin C (lead 2) and pin D (lead 4). Pin Properly equipped, the Invertec® V450-Pro sup- C is positive. ports GMAW-P, FCAW, SMAW, GTAW and CAC-A • 6-Pin MS-style connector, the Weld Terminals are processes for a variety of materials, including mild controlled from pin D (lead 2) and pin E (lead 4). In steel, stainless steel, cored wires, and aluminum. the 6-pin MS-style connector pin D is positive., C-1 TABLE OF CONTENTS - ACCESSORIES SECTION C-1 Accessories ..C-1 Options/Accessories ..C-2, C-2 ACCESSORIES C-2 OPTIONS / ACCESSORIES K857 Remote Output Control K814 Arc Start Switch K812 Hand Operated Amptrol K870 Foot Operated Amptrol NOTE: All of the above remote controls connect direct- ly to the 6-pin MS-style connector, with either a K864 or K876 adapter and connect it to the 14 pin wire feed- er MS-style connector. (See Diagram in Operator Manual) K930-[ ] TIG Module K428, K446, K449 LN-25 * K617 (-1 or -2) K618 (-1 or -2) LN-742 K2327-[ ] LF-72 K2426-[ ] LF-74 K1559-1, K1564-1 LN-10 K1499-1, K1521-1 DH-10 K1587-1 Cobramatic *Not recommended for pulse welding

FIELD INSTALLED OPTION (ALL VERSIONS)

• K1763-1 Advanced Process Panel, D-1 TABLE OF CONTENTS - MAINTENANCE SECTION D-1 Maintenance ..D-1 Safety Precautions ..D-2 Routine Maintenance ..D-2 Major Component Location ..D-3, D-2 MAINTENANCE D-2

SAFETY PRECAUTIONS VISUAL INSPECTION

Clean interior of machine with a low-pressure air

WARNING stream. Make a thorough inspection of all compo-

ELECTRIC SHOCK can kill. nents. Look for signs of overheating, broken leads or • Do not touch electrically live parts or other obvious problems. Many problems can be electrode with skin or wet clothing. uncovered with a good visual inspection. • Insulate yourself from work and ground • Always wear dry insulating gloves. ROUTINE MAINTENANCE - EXPLODING PARTS can cause 1. Every 6 months or so, the machine should be injury. cleaned with a low pressure airstream. Keeping • Failed parts can explode or cause other the machine clean will result in cooler operation parts to explode when power is applied. and higher reliability. Be sure to clean these areas: • Always wear a face shield and long sleeves when servicing. • All printed circuit boards - • Power switch See additional warning information • Main transformer throughout this Operator’s Manual • Input rectifier • Auxiliary Transformer - • Reconnect Switch Area CAPACITOR DISCHARGE PROCEDURE • Fan (Blow air through the rear louvers) 1. Obtain a power resistor (25 ohms, 25 watts). 2. Examine the sheet metal case for dents or breakage. 2. Hold resistor body with electrically insulated glove. Repair the case as required. Keep the case in good DO NOT TOUCH TERMINALS. Connect the resis- condition to insure that high voltage parts are protected tor terminals across the two studs in the position and correct spacings are maintained. All external sheet shown. Hold in each position for 1 second. metal screws must be in place to insure case strength Repeat for all three capacitors. and electrical ground continuity.

TCEARPMAICNRESISI ATOLSR CTEARRP MAICNIALS TOR ESIST TOORR OVERLOAD PROTECTION

The machine is electrically protected from producing high output currents. Should the output current exceed 570A, an electronic protection circuit will reduce the current to approximately 100A. The machine will con- tinue to produce this low current until the protection cir- cuit is reset. Reset occurs when the output load is

RESISTOR

removed.

RESISTOR CAPACITOR THERMAL PROTECTION TERMINALS CAPACITOR TERMINALS Thermostats protect the machine from excessive oper-

ating temperatures. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating. If excessive operating temperature should occur, the thermostat will prevent output voltage or current. The meter will remain energized during this time. 3. Use a DC voltmeter to check that voltage is not present across the terminals on three capacitors. Thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the Power Switch may be left on and the reset should occur within a 15 minute period. See Voltage Current Calibration Procedure., D-3 MAINTENANCE D-3 1. Case Front Assembly 2. Control Box & Horizontal Plate 3. Base, Lift Bale & Fan Assembly 4. Input Assembly 5. Transformer & Output Assembly 6. Switch Board Heatsink Assembly 7. Covers Assembly

Figure D.1 - Major Component Location

23147, D-4 NOTES D-4, E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 Theory of Operation ... Section E Block Logic Diagram ..E-1 General Description, Input Voltage ..E-2 Switch Boards ..E-3 Control Board ..E-4 Output Rectifier ..E-5 Thermal Protection ..E-6 IGBT Operation ..E-7 Typical IGBT Outputs ..E-8 FIGURE E.1 BLOCK LOGIC DIAGRAM

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. DR RECA C

TOIFNIETRR6O5LV SDICGNALS DBPROW F OENETDRBOALC KBOARD CTUHRERREMNOT SFTEAETDSBACK ORPEWWSTHCI NI OB T SRW IVME IGAIHTRCDH VCOALPTAACGITET OR CHOKE TOEURTMPINUATLEC HC FVEOELDTABGACEK CONTACTOR RECTIFIER RENCON SWIT CAPACITORINPUT INPUT D SENSORPRWIVME CPURRIMREANRTYBLSEWOFAITTRCDH TOEURTMPINUALTRANMSF T AOINRMER CSUERNRSEONRT MAIN TRANSFORMER CURRENT SENSOR LEFT SWITCH BOARD OUTPUT TERMINAL PWM INPUT INPUT DRIVE CONTACTOR RECTIFIER R S E C W PRIMARY O I CURRENT N SENSOR N T CAPACITOR E C VOLTAGE C FEEDBACK T H P S OW W I E T CHOKE RCIBRIGHTH N O SWITCH P A BOARD U R OUTPUT T D CONTROL SIGNALS TERMINALPWM CAPACITOR DRIVE VOLTAGE FEEDBACK THERMOSTATS

#1 AUX.

TRANS. RECTIFIER

65VDC CURRENT FEEDBACK

CONTROL BOARD AUX. RECONNECT VOLTAGE FEEDBACK#2AUX. TRANS. FAN MOTOR POWER BOARD

40VDC STATUS

LIGHT WIRE FEEDER RS232 VOLTAGE THERMAL

115VAC RECEPTACLE CONN. SENSE LIGHT

RECEPTACLE RECEPTACLE

, E-2 THEORY OF OPERATION E-2 FIGURE E.2 - INPUT VOLTAGE AND PRECHARGE.

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#T1RAAUNXS.. RECTIFIER65VDC CONTROL BOARD

VOL CONTROL SIGNALS DPRWIVME VFOEELTDABGAECK CTUHRER TEANGTE F FEEEDBACK TPU ARD CAPACITOR RMOSTA ETDSBACK PREOWWCHSTI IN BO SR BOWIGAIHTRTCDH TOEURTMPINUATLCHOKE COINNTPAUCTTOR REINCPTUIFTIE R OERC ENTNC TICWH CFVEOAEPLDTAABCGAS IT CEOKR CPSURERINMRSEAORDPRWIVE NRTM YSLBEWOFAITTRCDH TOEURTMPINUATLTRANMSFAOINRMER CSUERNRSEONRT MAIN TRANSFORMER CURRENT SENSOR LEFT SWITCH BOARD OUTPUT TERMINAL PWM INPUT INPUT DRIVE CONTACTOR RECTIFIER R S E C W PRIMARY O I CURRENT N SENSOR N T CAPACITOR E C VOLTAGE C H FEEDBACKT P S OW W I E TC RIGHT CHOKERHIB N O SWITCH P A BOARD U R OUTPUT T D TERMINALCONTROL SIGNALS PWM CAPACITOR DRIVE VOLTAGE FEEDBACK THERMOSTATS

#1 AUX.

TRANS. RECTIFIER

65VDC CURRENT FEEDBACK

CONTROL BOARD AUX. RECONNECT VOLTAGE FEEDBACK#2AUX. TRANS. FAN MOTOR POWER BOARD

40VDC STATUS

WIRE FEEDER RS232 VOLTAGE THERMAL LIGHT

115VAC RECEPTACLE CONN. SENSE LIGHT

RECEPTACLE RECEPTACLE

POWER  SOURCE GENERAL DESCRIPTION The INVERTEC® V450-PRO is an inverter based The 65 VDC produced from the power board rectifier is welding power source that is designed to be a multi- utilized by the power board to provide various DC volt- process welding system. It is a high performance, dig- ages for the control board and wire feeder. itally controlled inverter capable of complex, high- speed waveform control. With the appropriate modu- The two phases, which are connected to the input lar components it can support constant current, con- board through the power switch, are connected to the stant voltage and pulse welding processes. The output input rectifier. During precharge or “soft start” these rating is 450 amps at 36 volts with a 100% duty cycle. two phases are current limited by the input board. This AC input voltage is rectified, and the resultant DC volt- age is applied through the reconnect switches to the INPUT VOLTAGE AND input capacitors located on the switch boards. The PRECHARGE control board monitors the voltage across the capaci- tors. When the capacitors have charged to an accept- The INVERTEC® V450-PRO can be connected for a able level, the control board signals the input board to variety of three phase voltages. Refer to Figure E.2. energize the main input contactor making all three The initial input power is applied to the INVERTEC® phases of input power, without current limiting, avail- V450-PRO through a line switch located on the front of able to the input capacitors. At this point, the the machine. Two phases of the three-phase input INVERTEC® V450-PRO is in the “Run Mode” of oper- power is applied to the input board and both auxiliary ation. If the capacitors become under or overvoltage, transformers. The various secondary voltages devel- the control board will signal the input board to de- oped by the #1 auxiliary transformer are applied to the energize the main input contactor, and the input board, the power board rectifier and the fan INVERTEC® V450-PRO will be disabled. motor. The 115 VAC secondary voltage developed by the No. 2 auxiliary transformer is applied to the 115 VAC receptacle. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion, RE1C1E5PVTAACCLE 40VWRDEIRCCEE PFETAECDLEER CROSN23N2. RVESOCELENTPSATEGAECLETLHIEGRHMTAL SLTIAGTHUTS RECOANUNXE.CT #T2RAAUNXS.. MFOATNOR BPOOWAREDR VOLTAGE FEEDBACK #T1RAAUNXS. RECTIFIER65VDC CONTROL BOARD CURRENT FEEDBACK ER TCH U . PT ARD CONTROL SIGNALS DPRWI FEEN O BOA VMRED VCOALPT DAABCGAITECOKR THERMOSTATSIBSRWIGIHTCTH TECHOKE OU

RTMPINUATL

WOP SWI NNCTECO WHER CSIT

FCVEOAEPLDTAABCGAITCEOKR

COINNTPAUCTTOR REINCPTUIFTIE R SENSORDRIVE CPURRIMREPWM A

NRTY

BLSEWOFAITTRCDH TOEURTMPINUATLTRANMSFAOINRMER CSUERNRSEONRT

E-3 THEORY OF OPERATION E-3 FIGURE E.3 — SWITCH BOARDS AND MAIN TRANSFORMER MAIN

TRANSFORMER CURRENT

SENSOR LEFT SWITCH

BOARD OUTPUT

TERMINAL PWM

INPUT INPUT DRIVE CONTACTOR RECTIFIERRS

E

C W PRIMARYOICURRENT N SENSORNTCAPACITORECVOLTAGECHFEEDBACKTPS

OW

WIETRCIBRIGHT

CHOKE H

N O SWITCHPABOARDUROUTPUTTDTERMINALCONTROL SIGNALS PWM CAPACITOR DRIVE VOLTAGE FEEDBACK THERMOSTATS #1 AUX. TRANS. RECTIFIER 65VDC CURRENT FEEDBACK CONTROL BOARD AUX. RECONNECT VOLTAGE FEEDBACK#2AUX. TRANS.

FAN

MOTOR POWER

BOARD

40VDC STATUS VOLTAGE THERMAL LIGHTWIRE FEEDER RS232 115VAC RECEPTACLE CONN. SENSE LIGHT RECEPTACLE RECEPTACLE

SWITCH BOARDS AND MAIN TRANSFORMER There are two switch boards in the INVERTEC® V450- Each switch board feeds current to a separate, oppo- PRO, each containing an input capacitor and insulated sitely wound primary winding of the main transformer.

gate bipolar transistor (IGBT) switching circuitry. Refer The reverse directions of current flow through the main to Figure E.3. When the machine reconnect switches transformer primaries and the offset timing of the IGBT are configured for a lower input voltage (below 300 switch boards induce an AC square wave output signal

VAC) the input capacitors are connected in parallel. at the secondary of the main transformer. These pri- When the machine is configured for higher input volt- mary currents are monitored by the current transformer

ages (300 VAC and above) the input capacitors are (CT). If the primary currents become abnormally high, connected in series. the control board will shut off the IGBTs, thus disabling machine output. The DC current flow through each pri-

When the input capacitors are fully charged they act as mary winding is clamped back to each respective input

power supplies for the IGBT switching circuit. The capacitor when the IGBTs are turned off. This is need-

Insulated Gate Bipolar Transistors switch the DC ed due to the inductance of the transformer primary

power, from the input capacitors, “on and off” thus sup- winding. The firing of the two switch boards occurs plying pulsed DC current to the main transformer pri- during halves of a 50 microsecond interval, creating a mary windings. See IGBT Operation Discussion and constant 20 kHz output.

Diagrams in this section. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion

, E-4 THEORY OF OPERATION E-4 FIGURE E.4 - CONTROL BOARD & MODE SELECTION BOARD

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65VDC CONTROL BOARD

NTROL SIGNALS DPRWIVME VFOEELTDABGAECK CTUHRERREMNOT UTP ARD CAPACITOR S FTEAETDSBACK RE TCH NI BO RBSWOIGAIHTRCTDH TER CHOKE OUT MPINUATL WOP SWI TNEC CH CFVEOAEPLDTAABCGAITCEOKR COINNT

N T

PAUCTTOR REINCPTUIFTIE R REOC WSI SDRIVE CPUR

ERINMRSEAONPWM R

RTY LSBEWOFAITTRCDH TOEURTMPINUATLTRANMSFAOINRMER CSUERNRSEONRT MAIN TRANSFORMER CURRENT SENSOR LEFT SWITCH BOARD OUTPUT TERMINAL PWM INPUT INPUT DRIVE CONTACTOR RECTIFIER

R S

E

C W PRIMARYOICURRENT N SENSORNTCAPACITORECVOLTAGECHFEEDBACKT

P S OW W I E T RCIBRIGHT CHOKE H N O SWITCH P A BOARD U R OUTPUT T D CAPACITOR TERMINALCONTROL SIGNALS PWM DRIVE VOLTAGE FEEDBACK THERMOSTATS

#1 AUX.

TRANS. RECTIFIER

65VDC CURRENT FEEDBACK

CONTROL BOARD AUX. RECONNECT VOLTAGE FEEDBACK#2AUX. TRANS. FAN MOTOR POWER BOARD MODE BOARD OR ADVANCED MODE

40VDC STATUS BOARD

WIRE FEEDER RS232 VOLTAGE THERMAL LIGHT

115VAC RECEPTACLE CONN. SENSE LIGHT

RECEPTACLE RECEPTACLE

CONTROL BOARD & MODE

SELECTION

The control board performs the primary interfacing The control board also monitors the thermostats, main functions to establish and maintain output control of the transformer primary current, and capacitor voltage, INVERTEC® V450-PRO. Refer to Figure E.4. The and activates either the thermal light and/or the status control board sends and receives digital command light. Dependent upon the fault situation, the control information through the wire feeder receptacle and or board will either disable or reduce machine output, or the RS232 connector. The software that is contained de-energize the main input contactor. within the control board processes and compares these commands with the voltage and current feed- back information it receives from the current sensor and voltage sensing leads. The appropriate pulse width modulation (PWM) signal (See Pulse Width Modulation in this section) is sent to the switch board IGBTs. In this manner, the digitally controlled high- speed welding waveform is created. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion, E-5 THEORY OF OPERATION E-5 FIGURE E.5 - OUTPUT RECTIFIER AND CHOKE

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65VDC CONTROL BOARD

UP AR CONTROL SIGNALS DPBRWOIVME V FOEELTDABGAECK CURCAPACITOR THE RREMNOT SFTEAETDSBACK PEOWR HCWTSI NI BO SRWIG AIHTRTCDH TOEURTMPINUATL

CT H FEEDBACK CHOKEEN C

COINNTPAUCTTOR REINCPTUIFTIE R CEOR

N WITS CVOAPLTAACGITEOR CPSURENSORDPRWIVME

RIMREANRTY SLBEWOFAITTRCDH TOEURTMPINUATLTRANMSFAOINRMER CSUERNRSEONRT MAIN TRANSFORMER CURRENT SENSOR LEFT SWITCH BOARD OUTPUT TERMINAL PWM INPUT INPUT DRIVE CONTACTOR RECTIFIER

R S

E

C W PRIMARYOICURRENT N SENSORNTCAPACITORECVOLTAGECHFEEDBACKT

P S OW W I E T RCIBRIGHT CHOKE H N O SWITCH P A BOARD U R OUTPUT T D CAPACITOR TERMINALCONTROL SIGNALS PWM DRIVE VOLTAGE FEEDBACK THERMOSTATS

#1 AUX.

TRANS. RECTIFIER

65VDC CURRENT FEEDBACK

CONTROL BOARD AUX. RECONNECT VOLTAGE FEEDBACK#2AUX. TRANS. FAN MOTOR POWER BOARD

40VDC STATUS

LIGHT WIRE FEEDER RS232 VOLTAGE THERMAL

115VAC RECEPTACLE CONN. SENSE LIGHT

RECEPTACLE RECEPTACLE

OUTPUT RECTIFIER AND CHOKE The output rectifier receives the AC output from the main transformer secondary and rectifies it to a DC voltage level. Since the output choke is in series with the negative leg of the output rectifier and also in series with the welding load, a filtered DC output is applied to the machine output terminals. See Figure E.5. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion, E-6 THEORY OF OPERATION E-6

THERMAL PROTECTION OVER CURRENT PROTECTION

Two normally closed (NC) thermostats protect the machine from excessive operating temperatures. If the average current exceeds 590 amps, then the These thermostats are wired in series and are con- peak current will be limited to 100 amps until the aver- nected to the control board. One of the thermostats is age current decreases to fewer than 50 amps. located on the heat sink of the output rectifier and the other is located near the fan. (On later production machines this thermostat is located on the output choke) Excessive temperatures may be caused by a UNDER/OVER VOLTAGE PROTEC- lack of cooling air or operating the machine beyond its TION duty cycle or output rating. If excessive operating tem- peratures should occur, the thermostats will prevent A protective circuit is included on the output from the machine. The yellow thermal light, control board to monitor the voltage across located on the front of the machine, will be illuminated. the input capacitors. In the event that a The thermostats are self-resetting once the machine capacitor voltage is too high, or too low, the protection cools sufficiently. If the thermostat shutdown was circuit will de-energize the input contactor. Machine caused by excessive output or duty cycle and the fan output will be disabled and the “soft start” mode will be is operating normally, the power switch may be left on repeated. The protection circuit will prevent output if and the reset should occur within a 15-minute period. any of the following circumstances occur. If the fan is not turning or the air intake louvers are obstructed, then the power must be removed from the 1. Capacitor conditioning is required. (May be machine, and the fan problem or air obstruction cor- required if machine has been off for a long period rected. The F.A.N. (fan as needed) system is con- of time and is connected for high input voltage trolled by the control board via a solid-state relay. operation.) 2. Voltage across a capacitor exceeds 390 volts.

PROTECTIVE CIRCUITS (High line surges or improper input voltage con-

nections.) Protective circuits are designed into the INVERTEC® V450-PRO to sense trouble and shut down the 3. Voltage across a capacitor is under 70 volts. (Due machine before damage occurs to the machine's inter- to improper input voltage connections.) nal components. 4. Internal component damage., E-7 THEORY OF OPERATION E-7 FIGURE E.6 - IGBT OPERATION

A. PASSIVE B. DARCATINIVEDRAIN Pn++ BINUJFEFCETRIN LGA LAYER P+ INJECTING LAYER Pn- DBR YER n OADIYN RDERGIFIOT NREGION Pn

+- DBRUFFER BOADIYN RDER

LAYER

n+ n+ n+ n+ G

IFIOT NREGION SOURCE GATE SOURCE GATE VAOPPLTLIAEDPOSITIVGEE POSITIVE VOLTAGE APPLIED GATE GATE SOURCE SOURCE

n+ n+ n+ n+

P BODY REGION P BODY REGION

n- DRAIN DRIFT REGION n- DRAIN DRIFT REGION n+ BUFFER LAYER n+ BUFFER LAYER

P+ INJECTING LAYER P+ INJECTING LAYER DRAIN DRAIN A. PASSIVE B. ACTIVE

INSULATED GATE BIPOLAR TRANSISTOR (IGBT)

OPERATION

An IGBT is a type of transistor. IGBT are semiconduc- Example B shows the IGBT in an active mode. When tors well suited for high frequency switching and high the gate signals a positive DC voltage relative to the current applications. source, is applied to the gate terminal of the IGBT, it is capable of conducting current. A voltage supply con- Example A in Figure E.6 shows an IGBT in passive nected to the drain terminal will allow the IGBT to con- mode. There is no gate signal, zero volts relative to the duct and supply current to the circuit components cou- source, and therefore, no current flow. The drain termi- pled to the source. Current will flow through the con- nal of the IGBT may be connected to a voltage supply; ducting IGBT to downstream components as long as but since there is no conduction, the circuit will not sup- the positive gate signal is present. This is similar to ply current to components connected to the source. turning ON a light switch. The circuit is turned OFF like a light switch., E-8 THEORY OF OPERATION E-8 FIGURE E.7 - TYPICAL IGBT OUTPUTS

MAXIMUM OUTPUT

24 μsec 2 μsec 50 μsec 24 μsec (-) (+)

MIN50IM μsUeMc OUTPUT1 μsec 48 μsec (-) 1 μsec

(+) (+) (-) 1 μsec 48 μsec 1 μsec 50 μsec

MINIMUM OUTPUT

(+) 24 μsec (-) 2 μsec 24 μsec 50 μsec

MAXIMUM OUTPUT

PULSE WIDTH MODULATION The negative portion is the other IGBT group1. The dwell time (off time) is 48 microseconds (both IGBT groups off). Since only two microseconds of the 50- The term Pulse Width Modulation is used to describe microsecond time period is devoted to conducting, the how much time is devoted to conduction in the positive output power is minimized. and negative portions of the cycle. Changing the pulse width is known as modulation. Pulse Width Modulation (PWM) is the varying of the pulse width over the MAXIMUM OUTPUT allowed range of a cycle to affect the output of the machine. By holding the gate signal on for 24 microseconds each, and allowing only two microseconds of dwell time (off time) during the 50-microsecond cycle, the MINIMUM OUTPUT output is maximized. The darkened area under the top curve can be compared to the area under the bottom By controlling the duration of the gate signal, the IGBT curve. The more dark area that is under the curve indi- is turned on and off for different durations during the cates that more power is present. cycle. The top drawing in Figure E.7 shows the mini- mum output signal possible over a 50-microsecond An IGBT group consists of two IGBT modules feeding one trans- former primary winding. time period. The positive portion of the signal represents one IGBT group1 conducting for one microsecond., F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1 Troubleshooting and Repair ..F-1 How to Use Troubleshooting Guide ..F-2 PC Board Troubleshooting Procedures ..F-3 Troubleshooting Guide ..F-4 Input Filter Capacitor Discharge Procedure ..F-13 Voltage and Current Calibration Procedure ..F-15 Test Procedures ..F-19 Main Switch Board Test ..F-19 Input Rectifier Test ..F-21 Input Contactor Test ..F-25 Input Board Test ..F-29 Aux. Transformer No.2 Test ..F-33 Aux. Transformer No.1 Test ..F-35 Power Board Test ..F-39 Current Transducer Test ..F-43 Thermostat Test - Thermal Protection ..F-47 Fan Control and Motor Test ..F-49 Output Rectifier Test ..F-51 Choke Test ..F-53 Control Board Check ..F-55 SPI Cable Resistance and Voltage Test ..F-57 Removal and Replacement Procedures ..F-59 Control or Power Board ..F-59 Input Rectifier ..F-63 Input Contactor ..F-65 Aux. Transformer No.2 ..F-67 Aux. Transformer No.1 ..F-71 Control, Remote, Mode or Display ..F-75 Current Transducer ..F-77 Switch Board ..F-81 Retest and Repair ..F-84, F-2 TROUBLESHOOTING AND REPAIR F-2

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. RECOMMENDED help you locate and repair possible machine COURSE OF ACTION malfunctions. Simply follow the three-step The last column labeled “Recommended procedure listed below. Course of Action” lists the most likely com- ponents that may have failed in your Step 1. LOCATE PROBLEM (SYMPTOM). machine. It also specifies the appropriate Look under the column labeled “PROBLEM test procedure to verify that the subject com- (SYMPTOMS)”. This column describes pos- ponent is either good or bad. If there are a sible symptoms that the machine may exhib- number of possible components, check the it. Find the listing that best describes the components in the order listed to eliminate symptom that the machine is exhibiting. one possibility at a time until you locate the Symptoms are grouped into the following cause of your problem. categories: output problems and welding problems. All of the referenced test procedures referred to in the Troubleshooting Guide are Step 2. PERFORM EXTERNAL TESTS. described in detail at the end of this chapter. The second column labeled “POSSIBLE Refer to the Troubleshooting and Repair AREAS OF MISADJUSTMENT(S)” lists the Table of Contents to locate each specific obvious external possibilities that may con- Test Procedure. All of the specified test tribute to the machine symptom. Perform points, components, terminal strips, etc. can these tests/checks in the order listed. In be found on the referenced electrical wiring general, these tests can be conducted with- diagrams and schematics. Refer to the out removing the case wrap-around cover. Electrical Diagrams Section Table of Contents to locate the appropriate diagram.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. -, F-3 TROUBLESHOOTING AND REPAIR F-3

PC BOARD TROUBLESHOOTING PROCEDURES

- Remove the PC board from the static-shielding bag

WARNING and place it directly into the equipment. Don’t set the

ELECTRIC SHOCK PC board on or near paper, plastic or cloth which can kill. could have a static charge. If the PC board can’t be installed immediately, put it back in the static-shield- • Have an electrician install and ing bag. service this equipment. Turn the input power OFF at the fuse box - If the PC board uses protective shorting jumpers, before working on equipment. Do don’t remove them until installation is complete. not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop-

CAUTION er failure analysis.

Sometimes machine failures appear to be due to PC 4. Test the machine to determine if the failure board failures. These problems can sometimes be symptom has been corrected by the traced to poor electrical connections. To avoid prob- replacement PC board. lems when troubleshooting and replacing PC boards, please use the following procedure: NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting. 1. Determine to the best of your technical ability that the PC board is the most likely component NOTE: Allow the machine to heat up so that all causing the failure symptom. electrical components can reach their operating temperature. 2. Check for loose connections at the PC board to assure that the PC board is properly 5. Remove the replacement PC board and connected. substitute it with the original PC board to recreate the original problem. 3. If the problem persists, replace the suspect PC a. If the original problem does not reappear by board using standard practices to avoid static substituting the original board, then the PC electrical damage and electrical shock. Read board was not the problem. Continue to look the warning inside the static resistant bag and for bad connections in the control wiring perform the following procedures: harness, junction blocks, and terminal strips. PC board can be damaged by static electricity. b. If the original problem is recreated by the - Remove your body’s static substitution of the original board, then the PC charge before opening the static- board was the problem. Reinstall the shielding bag. Wear an anti-static replacement PC board and test the machine. wrist strap. For safety, usea16. Always indicate that this procedure was Meg ohm resistive cord connected followed when warranty reports are to be ATTENTION to a grounded part of the submitted. Static-Sensitive equipment frame. NOTE: Following this procedure and writing on the Devices - If you don’t have a wrist strap, warranty report, “INSTALLED AND SWITCHED PC Handle only at touch an un-painted, grounded, BOARDS TO VERIFY PROBLEM,” will help avoid Static-Safe part of the equipment frame. Keep denial of legitimate PC board warranty claims. Workstations touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time. - Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative., F-4 TROUBLESHOOTING AND REPAIR F-4 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical Contact the Lincoln Electric damage is evident when the Service Department at 1-888- sheet metal covers are removed. 935-3877. The input fuses repeatedly fail or 1. Input fuses or breakers may be 1. Check the reconnect panel the input circuit breakers keep improperly sized. connections and associated tripping. wiring. See the Wiring 2. The reconnect panel may not Diagram and Input be configured properly for the Information in Section A for applied voltage. the proper input voltage. Check the input voltage and make sure it is correct. The input fuses fail or input 1. Input fuses or breakers may be 1. Check the re-connect panel breakers trip after the CR-1 improperly sized. connections and associated contactor closes wiring. See the Wiring 2. The reconnect panel may not Diagram and Input be configured properly for the Information in Section A. applied voltage. 2. Perform the Input Rectifier 3. A component in the input Test. If the Input Rectifier is circuitry has failed. defective, perform tests 3 and 4. 3. Perform the IGBT Switch Board Test. 4. Perform the Input Board Test

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877., F-5 TROUBLESHOOTING AND REPAIR F-5 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS The machine is dead - - no lights 1. Make sure the input power 1. Check the input power switch - - no output - - the machine switch SW1 is in the ON SW1 for proper operation. appears to have no power. position. Also check the associated leads for loose or faulty 2. Check the main input fuses or connections. See the Wiring breakers and make sure all Diagram or Machine Diagram three phases are present. for the welder in Section G. 3. Check the CB3 breaker 2. Replace or reset input fuses (located in the reconnect or breaker. area). Reset if tripped. 3. If CB-3 opens repeatedly, perform the Auxiliary Transformer Test. 4. The power board rectifier may be faulty. Check the rectifier and associated wiring. See the Wiring Diagram or Machine Diagram for the welder in Section G. 5. Perform the Power Board Test. 6. Perform the Control Board Check. The Control Board may be faulty. The Auxiliary Receptacle is “dead”. 1. Check CB-2 on the case front. 1. Check the receptacle and asso- No 120VAC present. Reset if necessary. ciated wiring. See the Wiring Diagram or Machine Diagram in 2. Check CB-3 in the reconnect Section G. area. Reset if necessary. 2. Perform the Auxiliary 3. Make sure all three input phases Transformer Test #2. are present

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877., F-6 TROUBLESHOOTING AND REPAIR F-6 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS The INVERTEC® V450-PRO 1. The input voltage may be too 1. Make certain that the input does not have welding output. high or too low or reconnect voltage is proper, according The main input contactor (CR1) is panel may be incorrectly to the Rating Plate located on not activating. connected the rear of the machine. See Installation Section of this NOTE: This problem wil l manual. normally be accompanied 2. May be a thermal shutdown. by an error code. 2. See “Thermal LED is ON” inCheck to see if the Thermal this section. LED is ON The Diagnostic Utility is also 3. Possible short in output available on the Service 3. The primary current limit has circuit. Turn machine off. Navigator. been exceeded (CR1 drops out Remove all leads from the when the output is initiated). output of the machine. 4. Perform the Input Contactor 4. The power source (upper Test. section) has failed. If nothing 5. Perform the Input Board is evident from a visual Test. inspection, perform tests as shown. 6. Perform the Auxiliary Transformer test for T-1 NOTE: Error codes as indicated by LED 9 and 10 on the 7. Preform the Input Rectifier Control Board. test. 8. Perform the IGBT Switch Board Test. 9. Perform the Power Board Test. 10. Perform the Control Board Check. The Control Board may be faulty.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877., F-7 TROUBLESHOOTING AND REPAIR F-7 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS Thermal light is ON. The 1. The welding application may 1. One of the thermostats may machine regularly “overheats.” be exceeding the be faulty. Also check recommended duty cycle associated wiring for loose or and/or limits of the machine. faulty connections. See the Wiring Diagram or the 2. Dirt and dust may have Machine Diagram in Section clogged the cooling channels G. There are a total of 2 inside the machine. Refer to thermostats in the system. the Maintenance Section of this manual. 2. Temporarily jumper out the thermostat circuit at the 3. Air intake and exhaust louvers Control Board. See the may be blocked due to Machine Diagram in this inadequate clearance around manual to jump this circuit the machine. Check the upper function for test only. If the section of the machine and machine does not reset, the AC/DC switch lower section Control Board is defective. If intakes. it does reset, perform the 4. Make sure the fan is Thermostat Test. functioning correctly. Machines 3. Temporarily jump around the are equipped with F.A.N. (fan fan relay contacts to test fan as needed) circuitry. The fans relay function. See the run whenever the output is Machine Diagram in Section enabled and will continue G to test the fan relay running for a period of time function. (approximately 5 minutes) after the output is disabled. CAUTION: 120VAC is used to run the fan.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877., F-8 TROUBLESHOOTING AND REPAIR F-8 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION WELD AND ARC QUALITY PROBLEMS General degradation of weld 1. Wire feed problem. 1. Check for proper wire speed performance. and consistent feeding. 2. Check for poor connections 2. Cabling problems. and/or excessive loops in the weld cables. 3. Verify weld mode is correct for NOTE: The presence of heat in external welding circuits process. indicates poor connections or undersized weld cables. 4. Machine calibration. 3. Select the correct weld mode for the application. Refer to the Instruction Manual. 4. Perform Choke Test. 5. Perform Current Transducer Test and Check Sense Lead Routing.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877., F-9 TROUBLESHOOTING AND REPAIR F-9 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION WELD AND ARC QUALITY PROBLEMS Machine shuts down during a weld. 1. Secondary over-current 1. Adjust parameters to minimize occurred. momentary shorting of the arc. NOTE: The Diagnostic Utility can be used to check the 2. Check for single phase input, ‘event log’ to determine (loss of L2) which will reduce cause of shut-down. the secondary current limit. Check input fuses or current in all three phases for balance (+/- 5 amps).

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877., F-10 TROUBLESHOOTING AND REPAIR F-10 Observe Safety Guidelines detailed in the beginning of this manual. STATUS LIGHTS ARE LED’S 9 AND 10 ON CENTER TOP OF CONTROL BOARD Fault Codes Code Description Corrective Action 31 Primary over current. If condition persists The machine needs to contact an authorized be turned off and back Lincoln Field Service on to reset the machine. Shop 32 CAP bank A under voltage. Check input power Self-clearing as 33 CAP bank B under voltage. reconnect to make sure condition ceases. 34 CAP bank A over voltage. the machine 35 CAP bank B over voltage. is connected for the input 37 Soft start Failed. power being supplied. Cycle power. 39 Glitch on the primary over Check the machine Self-clearing as current fault interrupt; possibly ground. condition ceases. caused by noise or a signal level If problem persists (misc. hardware fault #1) contact an authorized Lincoln Field Service Shop 43 CAP delta; CAP A and B are out Check input power of balance. reconnect to make sure the machine is connected for the input power being supplied. 44 Main CPU problem. The DSP Check the machine has detected a problem with the ground. CPU. 47 Possible erroneous electrical If problem persists noise on Voltage/Frequence contact an authorized capacitor feed back circuit. Lincoln Field Service Shop (misc. hardware fault #2) 48 The main contactor opened If condition persist Self-clearing unexpectedly. (misc. hardware contact an authorized fault #3) Lincoln Field Service Shop "bad The selected weld mode does If condition persists Press the Mode node’ not exist in the weld table that is contact an authorized Select button to “####” presently loaded in the machine. Lincoln Field Service select a different Shop mode

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877., F-11 TROUBLESHOOTING AND REPAIR F-11 Observe Safety Guidelines detailed in the beginning of this manual. Displays Description Scrolling dash Appears at power up while the machine is going through its self con- figuration "Err" "####" Fault code display. The first fault to occur will be displayed for three seconds. The display will cycle through fault codes for all faults that persist after the initial three-second period are displayed for 1 second each. "-" "-" Weld mode is changing "-" "####" A constant voltage weld mode is selected, machine output is off. The numeric value in the right display is the work point. "####" "-" A constant current weld mode is selected, machine output is off. The numeric value in the left display is either the work point or a work point limit, depending on the weld mode and remote configu- ration. "####" "####"(on steady) Machine output is on. Left display is current, right display is volt- age. If actively welding, the displays are arc current and arc volt- age. If not actively welding, the display will show work point. "####" "####" (blinking) Weld just finished – the average arc voltage and current will be blinked for 5 seconds following a weld. If the work point changes during this 5 second period, the display will revert to the above mode.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877., F-12 NOTES F-12, F-13 TROUBLESHOOTING AND REPAIR F-13

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This procedure will drain off any charge stored in the four large capacitors that are part of the switch board assembly. This procedure MUST be performed as a safety precau- tion before conducting any test or repair procedure that requires you to touch internal components of the machine.

MATERIALS NEEDED

5/16” Nut Driver Insulated Pliers Insulated Gloves High Wattage Resistor (25-1000 ohms and 25 watts minimum) DC Volt Meter, F-14 TROUBLESHOOTING AND REPAIR F-14 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.1 – CAPACITOR TERMINAL LOCATION

TCEARPMAICNIATOLSR CTEARPMAICNIATOLSR RESISTOR RESISTOR RESISTOR RESISTOR CAPACITOR TERMINALS CAPACITOR TERMINALS PROCEDURE

1. Remove input power to the INVERTEC® V450- 6. Using the high wattage resistor (25-1000 ohms PRO. @ 25 watts (minimum), electrically insulated gloves and pliers, connect the resistor across 2. Using the 3/8” nut driver, remove the left and the two capacitor terminals. Hold the resistor in right case sides. place for 10 seconds. DO NOT TOUCH THE 3. Be careful not to make contact with the capaci- CAPACITOR TERMI-NALS WITH YOUR BARE tor terminals that are located in the bottom cen- HANDS. NEVER USE A SOLID CONDUCTOR ter of the left and right side switch boards. See W/LESS THAN 25 OHM RESISTANCE FOR Figure F.1. THIS PROCEDURE. 4. Carefully check for a DC voltage at the capaci- 7. Repeat procedure for the other capacitor. tor terminals on both boards. Note the polarity 8. Recheck the voltage across the capacitor termi- is marked on the PC board and also lead #19 is nals. The voltage should be zero. If any volt- positive. age remains, repeat the discharge procedure. 5. If any voltage is present, proceed to Step #6. If no voltage is present, the capacitors are dis- charged. NOTE: Normally the capacitors discharge in about two minutes after input power is removed., F-15 TROUBLESHOOTING AND REPAIR F-15

VOLTAGE AND CURRENT CALIBRATION PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the machine is capable of producing welding output and to check and adjust, if necessary, the voltage and or current calibration.

MATERIALS NEEDED

Resistive Load Bank Calibrated Test Voltmeter Calibrated Test Ammeter, F-16 TROUBLESHOOTING AND REPAIR F-16

VOLTAGE AND CURRENT CALIBRATION PROCEDURE (continued) CALIBRATION CHECK VOLTAGE CALIBRATION

The calibration of the V450-PRO can be checked NOTE: If the Mode SELECT/MEMORY button is using a resistive load bank with the V450-PRO in not pressed within 30 seconds after mode 200. Mode 200 is a constant current test adjusting the Output Control knob the mode. machine will leave the calibration mode NOTE: Before attempting to calibrate the voltage and use the previous calibration settings. or current setting of the V450-PRO, be 1. Connect the resistive load band (approximate- sure to read the entire voltage or current ly .087 ohms) and test voltmeter to the welding calibration section. If the steps are not output terminals. completed quickly, the machine will auto- matically leave the calibration mode with- 2. Press and hold in the Mode SELECT/MEMO- out changing the calibration settings. The RY button. voltage and current calibration settings of the V450-PRO are completely indepen- 3. Turn on the V450-PRO. dent of each other. Adjusting one will not 4. Rotate the Output Control knob until the dis- affect the other. play reads “vol cAL”. 1. Press and hold in the Mode SELECT button. 5. Release the Mode SELECT/MEMORY but- 2. Turn on the V450-PRO. ton. 3. Rotate the Output Knob, while still holding the 6. Adjust the Output Control knob until the actu- mode select button in, until the displays read al output voltage reading on the test voltmeter “mode 200”. is 20volts +/- .5 volts. NOTE: Machines with an Advanced Process 7. Wait for the machine’s output to be automati- Panels do not have a mode select button. cally turned off and then back on. Use the same procedure except hold in 8. Adjust the Output Control knob again if nec- the Memory button on the advanced essary to make the actual voltage output 20 process panel instead of the mode select volts +/- .5 volts. button. 9. Wait for the machine’s output to be automati- 4. Release the Mode SELECT/MEMORY but- cally turned off and then back on. ton and the machine will be in mode 200. 10. Repeat the above two steps if necessary. 5. With the machine in mode 200 apply a resis- tive load to the welding output terminals 11. Press and release the Mode SELECT/MEM- (approximately .087 ohms) set the machine ORY button to save the calibration. output to 300 amps and enable the Weld Terminals. (Weld Terminals Select ON). 6. Using the test meters note the output voltage and current. 7. The V450-PRO voltmeter must match the test meter reading to within +/- 1 volt. 8. The V450-PRO ammeter must match the test meter within +/- 5 amps. 9. If the voltmeter does not meet the specification then proceed to the Voltage Calibration Procedure. 10. If the ammeter does not meet the specification then proceed to the Current Calibration Procedure., F-17 TROUBLESHOOTING AND REPAIR F-17

VOLTAGE AND CURRENT CALIBRATION PROCEDURE (continued) CURRENT CALIBRATION PROCEDURE 7. The right display will scroll the following mes-

sage: Adj oCP SorEAL cur-300A. NOTE: If the Mode SELECT/MEMORY button is 8. Adjust the Output Control knob until the actual not pressed within 30 seconds after output current reading on the test ammeter is adjusting the Output Control knob the 300amps +/-2A. machine will leave the calibration mode and use the previous calibration settings. 9. Wait for the machine’s output to be automatically turned off and then back on. 1. Connect the resistive load band (approximate- ly .087 ohms) and test ammeter to the welding 10. Adjust the Output Control knob again if nec- output terminals. essary to make the actual output current read- ing on the test ammeter 300 amps +/-2A. 2. Press and hold in the Mode SELECT/MEMO- 11. Wait for the machine’s output to be automati- RY button. cally turned off and then back on. 3. Turn on the V450-PRO. 12. Repeat the above two steps if necessary. 4. Rotate the Output Control knob until the dis- 13. Press and release the Mode SELECT/MEM- play reads “cur cAL”. ORY button to save the calibration. 5. Release the Mode SELECT/MEMORY but- 14. The left display will scroll the message IcAL ton. SAVEd. 6. The left display will change to “IcAL” to indicate 15. The machine will reset to normal operation. that current calibration is in progress., F-18 NOTES F-18, F-19 TROUBLESHOOTING AND REPAIR F-19

MAIN SWITCH BOARD TEST PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the “power section” of the switch boards are functioning cor- rectly. This test will NOT indicate if the entire PC board is functional. This resistance test is preferable to a voltage test with the machine energized because this board can be dam- aged easily. In addition, it is dangerous to work on this board with the machine energized.

MATERIALS NEEDED

Analog Volt/Ohmmeter 5/16 in. Wrench 7/16 in. Wrench, F-20 TROUBLESHOOTING AND REPAIR F-20

MAIN SWITCH BOARD TEST PROCEDURE (continued)

FIGURE F.2 - CAPACITOR TERMINAL LOCATIONS

TCEARPMAICNIATOLSR TCEARPMAICNIATOLSR RESISTOR RESISTOR RESISTOR RESISTOR CAPACITOR TERMINALS CAPACITOR TERMINALS

TEST PROCEDURE 1. Remove input power to the INVERTEC® Check 11/12 to -20 and 11/12 to +19 V450-PRO. Check 15/16 to -20 and 15/16 to +19 2. Perform the Capacitor Discharge Procedure. Check 13/14 to -20 and +19 to 13/14 3. Use a DC voltmeter to check that the voltage is Check 17/18 to -20 and +19 to 17/18 not present across the terminals on three capacitors. 6. If any test fails (measures a short) isolate the PC board and retest, if board still fails, replace 4. Locate label and remove leads 19C and 19D switch board. See Switch Board Removal from the reconnect switches with the 3/8” and Replacement. wrench. Note lead placement for reassembly. Clear leads. See Figure F.2. 7. If the switch board tests are OK, check the molex pin connections and associated wiring 5. Using the Analog ohmmeter, perform the following from the switch boards to the control board. resistance tests. See Figure F.2 for the test points. See the Wiring Diagram. Any readings below 100 ohms can be considered a short circuit. However, readings usually are below 30 8. Reconnect leads 19C and 19D to the reconnect ohms. A short on any of the following points indicates switches. Ensure that the leads are installed in a possible failed switch board. the same location they were removed from. 9. Install the right and left case sides and top using the 3/8” nut driver., F-21 TROUBLESHOOTING AND REPAIR F-21

INPUT RECTIFIER TEST PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the input rectifier has “shorted” or “open” diodes.

MATERIALS NEEDED

Analog Voltmeter/Ohmmeter (Multimeter) 5/16” Nut Driver Phillips Head Screwdriver Wiring Diagram,

POS (+)NEG (-) REICNTPIUFTIERCBA

F-22 TROUBLESHOOTING AND REPAIR F-22

INPUT RECTIFIER TEST PROCEDURE (continued)

FIGURE F.3 - INPUT RECTIFIER

INPUT C RECTIFIER B A NEG (-) POS (+) PROCEDURE

1. Remove input power to the INVERTEC® NOTE: Some RTV sealant may have to be V450-PRO. removed from the input rectifier terminals. The RTV should be replaced when test is 2. Using the 3/8” nut driver, remove the case top. complete. 3. Perform the Capacitor Discharge Procedure. 5. With the Phillips head screwdriver remove the 4. Locate the Input Rectifier and lead locations. positive and negative leads from the rectifier. Refer to Figure F.3., F-23 TROUBLESHOOTING AND REPAIR F-23

INPUT RECTIFIER TEST PROCEDURE (continued)

6. Use the analog ohmmeter to perform the tests 9. If the input rectifier is good, be sure to recon- detailed in Table F.1. nect the positive and negative leads to the cor- rect terminals and torque to 31 in.-lbs. See the 7. If the input rectifier does not meet the accept- Wiring Diagram. able readings outlined in the table, the compo- nent may be faulty. Replace. 10. Replace any RTV sealant previously removed. NOTE: Before replacing the input rectifier, perform 11. Install the case top. the Switch Board Test and the Input Contactor Test. 8. When installing a new input rectifier, see Input Rectifier Removal and Replacement proce- dure. TABLE F.1 – INPUT RECTIFIER TEST POINTS AND ACCEPTABLE READINGS TEST POINT TERMINALS ANALOG METER X100

RANGE

+ Probe - Probe Acceptable Meter Readings A NEG Greater than 1000 ohms B NEG Greater than 1000 ohms C NEG Greater than 1000 ohms A POS Approx. 500 ohms B POS Approx. 500 ohms C POS Approx. 500 ohms NEG A Approx. 500 ohms NEG B Approx. 500 ohms NEG C Approx. 500 ohms POS A Greater than 1000 ohms POS B Greater than 1000 ohms POS C Greater than 1000 ohms, F-24 NOTES F-24, F-25 TROUBLESHOOTING AND REPAIR F-25

INPUT CONTACTOR TEST PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the input contactor is functional and if the contacts are functioning correctly.

MATERIALS NEEDED

3/8” Nut Driver Volt-Ohmmeter External 24 VAC supply, F-26 TROUBLESHOOTING AND REPAIR F-26

INPUT CONTACTOR TEST PROCEDURE (continued)

FIGURE F.4 – INPUT CONTACTOR COIL

X4 CINO

6N01PUTTACTOR

INPUT CONTACTOR X4 PROCEDURE

1. Remove input power to the INVERTEC® 4. Using the external 24 VAC supply, apply 24 V450-PRO. VAC to the terminals of the input contactor coil. If the contactor does NOT activate, the input 2. Using the 3/8” nut driver, remove the input contactor is faulty. Replace. access panel and case top. 3. Locate, mark, and remove the two leads (601, X4) that are connected to the input contactor coil. See Figure F.4., F-27 TROUBLESHOOTING AND REPAIR F-27

INPUT CONTACTOR TEST PROCEDURE (continued)

FIGURE F.5 – INPUT CONTACTOR TEST POINTS

L1 T1 L2 T2 L3 T3 L3 T3 L2 T2 L1 T1

5. With the input contactor activated, check the 7. Reconnect the two leads (601, X4) to the input continuity across the three sets of contacts. contactor coil. (Zero ohms or very low resistance is normal.) 8. Install the input access door and case top using See Figure F.5. If the resistance is high, the the 3/8” nut driver. input contactor is faulty. Replace the input con- tactor. 6. When the contactor is NOT activated, the resis- tance should be infinite or very high across the contacts. If the resistance is low, the input con- tactor is faulty., F-28 NOTES F-28, F-29 TROUBLESHOOTING AND REPAIR F-29

INPUT BOARD TEST PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the Input Board is sending the correct voltages, as well as if the Input Board is regulating and producing the correct DC voltages.

MATERIALS NEEDED

3/8” Nut Driver Volt-Ohmmeter Wiring Diagram, F-30 TROUBLESHOOTING AND REPAIR F-30 INPUT BOARD TEST PROCEDURE (continued) FIGURE F.6 – INPUT CONTACTOR CR1 5 6J607867J681 9 10 CONTACTOR123412345INPUT X6401

J60 J61 J60 J61

123412345

X4 INPUT CONTACTOR

5678678910

J60 J61

PROCEDURE WARNING 1. Remove input power to the INVERTEC® 450-PRO. ELECTRIC SHOCK can kill. 2. Using the 3/8” nut driver, remove the case top. High voltage is present when input 3. Remove lead X4 from the coil terminal of main power is applied to the machine. input contactor CR1. Insulate lead X4. See Figure F.6. 5. Turn on the INVERTEC® 450-PRO. Carefully 4. Carefully apply input power to the INVERTEC® test for the correct voltages according to Table 450-PRO. F.2., F-31 TROUBLESHOOTING AND REPAIR F-31

INPUT BOARD TEST PROCEDURE (continued)

6. Remove input power to the INVERTEC® V- 9. Turn on the INVERTEC® V-450 PRO. 450 PRO. If any of the voltages are low or Check for the presence of 24 VAC from not present, perform the Input Contactor lead X4 to lead 601. See Figure F.6. If the Test. If that checks out, the Input Board voltage is not present, perform the may by faulty. Auxiliary Transformer #1 Test. 7. Reconnect lead X4 to the main input contac- 9. This 24 VAC is the coil voltage for main tor CR1 coil terminal. input contactor CR1. It will normally be present approximately 12 seconds after 8. Carefully apply the correct input voltage to input line switch (SW1) is activated. the INVERTEC® V-450 PRO. 10. When the test is completed, remove input power from the INVERTEC® V-450 PRO.

WARNING

11. Install the case top using the 3/8” nut driver. ELECTRIC SHOCK can kill. High voltage is present when input power is applied to the machine., F-32 TROUBLESHOOTING AND REPAIR F-32

INPUT BOARD TEST PROCEDURE (continued)

TABLE F.2 – INPUT BOARD VOLTAGE CHECKS LEAD EXPECTED TEST POINTS NUMBERS VOLTAGE COMMENTS

READINGS

PLUG J61 PIN 8 (H1D) J61 SAME AS Present when Input TO INPUT Switch SW1 is closed. PLUG J61 PIN 2 (612) VOLTAGE #612 H1D PLUG J61 PIN 10 (T3) J61 A LITTLE LESS This is Pre-Charge Voltage and TO THAN INPUT will normally be present 6 sec- T1 PLUG J61 PIN 2 (T1) VOLTAGE onds after activating Input Switch SW1. The Pre-Charge Voltage should remain for approximately 6 seconds and then be removed. T3 PLUG J60 PIN 3 (238) J60 13 – 15 VDC This is the Coil Voltage for the TO Pre-Charge Relay. Normally this PLUG J60 PIN 4 (604) DC Voltage will be present 6 sec- #238 #604 onds after Input Switch SW1 is activated. This 13 - 15 VDC will remain for approximately 6 sec- onds and then be removed. The Relay is controlled by the Control Board. See the Wiring Diagram. PLUG J60 PIN 3 (238) J60 13 – 15 VDC This is the DC Coil Voltage for the TO Control Relay. Normally this DC PLUG J60 PIN 5 (232) Voltage will be present approxi- mately 12 seconds after Input #238 Switch SW1 is activated. The Relay is controlled by the Control PC Board. See the Wiring Diagram. #232, F-33 TROUBLESHOOTING AND REPAIR F-33

AUXILIARY TRANSFORMER NO. 2 TEST WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if the correct voltage is being applied to the primary of Auxiliary Transformer No. 2, as well as if the correct voltage is being induced on the secondary winding of the transformer.

MATERIALS NEEDED

Volt-Ohmmeter (Multimeter) 3/8 in. Nut Driver Wiring Diagram, F-34 TROUBLESHOOTING AND REPAIR F-34

AUXILIARY TRANSFORMER NO. 2 TEST (continued)

FIGURE F.7 – PLUGS P52 AND P54

TRANSFORMER #2 P52 P50

3 S/8C” RMEOWUSN T(2IN) G 3/8” MOUNTING

SCREWS (2) TRANSFORMER #2 PROCEDURE

1. Remove the main input supply power to the 8. If 115 VAC is not present between pins #1 and INVERTEC® V-450 PRO. #4, check the associated leads and plugs for loose or faulty connections. 2. Remove any load that may be connected to the 115 VAC receptacle. WARNING 3. Using the 3/8 in. nut driver, remove the left and High voltage is present at plug P50. right case sides. 9. Carefully test for the correct AC input voltage 4. Perform the Capacitor Discharge Procedure. applied to the primary windings at H6 and H1. (P50 Pins 1 and 5) Normal is 550-575 VAC. 5. Locate plugs P50 and P51 at the Auxiliary See wiring diagram. Transformer No. 2. See Figure F.7. 10. If the correct AC input voltage is applied to the 6. Carefully apply the correct input power and primary of the Auxiliary Transformer No. 2 and check for 115 VAC at plug P51 pins #1 and #4. the secondary voltage is NOT correct, the transformer may be faulty. Replace. 7. If 115 VAC is present, the Auxiliary Transformer No. 2 is good. 11. Install the left and right case sides using the 3/8 in. nut driver., F-35 TROUBLESHOOTING AND REPAIR F-35

AUXILIARY TRANSFORMER NO. 1 TEST WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if the correct voltage is being applied to the primary of Auxiliary Transformer No. 1, as well as if the correct voltage is being induced on the secondary windings of the transformer.

MATERIALS NEEDED

Volt-Ohmmeter (Multimeter) 3/8 in. Nut Driver Wiring Diagram, F-36 TROUBLESHOOTING AND REPAIR F-36

AUXILIARY TRANSFORMER NO. 1 TEST (continued)

FIGURE F.8 – TEST LEAD LOCATIONS

P PL5U9G TRANSFORMER #1

3 S/8C” RMEOWUSN T(2IN) G 3/8” MOUNTING

SCREWS (2) TRANSFORMER #1 PLUG PROCEDURE

1. Remove the main input supply power to the NOTE: The secondary voltages will vary if the INVERTEC® V450-PRO. input line volage varies. 2. Using the 3/8 in. nut driver, remove the case 8. If the secondary voltages are present, the T1 sides and top. auxiliary transformer is functioning properly. If any of the secondary voltages are missing or 3. Perform the Capacitor Discharge Procedure. low, check to make certain the primary is con- figured correctly for the input voltage applied. 4. Locate leads X8 and 41B at Power Board See Wiring Diagram. Bridge. 9. If the correct voltage is applied to the primary, 5. Locate secondary leads X3 and X5 (fan motor and the secondary voltage(s) are not correct, leads). the T2 transformer may be faulty. 6. Locate secondary lead X4 (at main 10. Install the case sides and top using the 3/8” nut contactor). driver. 7. Carefully apply the correct input voltage to the INVERTEC® V450-PRO and check for the cor- rect secondary voltages per Table F.3., F-37 TROUBLESHOOTING AND REPAIR F-37

AUXILIARY TRANSFORMER NO. 1 TEST (continued)

TABLE F.3 NORMAL EXPECTED LEAD IDENTIFICATION VOLTAGE X8 to 41B 28 VAC X3 to X5 115 VAC X3 to X4 24 VAC X6 to X7 24 VAC X6 to X9 42 VAC, F-38 NOTES F-38, F-39 TROUBLESHOOTING AND REPAIR F-39

POWER BOARD TEST WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the power board is receiving the correct voltages as well as if the power board is regulating and producing the correct DC voltages.

MATERIALS NEEDED

3/8 in. Nut Driver Volt-Ohmmeter Wiring Diagram,

F-40 TROUBLESHOOTING AND REPAIR F-40 POWER BOARD TEST (continued) FIGURE F.9 – POWER BOARD

4 J 452 6 3J414789J 4 130 11 1212312123456J42 J41 J43 J42 J41 J43123121234564563478910 11 12 J42 J41 J43

PROCEDURE

1. Remove input power to the INVERTEC® V-450 6. Turn on the INVERTEC® V-450 PRO. Carefully

PRO. test for the correct voltages at the Power Board

according to Table F.4. 2. Using the 3/8” nut driver, remove the case top. 7. If either of the 40 VDC voltages is low or not 3. Perform the Capacitor Discharge Procedure. present at plug J41, check capacitor C3 and the 4. Locate the Power Board and plugs J42 and rectifier bridge. See the Wiring Diagram. Also

J43. Do not remove plugs or leads from the perform the T1 Auxiliary Transformer Test. Power Board. See Figure F.9. 8. If any of the DC voltages are low or not present

5. Carefully apply input power to the INVERTEC® at plugs J42 and/or 43, the Power Board may

V-450 PRO. be faulty. WARNING 9. Install the case top using the 3/8” nut driver. ELECTRIC SHOCK can kill. High voltage is present when

input power is applied to the machine., F-41 TROUBLESHOOTING AND REPAIR F-41

POWER BOARD TEST (continued)

TABLE F.4 – POWER BOARD VOLTAGE CHECKS CHECK POINT TEST CONNECTOR LEAD NO. OR NORMAL LOCATION DESCRIPTION PLUG PIN NO. IDENTITY ACCEPTABLE

VOLTAGE READING

POWER BOARD CHECK 40 VDC 2 (+) 477 (+) 38 – 42 VDC CONNECTOR INPUT FROM 1 (-) 475 (-) PLUG J41 DC BUS BOARD NEG. POS. POWER BOARD CHECK +15 1 (+) 225 (+) +15 VDC CONNECTOR VDC SUPPLY FROM 5 (-) 222 (-) PLUG J42 POWER BOARD POWER BOARD CHECK +5 VDC 3 (+) 221 (+) +5 VDC CONNECTOR SUPPLY FROM 5 (-) 221 222 (-) PLUG J42 POWER BOARD POWER BOARD CHECK -15 VDC 2 (+) 222 (+) -15 VDC CONNECTOR SUPPLY FROM 5 (-) 223 (-) PLUG J42 POWER BOARD 4 (+) 226 (+) +5 VDC POWER BOARD CHECK +5 VDC 9 (-) 226 228 (-) CONNECTOR “RS-232” SUPPLY PLUG J43 FROM POWER BOARD 6 (+) 266 (+) +15 VDC POWER BOARD CHECK +15 VDC 11 (-) 266 267 (-) CONNECTOR SPI SUPPLY FROM PLUG J43 POWER BOARD 3 (+) POWER BOARD CHECK +5 VDC 12 (-) 268A 268A (+) +5 VDC CONNECTOR SPI SUPPLY FROM 262 (-) PLUG J43 POWER BOARD 7 (+) POWER BOARD CHECK +20 VDC STT 1 (-)346 345 (+) +20 VDC CONNECTOR SUPPLY FROM 346 (-) PLUG J43 POWER BOARD, F-42 NOTES F-42, F-43 TROUBLESHOOTING AND REPAIR F-43

CURRENT TRANSDUCER TEST WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the V450-PRO current transducer and associated wiring are functioning correctly.

MATERIALS NEEDED

3/8” Nut Driver Volt-Ohmmeter, F-44 TROUBLESHOOTING AND REPAIR F-44 CURRENT TRANSDUCER TEST (continued) FIGURE F.10 – CURRENT TRANSDUCER TEST 1234 P91

TRCAUNRSRDEUNCTE

5 62 1

R

67821112122

J8

2 133 4

J8 CONTROL BOARD CONTROL BOARD J8

211 212 2131234

J8

5678

CURRENT TRANSDUCER

TEST PROCEDURE WARNING 1. Remove input power to the V-450 PRO. 2. Using the 3/8” nut driver, remove the case ELECTRIC SHOCK can kill. top and the control box cover. High voltage is present when 3. Locate the current transducer leads at input power is applied to the Control Board plug J8. See Figure F.10. machine. 4. Carefully apply input power to the V-450 PRO., F-45 TROUBLESHOOTING AND REPAIR F-45

CURRENT TRANSDUCER TEST (continued)

5. Turn on the V-450 PRO. Check for the correct 8. If for any reason the machine cannot be loaded DC supply voltage to the current transducer at to 250 amps, Table F.5 shows what feedback plug J8. See Figure F.10. voltage is produced at various current loads. A. Pin 2 (lead 212+) to pin 6 (lead 216-) 9. If the correct supply voltages are applied to the should read +15 VDC. current transducer, and with the machine loaded, the feedback voltage is missing or not B. Pin 3 (lead 213-) to pin 6 (lead 216+) correct, the current transducer may be faulty. should read -15 VDC. Also make certain that lead 211 (plug J8 pin 1) If the DC supply voltages are not present, the has continuity (zero ohms) between the current control board may be faulty. transducer and the control board. See the Wiring Diagram. 6. If both of the supply voltages are low or missing, check the associated leads between plug J8 10. Install the right side case cover using the 3/8” and current transducer plug P91 and the nut driver. Control Board. 7. With the V-450 PRO triggered, check the feed- back voltage from the current transducer. The current feedback voltage can be read at plug J8 on the Control Board. A. Pin 1 (lead 211) to pin 6 (lead 216) should read 2.0 VDC (machine loaded to 250 amps). TABLE F.5 - CURRENT FEEDBACK AT VARIOUS OUTPUT LOADS OUTPUT LOAD CURRENT EXPECTED TRANSDUCER FEEDBACK

VOLTAGE

500 4.0 450 3.6 400 3.2 350 2.8 300 2.4 250 2.0 200 1.6 150 1.2 100 0.8 50 0.4, F-46 NOTES F-46, F-47 TROUBLESHOOTING AND REPAIR F-47

THERMOSTAT TEST – THERMAL PROTECTION WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877. NOTE: The procedures and tests described in this test are written with the under- standing that the repair technician fully understands the process of locating and accessing (within the welding machine) the specific board or device involved in each procedure or test.

TEST DESCRIPTION

The Thermostats are located in various locations within the welding machine. See Machine Diagram for specific locations. This test will determine if a thermostat is intermittently opening or is fully open.

MATERIALS NEEDED

Small, gauge (#18) short jumper wire (Wire should be approximately 4 inches in length), F-48 TROUBLESHOOTING AND REPAIR F-48 THERMOSTAT TEST – THERMAL PROTECTION (continued) FIGURE F.11 – THERMOSTAT CIRCUIT 5J2- J522-30 224 220 O (U B TOTLHPTEEUDRT CM ORNOENSCECTTTAIIOFTNIE) R291 ( C OTNHNEECCRHTMEODOK WES/E TPAO2XTY2) 4A 224 224A 224 224A 220 291 224 224AOUTPUT RECTIFIER CHOKE

THERMOSTAT THERMOSTAT

(BOLTED CONNECTION) (CONNECTED W/EPOXY)

LED 6 TheJrm5ostat Thermostat J5 LED 6

SIMPLIFIED TEST PROCEDURE NOTE: Never run the V-450 PRO under load when All thermostats are normally closed so moving the any of the thermostats are bypassed. This is jumper as indicated and watching the Thermal LED only a means of isolating the inoperative or should help determine which thermostat or open thermostat. associated wiring is defective. 1. Temporarily bypass thermostat circuits with a Don’t forget to check the incline splice 224 to 224A as shorting jumper as follows: a possible open. • All thermostats at the Control Board (2J5 to 3J5) • Choke thermostat only (224A to 291) • Output Rectifier thermostat only (220 to 291) Located on the Output Rectifier Heat Sink

J5-2 J5-3

, F-49 TROUBLESHOOTING AND REPAIR F-49

FAN CONTROL AND MOTOR TEST WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION

This test will help determine if the fan motor, control board, switch board, and associated leads and connectors are functioning correctly.

MATERIALS NEEDED

Voltmeter 3/8” Nut Driver, F-50 TROUBLESHOOTING AND REPAIR F-50 FAN CONTROL AND MOTOR TEST (continued) TEST PROCEDURE 1. Remove the input power to the V450-PRO 3. Perform the Capacitor Discharge Procedure. machine. 2. Using the 3/8” nut driver, remove the case top and control box cover. FIGURE F.12

PLoocwaeterSdo iunr Rceear of S RELAYFAN OLID STATE

444 -

TP4 CR2 X3A 3+ 3 WR JJ77-1156 FFAANN CCOONNTTRROOLL ((-+)15VDC) F a no uctopmute sis oenn awbhleen

+

X3A 3R J7-15 FAN CONTROL (+15VDC) Fan comes on when

3W J7-16 FAN CONTROL (-) output is enable

TP4 CR2

-

FAN SOLID STATE Located in Rear of RELAY PowerSource

4. Carefully apply the correct input power to the FAN CONTROL TEST PROCEDURE machine. 5. Carefully check for 115VAC at X3A and 444. See Figure F.12. 1. Locate plug J7 on the control board. Do not remove the plug from the control board. See WARNING: HIGH VOLTAGE IS PRESENT AT Figure F.12. THE RELAY TERMINALS. 2. Energize the weld output terminals (Select 6. If the 115VAC is low or not present, perform the Weld Terminals ON) and carefully check for Auxiliary Transformer Test. Check circuit +15VDC at plug J7 pins 15 & 16 on the control breaker CB2 and associated leads for loose or PC board. If the 15VDC is present and the fan is not running then the relay or fan may be faulty connections. See Wiring Diagram. faulty. If the 15VDC is not present when the 7. Energize the weld output terminals (Select weld terminals are energized, then the control Weld Terminals ON) and carefully check for board may be faulty. 115VAC at the fan motor leads. If the 115VAC is present and the fan is not running, the fan WARNING motor may be faulty. See Wiring Diagram. HIGH VOLTAGE IS PRESENT WARNING: HIGH VOLTAGE IS PRESENT AT AT THE SWITCH BOARD. THE FAN LEADS.

WARNING

ELECTRIC SHOCK can kill. High voltage is present when input power is applied to the machine., F-51 TROUBLESHOOTING AND REPAIR F-51

OUTPUT RECTIFIER TEST PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if any of the output rectifiers are shorted.

MATERIALS NEEDED

Analog Volt-Ohmmeter 3/8” Nut driver 5/16” Wrench, F-52 TROUBLESHOOTING AND REPAIR F-52 OUTPUT RECTIFIER TEST PROCEDURE (continued) FIGURE F.13 - OUTPUT TERMINAL LOCATION

NOTEEURGTMPATUINITVAEL (-) PTOEOURSTMPITUIINVTAEL (+)

STTOITGAURCTH HTIIG-FREQ SOFT CRIP CSOENLETRCOTLRLEOMCOATLE AMPS OUTPVUTOLTS

AMPS VOLTS

CONTROL OUTPUT

REMOTE LOCAL SELECT TOUCH

START HI-FREQ TIG TIG SOFT CRIP

NEGATIVE (-) POSITIVE (+) OUTPUT OUTPUT TERMINAL TERMINAL PROCEDURE

1. Remove main input supply power to the V450- 5. Remove the case top perform the Input Filter PRO. Capacitor Discharge procedure. 2. Remove any output load that may be connect- 6. Using the 5/16” wrench, remove and insulate ed to the V450-PRO. lead 202A from the negative output terminal. Repeat step 4 to confirm if it is less than 10 3. With the analog ohmmeter, measure the resis- ohms short. tance between the positive and negative output terminals. Refer to Figure F.13. 7. Reconnect lead 202A to the negative output ter- minal. Important: The positive (+) meter probe must be attached to the positive output terminal and the 8. Replace the shorted modules if necessary. negative (-) meter probe must be attached to the negative output terminal. 4. If the reading is approx. 50 ohms, the output rectifier modules are not shorted. If the reading is less than 10 ohms, one or more of the rectifi- er modules may be shorted. Reverse meter probe and verify low reading., F-53 TROUBLESHOOTING AND REPAIR F-53

CHOKE TEST PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The Weld Choke is located down and behind the work stud. This test will help determine whether the Choke is shorted to ground or is open.

MATERIALS NEEDED

Digital Volt/Ohmmeter,

F-54 TROUBLESHOOTING AND REPAIR F-54 CHOKE TEST PROCEDURE (continued) FIGURE F.14 – CHOKE ASSEMBLY

CHOKE/IRON CHOKE/IRON

PROCEDURE

1. Using an Ohmmeter, make sure that the No windings or terminal connections should look choke windings are not grounded to the burned or over-heated. AC welding may cause lamination (> 1megohm). choke to buzz slightly., F-55 TROUBLESHOOTING AND REPAIR F-55

CONTROL BOARD CHECK

Since the functions of the Control Board are primarily software related, there are not very many tests to be per- formed that will help in diagnosing a problem with the board itself. Elimination of problems in the areas where loss of function is taking place will help decide by process of elimination if the Control Board is the defective component. As a result, the troubleshooting chart will typically recommend other areas to be tested before the Control Board. If the Control Board does seem to be the most likely solution, perform the checks outlined below, and then try downloading the latest software into the machine. If a solution is still not evident, use the Diagnostic facility to take a “snapshot” that can then be sent to the Lincoln Service Department via e-mail for assistance in determin- ing where the problem. Contact the Lincoln Service Department at 1-888-935-3877.

TEST PROCEDURE

1. Check the LED’s on the Control Board. Compare 3. If LED’s 9 & 10 are flashing an error code and all the pattern to Page 3 of the Machine Schematic. other LED’s are correct: Normal operation will show 8 Green LED’s ON Check the Error Code list in this section to deter- and both Red LED’s OFF. mine where the problem may be. Green LED’s 1 through 8 indicate the pres- If the Error Code is not listed, contact the Lincoln ence of the various DC supplies to the Board. Service Department for determination. LED 7 (red) will only be ON in the event of a 4. Check the DIP switches. In a single machine set- Primary Over Current. Cycle the Power up, switches 1 through 7 should be OFF. Switch 8 Switch to reset LED 7. should be ON if a remote sense lead is attached. LED’s 9 (green) & 10 (red) will mimic the NOTE: If any switches need to be changed because Status LED on the front panel in the event of the machine was removed from a multi an error. If the Status LED is OFF, these will machine application be sure to write down still indicate the error code. their position before changing them so they can be properly reset when the machine is 2. If any of the Green LED’s 1 through 8 are not lit or returned to it’s position. are dimmer than the others: Turn the power off and disconnect all of the Control Board Molex connectors except J4 and turn the power back on . If the LED(s) in question stay the same: Check the DC voltage levels in connector J4. See the Machine Schematic for correct read- ings. If voltages are correct, replace the Control Board. If not, replace the Power Board., F-56 NOTES F-56, F-57 TROUBLESHOOTING AND REPAIR F-57

SPI CABLE RESISTANCE AND VOLTAGE TEST PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if there is a possible “open” in the SPI cable and also if the correct supply voltages are being applied to the boards in the SPI network.

MATERIALS NEEDED

Volt/Ohmmeter 5/16” Nut Driver Phillips Head Screwdriver, F-58 TROUBLESHOOTING AND REPAIR F-58

SPI CABLE RESISTANCE AND VOLTAGE TEST PROCEDURE (continued)

TEST PROCEDURE 1. Remove the input power to the V450-PRO. 10. Turn on the machine. 2. Using the #2 Phillips screwdriver, remove the 11. Carefully check for the presence of +15VDC case front panel. from plug J33 pin -1(+) to plug J33 pin -10(-) at the display board receptacle. 5. Locate and remove plug J33 from the control board. See Figure F.15. 12. Carefully check for the presence of +5VDC from plug J33 pin -2(+) to plug J33 pin -10(-) at 6. Check the resistance and continuity of the SPI the display board receptacle. cable by testing with the ohmmeter from each pin on plug J33 to the corresponding pins on 13. If either of these voltages are low or not pre- plug J34. See the Wiring Diagram. sent, the control board may be faulty. Replace. Also Perform the Power Board Test. 7. The resistance reading pin to corresponding pin should be zero ohms or very low resis- 14. Remove the input power to the V450-PRO tance. If the resistance reading is high or machine. “open” check the plug connections to the SPI 15. Replace any cable ties previously removed. network PC boards. If the connections are OK and the resistance is high or “open” the SPI 16. Replace the case front. cable may be faulty. 8. Reconnect the plug into the control board. 9. With plug J33 reinstalled in the control board, carefully apply the correct input power to V450-PRO. FIGURE F.15 - Plug J33

J33

PLUG J3316273849510 5 1049

J33 3 8

2716, F-59 TROUBLESHOOTING AND REPAIR F-59

CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION

This procedure will aid the technician in the removal and replacement of either the power board or the control board.

MATERIALS NEEDED

3/8 in. Nut Driver Phillips Head Screwdriver Anti-Static Wrist Strap,

F-60 TROUBLESHOOTING AND REPAIR F-60 CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.16 – BOARD LOCTION

COMPCAORVTEMRENT CONTROL BOARD POWER BOARD COMPARTMENT POWER BOARD

COVER

CONTROL BOARD

REMOVAL PROCEDURE

1. Remove input power to the V450-PRO. 7. Label and remove the two molex plugs and white and black wires with quick connects from 2. Remove the case top, sides and front. the power PC board. 3. Perform the Capacitor Discharge 8. Using the 3/8 in. nut driver, remove the two

Procedure. screws holding the rear of the Control Box in

place. 4. Observe all static electricity precautions. 9. Clear the lead harnesses from the left and right 5. Using the 3/8 in. nut driver, remove the PC sides, and carefully remove the power and con- board compartment cover. Refer to Figure trol PC board assembly.

F.16.

10. Remove either the power or the control board 6. Remove the molex plugs from the control from the PC board assembly. board., F-61 TROUBLESHOOTING AND REPAIR F-61

CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued)

INSTALLATION PROCEDURE 1. Install either the power or control board to the 5. Connect the molex plugs to the control PC PC board assembly and secure it in place. board. 2. Carefully slide the power and control PC 6. Install the PC board compartment cover using board assembly into place, making sure to the 3/8 in. nutdriver. clear the lead harnesses on the right and left side of the PC board compartment. 7. Install the case top and sides using the 3/8 in. nut driver and Phillips screwdriver. 3. Secure the rear of the control box in place. 4. Connect two molex plugs and black and white wires with quick disconnects to the power PC board., F-62 NOTES F-62, F-63 TROUBLESHOOTING AND REPAIR F-63

INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION

This procedure will aid the technician in the removal and replacement of the input rectifi- er module.

MATERIALS NEEDED

3/8” Nut Driver 3/16” Allen Wrench Phillips Head Screwdriver,

F-64 TROUBLESHOOTING AND REPAIR F-64 INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.17 – INPUT RECTIFIER LOCATION

POS (+)NEG (-) REICNTPIUFTIERABCINPUT A RECTIFIER B

C

NEG (-) POS (+)

REMOVAL PROCEDURE REPLACEMENT PROCEDURE

1. Remove input power to the V450-PRO. 1. Clean heat sink surfaces. 2. Using the 3/8” nut driver, remove the case top, 2. Apply an even coating of joint compound input access panel and sides. (Penetrox A-13) to both the heat sink and mod- ule mounting surfaces. The joint compound 3. Perform the Capacitor Discharge Procedure. should be 0.002 - 0.005 in. thick per surface. 4. Locate and remove the RTV sealant from the 3. Mount the module to the heat sink and evenly input rectifier connection terminals. See Figure torque the mounting screws (with washers) to

F.17.

44 in/lbs. 5. Label and, using the Phillips head screwdriver, 4. Assemble the leads to the correct module ter- carefully remove the five leads from the input minals and torque to 26 in/lbs. See Figure F.17. rectifier terminals. Note placement for reassembly. See Figure F.17. 5. Apply RTV sealant to the rectifier connection terminals. 6. Using the 3/16” allen wrench, remove the two mounting screws and washers from the rectifier 6. Install the case top, sides, and input access module. panel using the 3/8” nut driver. 7. Carefully remove the input rectifier module., F-65 TROUBLESHOOTING AND REPAIR F-65

INPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION

This procedure will aid the technician in the removal and replacement of the input con- tactor.

MATERIALS NEEDED

3/8” Nut Driver 5/16” Nut Driver Slot Head Screwdriver, F-66 TROUBLESHOOTING AND REPAIR F-66

INPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.18 – INPUT CONTACTOR LOCATION

CINOPNUTTACTORX4 X4 INPUT CONTACTOR

REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1. Remove input power to the V450-PRO. 1. Mount the contactor and tighten the mounting screws. 2. Using the 3/8” nut driver, remove the case top, and input access panel. 2. Assemble the previously removed leads to the correct terminals. See wiring diagram 3. Perform the Capacitor Discharge Procedure. 3. Install the case top, sides, and input access 4. Locate the input contactor. Label leads and, panel using the 3/8” nut driver. using the slot head screwdriver, carefully remove the leads from the input contactor ter- minals. Note placement for reassembly. See Figure F.18. 5. With the 5/16” nut driver, remove the three mounting screws. 6. Carefully remove the input contactor., F-67 TROUBLESHOOTING AND REPAIR F-67

AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION

This procedure will aid the technician in the removal and replacement of auxiliary trans- former No. 2.

MATERIALS NEEDED

3/8” Nut Driver Wire Cutters, F-68 TROUBLESHOOTING AND REPAIR F-68 AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.19 – TRANSFORMER AND PLUG LOCATIONS

TRANSFORMER #2 P52 P50

3 /S8C” RMEOWUSN T(2IN) G 3/8” MOUNTING

SCREWS (2) TRANSFORMER #2

REMOVAL PROCEDURE 1. Remove input power to the V450-PRO. 4. Using the 3/8” nut driver, remove the case back. 2. Using the 3/8” nut driver, remove the case top, 5. Disconnect plugs P50, P51, and P52 and clean. input access panel and case sides. 6. Using the 3/8” nut driver, remove the two trans- 3. Perform the Capacitor Discharge Procedure. former mounting screws. See Figure F19. 7. Label and clean all leads for transformer removal., F-69 TROUBLESHOOTING AND REPAIR F-69

AUXILIARY TRANSFORMER NO. 2 REMOVAL AND REPLACEMENT PROCEDURE (continued)

REPLACEMENT PROCEDURE 1. Carefully place the transformer into the V450- 4. Connect any leads and install cable ties as nec- PRO. essary. 2. Install the two mounting screws that hold the 5. Install the case back using the 3/8” nut driver. transformer to the machine base using the 3/8” 6. Install the case top, sides, and input access nut driver. panel using the 3/8” nut driver. 3. Connect plugs P50, P51 and P52., F-70 NOTES F-70, F-71 TROUBLESHOOTING AND REPAIR F-71

AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION

This procedure will aid the technician in the removal and replacement of auxiliary trans- former No. 1.

MATERIALS NEEDED

3/8” Nut Driver Wire Cutters Wire Splicer and Soldering Equipment, F-72 TROUBLESHOOTING AND REPAIR F-72 AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.20 – DOOR REMOVAL

P PL5U9G TRANSFORMER #1

3 /S8C” RMEOWUSN T(2IN) G 3/8” MOUNTING

SCREWS (2) TRANSFORMER #1 PLUG

REMOVAL PROCEDURE 1. Remove input power to the V450-PRO. 5. Remove leads 41B and unplug P59. See Figure F.20. 2. Using the 3/8” nut driver, remove the case top, and input access panel. 6. Label and cut or remove all primary and sec- ondary leads from transformer #1. See Wiring 3. Perform the Capacitor Discharge Procedure. Diagram. 4. Using the 3/8” nut driver, remove the case back. 7. Disconnect plug P59. See Figure F.20., F-73 TROUBLESHOOTING AND REPAIR F-73

AUXILIARY TRANSFORMER NO. 1 REMOVAL AND REPLACEMENT PROCEDURE (continued)

8. Cut any necessary cable ties and clear the leads. 9. Using the 3/8” nut driver, remove the two mounting screws that hold the transformer to the fan baffle and the machine base. 10. Carefully remove the transformer from the V450-PRO.

REPLACEMENT PROCEDURE

1. Carefully place the transformer into the V450- PRO. 2. Install the two mounting screws that hold the transformer to the fan baffle and the machine base using the 3/8” nut driver. 3. Reconnect plug P59 and lead 41B. 4. Reconnect all primary and secondary leads. See Wiring Diagram. 5. Reposition any wire leads and install cable ties as necessary. 6. Install the case back using the 3/8” nut driver. 7. Install the case top, sides, and input access panel using the 3/8” nut driver., F-74 NOTES F-74, F-75 TROUBLESHOOTING AND REPAIR F-75

CONTROL, REMOTE, MODE OR DISPLAY PC BOARD REMOVAL AND REPLACEMENT WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION

This procedure will aid the technician in the removal and replacement of the Control Board, Remote Board, Mode Board or Display PC Board.

MATERIALS NEEDED

3/8" Nut Driver Anti-Static Wrist Strap, F-76 TROUBLESHOOTING AND REPAIR F-76 CONTROL, REMOTE, MODE OR DISPLAY PC BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.21 – BOARD LOCATIONS

B MOOADRED

3 / 8 ” BMOOLUTSN T(4IN)G

CONTROL BOARD Front Tilts Forward DISPLAY BOARD DISPLAY BOARD F CONTROL BOARD ront Tilts Forward

3/8” MOUNTING

BOLTS (4) MODE BOARD

REMOVAL PROCEDURE 1. Remove input power to the V450-PRO. 3. Observe all static electricity precautions. 2. Using the Phillips screwdriver, remove the case 4. Remove, replace and add panels as needed front mounting screws and tilt forward. and/or follow advanced process panel kit instructions., F-77 TROUBLESHOOTING AND REPAIR F-77

CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION

This procedure will aid the technician in the removal and replacement of the Current Transducer.

MATERIALS NEEDED

3/8” Nut driver 5/16” Open-End Wrench 9/16” Wrench 3/4” Wrench Phillips Head Screwdriver Wire Cutters Wiring Diagram, F-78 TROUBLESHOOTING AND REPAIR F-78 CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.22 – CURRENT TRANSDUCER LOCATION

BCOASTE FRONT (3)3/8” STOCRME OWFS AT B(BOEHEAL HTIENDD CCOAVY LEADN SNE EFCRTOIONNT) T R CAUNRSRDEUNCTER CURRENT TRANSDUCER HEAVY LEAD BOLTED CONNECTION

(BEHIND CASE FRONT) 3/8” SCREWS AT

BOTTOM OF CASE FRONT (3)

REMOVAL PROCEDURE 1. Remove input power to the V450-PRO. 6. Label all leads to all output terminals. Using the 5/16” wrench and the 3/4” wrench, remove all 2. Using the 3/8” nut driver, remove the case top leads from the two output terminals. and sides and the control box cover. 7. Cut any necessary cable ties. Then carefully 3. Perform the Capacitor Discharge Procedure. swing the front panel aside. 4. Using the 3/8” socket wrench or nut driver, 8. Remove the insulating tape from the heavy lead remove the three screws along the bottom case bolted connection. Using the 9/16” wrenches, front. See Figure F.22. remove the bolt, lock washer and nut. 5. Using the 3/8” socket wrench, remove the four screws that hold the case front to the machine., F-79 TROUBLESHOOTING AND REPAIR F-79

CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE (continued)

9. Using the Phillips head screwdriver, remove 3. Run the heavy lead through transducer and the screws and lock washers that hold the secure the bolted connection with the 9/16” bolt, transducer to the front panel. lock washer and nut. Replace the insulating tape around the connection. 10. Remove the Current Transducer. 4. Replace plug P91 into the new current trans- 11. Remove the standoffs from the transducer ducer. and save them for reassembly with the new transducer. Note placement upon removal. 5. Using the 5/16” wrench and the 3/4” wrench, attach all leads previously removed to the three 12. Remove plug P91. See Wiring Diagram. output terminals. See the Wiring Diagram. 6. Replace any cable ties cut during removal.

REPLACEMENT PROCEDURE

7. Install the case top and sides using the 3/8” nut 1. Attach the stand-offs to the transducer. driver. 2. Position the transducer on the back of the front panel and attach it with the two phillips screws and lock washers. Feed the output leads through the transducer. Note direction of output lead through current transducer., F-80 NOTES F-80, F-81 TROUBLESHOOTING AND REPAIR F-81

SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION

This procedure will aid the technician in the removal and replacement of the switch board(s) and/or filter capacitor(s).

MATERIALS NEEDED

3/8” Nut Driver 7/16” Wrench 3/16” Allen Wrench Slot-Head Screwdriver Penetrox A13 Thermal Joint Compound, F-82 TROUBLESHOOTING AND REPAIR F-82

SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.23 – SWITCH BOARD LOCATION

SWITCH BOARD SWITCH BOARD

REMOVAL PROCEDURE NOTE: Observe all static electricity precautions. 8. Using the 7/16” wrench, remove leads 11/12 or 15/16 from the switch board. See Figure F.24. Lead and plug references below use a slash (/) to indicate machine right side/left side wire number 9. Using the 7/16” wrench, remove leads 19C/D+ differences. and 20C/D- from the switch board capacitor connection bolts. See Figure F.24. 1. Remove input power to the V450-PRO. 10. With the slot head screwdriver, remove the 2. Using the 3/8” nut driver, remove the case top two nylon mounting screws at the bottom of and sides. the switch board. Note placement of the 3. Perform the Capacitor Discharge Procedure. shake-proof washers and fiber spacers. 4. Using the 3/8” nutdriver, remove the screw 11. Using the 3/16” allen wrench, carefully remove mounting the plastic high voltage protective the four cap screws that mount the switch shield. Remove the shield and it’s mount from board to the heat sink. the machine. 12. Carefully remove the switch board from the 5. Remove molex plug J50 from the top of the heat sink. switch board. See Figure F.24. 13. If the filter capacitor is to be removed, careful- 6. Remove the mylar insulating shield covering ly slide it out of the mounting bracket. leads 13/14 or 17/18 (marked clearly on the board). Cut any necessary cable ties. 7. Using the 7/16” wrench, remove leads 13/14 or 17/18 from the switch board. See Figure F.24., F-83 TROUBLESHOOTING AND REPAIR F-83 SWITCH BOARD AND FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE 1. If the filter capacitor is to be replaced, careful- 6. Make sure the capacitor is positioned correctly. ly slide the new capacitor into the mounting Connect leads 19C/D+ and 20C/D- to the cor- bracket. Position the capacitor so the correct rect terminals. Tighten to 55 in/lbs. polarity terminal is lined up with the correct 7. Position and mount the two nylon screws, fiber hole on the switch board. spacers, and washers. Torque from 4 to 8 in- 2. All heat sink and IGBT mounting surfaces lbs. must be clean. 8. Connect leads 15/16 to the correct terminal. 3. Apply a thin coat of thermal compound 9. Connect leads 17/18 to the correct terminal. (Penetrox A13) 0.005 to 0.010 inches thick to the mating surfaces. Do not apply around 10. Install the mylar insulating shield covering mounting holes. leads 15/16. Replace the cable tie. 4. Apply a thin coat of Penetrox A13 to the 11. Connect molex plug J40/J50 to the top of the capacitor terminals. Be careful not to apply switch board. compound to screw threads or threaded area 12. Using the 5/16” nut driver, install the plastic of terminals. high voltage protective shield. 5. Mount the new switch board and tighten the 13. Install the case top and sides using the 3/8” four cap head screws in the following manner. nut driver. Tighten all until snug. Tighten all from 24 to 28 in-lbs. Tighten all from 40 to 48 in-lbs. FIGURE F.24 – SWITCH BOARD LEADS ( Leads197C/1/6D”+ N aUnTd 20C/D-) ( Leads7 1/116/1” 2N oUrT 15/16)

PLUG J40/J50 ( Leads7 1/136/1” 4N UorT 17/18) PLUG J40/J50 7/16” NUT

(Leads 13/14 or 17/18) 7/16” NUT (Leads 11/12 or 15/16) 7/16” NUT (Leads 19C/D+ and 20C/D-), F-84 TROUBLESHOOTING AND REPAIR F-84

RETEST AFTER REPAIR Retest a machine:

If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics.

OR

If you repair or replace any electrical components.

INPUT IDLE AMPS AND WATTS

Input Volts/Hertz Maximum Idle Amps Maximum Idle KW 208/60 4.0 0.40 230/60 3.3 0.40 400/60 2.1 0.40 460/60 2.0 0.40 575/60 1.8 0.40

MAXIMUM OUTPUT VOLTAGES

Output Terminals Input Volts/Hertz 115 Volt Receptacles - No load 208/60 230/60 OCV 10 Amp Load 400/60 50-70 VDC 460/60 115 - 123 VAC 111 - 119 VAC 575/60, G-1 TABLE OF CONTENTS - DIAGRAM SECTION G-1 Electrical Diagrams ..G-1 Wiring Diagram - Complete Machine - (G4923) ..G-2 Schematic – Complete Machine - (G4875) ..G-3 / G-5 Schematic – Digital Control PC Board (G3789) ..G-6 / G-9 Schematic - Digital Power Supply PC Board (G5631) ..G-10 Schematic – Input PC Board - (M19528) ..G-11 PC Board Assembly – Input PC Board - (L11396) ..G-12 Schematic - Switch PC Board - (L11385) ..G-13 PC Board Assembly – Switch PC Board - (G3734) ..G-14 Schematic – SPI / Remote Control PC Board - (G4017) ..G-15 Schematic - Display PC Board - (L11108) ..G-16 PC Board Assembly – Display PC Board - (L11130) ..G-17 Schematic - LED Potentiometer PC Board - (S25258) ..G-18 PC Board Assembly – LED Potentiometer PC Board - (M19874) ..G-19 Schematic - LED Select PC Board - (S25259) ..G-20 PC Board Assembly – LED Select PC Board - (M19875) ..G-21 * NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-lay- ered and are therefore considered to be unserviceable. Assembly drawings of these boards are no longer provided.,

G-2 ELECTRICAL DIAGRAMS G-2 WIRING DIAGRAM - COMPLETE MACHINE - (G4923) INVERTEC V450-PROTM WIRING DIAGRAM LEFT SIDE OF MACHINE CONTROL BOARD SOLID 3R TO 3W CB3DIGITAL POWER J7 3.5A SUPPLY BOARD STATE 41B CIRCUIT

1 RELAY 276 + 3 4 -2 AUXILIARY TRANSFORMER #1 TO AUX #2

BREAKER

5 10 16 3316 SPI FLEX CIRCUIT SPI EXTENSION CIRCUIT TO TP6 18 225 TO P59 H1A 27532223 J4 (0 V) 49715 3315 202 TO J9 4 41A 221 1 X6 H6 H1B 5 J42 3 51 2 (24 V) (550-575) H6A TO INPUT SWITCH 277 J3 4 227 H5 H6 612B38614 3314 J37 X7TO TP365222 42 3 (28 V) (440-460) H53305 WORK721246 4 X827513 3313 TO R1 8 X9 (42 V) H4 H4 H4B TO J61 10A(380-415) 612163304 202A 1 NEGA TO FUSE 4 12 3312 9DISPLAY _ 10 2 POSA TO TO POWER BD.C3 RECTIFIER3303 N.J. AUX #2 3 11 202C J41 3 444 TP4 X3A X3 W H3 CB3H3 TO AUX #1

J33 X325114(220-230) RECONNECT PANEL H1

2 1021TO FAN TO AUX #1 224A (24V) N H2 H2

J333 3301

346 X419J60A J60B J2 CHOKE (200-208) 3313 25332(115V)254 R4 3 268 TO RECT THERM X5 H1 H1 3304 4 WELD 2 3316 4 226 TO THERM 291 TO FAN TO SOLID STATE RELAY3 C1 1 MAIN CHOKE 444 8 16 3216 3314 267 J4 TO3207 3312 3 TERMINALS R5 TP1543305 .05/600V 2 266 266 CR1 15 3215 3315 2 10K/2W OUT1PUT 3 268 J4377345 J60 FAN3206 5 TO J8 P91 6 14 3303 1 CONTROL48CURRENT5 228 216 4 3205 9 228 211 3 + TRANSDUCER X3A X5J4 6 226 10 213 2 TO SOLID STATE RELAY13 3213 TO AUX#15 3204 LED SELECT 277 276 275 LED SELECT 7 227 TO 11 2678 221 J42 212 14 12 3212 3203 9 J43 12 THIS AREA VIEWED FROM TO J5 220 3 11 3211 10 222 REAR OF MACHINE 3202 11 223 224 MAIN N.B., N.G., N.H. 2 10J332 12 225 OUTPUT TRANSFORMER TO J6,J10A 3201 1 224AR19TO RECT LEFT SIDES3 TO RECONNECT SWITCH4A 2J5 224 RECT CHOKEE 6 12 RS232 3 220 THERM THERM TO

J331 CONNECTOR 4 291 220 16

SWITCH BD #2 TO

M 4 13 SWITCH BD #1 RECONNECT2 1 231 RECT5 11 14 POS PANEL O 75 1 232 THERM 19C N.C. TO SW14 10 77 22 253 3 TO 291 SEC PRI TOT 76 3 254 4 (TOP N.J.3 9 76A J40 (TOP SWITCHLEFT) LEFT) BD #2 19 E 554

4 TO 5 504 J50 TO TO AUX #1 200-208V28553 ADVANCED 5 J2 6 503 J60 D4 HARMONIC H2 220-230V617MODE PANEL J34 7 406OR 7 251 405 F4 FILTER TO H3 'A 440-460VPROCESS J6 8 189 238 J40 SWITCH BD #1 H5 ' 550-575V 554 20 10 505 NEG H6F4

J61 11 SWITCH#1BOARD

20D

TO

553 12 604 12 SWITCH BD #213 TO 20 14 506 15 403 2.7 10W

HARMONIC

3500 F FILTER

N.G. 16 404 PRI TOSEC C4 500VNOTE: IF ADVANCED PROCESS PANEL IS WIRE FEEDER REMOTE 1 .022 (BOTTOM (BOTTOM SWITCHLEFT) BD #1

INSTALLED TSHPEI FRLEXMCOIRTCEUISTPI CABLE (REAR VIEW) 2 800V LEFT) PLUGS INTO THE ADVANCED PROCESS 3 D3 20C 19C4 TO PANEL. ADVANCED PROCESS PANEL 6 PIN F3 MAIN TRANSFORMER5 14 SPI CABLE CONNECTS TO THE SPI REMOTE 32A 31A 641 11 12 EXTENSION CABLE. GND 42 7 F3 TO41A J7 8A RECONNECTJ 9 TO RECONNECT HARMONIC N.G. SWITCH42BKI41B CB1 10A 102A 20 FILTER 1941B 11 2ACLNH21 12 2.7

SWITCH

(REAR VIEW ) E D 51 GNDFC75ADMG24 13 10W .022 NEG POS 4A 14ABEF15 3R TO 800V PRI TO (BOTTOM SWITCH 75 77A 75A 16

SSR

3W SEC RIGHT) BD #2 INPUT 76A 77 77A 206D 1 211 POWER BD (BOTTOM RIGHT) 76 2 212 RECTIFIER D2 RECTIFIER20C 19D 3 213 TO POS F2 J8 4 P91 175 TO TO J6, J10B NEG POS 21 6 216 AC AC 41B C3SW2 7 AUX. #1 F2 8 11 INPUT BOARD AC AC ACNEG321206 1 202C TP7 2.72 10W 1 601202 X8 173 2 X3CBA4J9 .022 SEC PRI TO (TOP (TOP SWITCH 3 238 TO N.F. 5 NEG 800V RIGHT) RIGHT) BD #1 4 604 CR1 6 J60 5 232 J6 TO 414 1 NEGA

LOAD

D1 6 AUX #1 INPUT J40 418 2 J10A 7 LINE J50 514 1 J10B518 2 POSA F1 13 8 231 FILTER POS J50

LINE

C3 2400 F F1 1 TO 100V SWITCH TO WORK J43 RIGHT SIDE #2

BOARD 2 T1

3 TO 4 T2 CR1 TP3 5 SW1 TO J61 3500 F J61 6 612 N.K. TO ELECTRODE C5 500V78H1D TO J60 T3 T2 T1 202A 15 16 9 601 R1 20D 19D 10 T3 CR1 X4

TO MAIN TO206A RECONNECT TO AUX #1 L3 L2 L1 TRANSFORMER SWITCH N.E. H6(550-575) 5 H6A

P511W31 1 (115V) R TO L3B L1B 4 CB3 34 4 (230V) AUX #12

SW1 352A 6

H1 L3AH1A C6WVUTO RECONNECT PANEL TO 1 L3 A (TOP) S4CB2 AUXILIARY TRANSFORMER #2 TO SUPPLY LINES .0047 F TO J61 LOAD LINE TO CONTACTOR 440 H1D L3A C7

TO SW 1 L1A N.F. G N.G. S4 TO CB4 TO CONTACTOR115V 612B L1A SWITCH LEAD

RECEPTACLE FILTER TO A SYSTEM GROUND PER NATIONAL ELECTRICAL CODE. 31A 32A 206 TO J9 NOTES:

ELECTRODE CB2 206A TO R1 N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (CATHODE)

15A CIRCUIT ALIGNS WITH BLACK LEAD OF LED SOCKET. BREAKER TO TP3 206D N.B. PLACE SWITCH IN APPROPRIATE POSITION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR 440-575V OPERATION. FRONT REAR FAN RECONNECT RECONNECT C2 HORIZONTAL HORIZONTAL SHROUD SHELL BRACKETTP2 .05/600V

OR BAFFLE BAFFLE N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR

INPUT VOLTAGE. CONNECTION SHOWN IS FOR 550-575V OPERATION. N.D. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE) CASE FRONT REAR AUX. AUX. N.F.

S4 ALIGNS WITH WHITE LEAD OF LED SOCKET. FRONT UPPER UPPER 2

BASE BASE 220V 352A RECEPTACLE N.E. LEAD 34 IS PRESENT IN MODELS WITH 115V RECEPTACLE 31 5A CIRCUIT ON THE CASE FRONT. LEAD 352A IS PRESENT ONLY IN PROTECTIVE BONDING CIRCUIT

N.F. CB2 BREAKER MODELS WITH 220V RECEPTACLE ON THE CASE FRONT.

LEGEND COMPONENT VALUE UNITS: N.F. ONLY PRESENT ON CE MODELS PHANTOM " " = OPTION351 CAPACITOR: MFD/VOLTS RESISTOR: OHMS/WATTS N.G. ONLY PRESENT ON NON-CE MODELS. (EARLIER MODELS USED LEAD COLOR CODINGB=BLACK 10A CIRCUIT BREAKER). G=GREEN CONNECTOR PIN NUMBERS: N=BROWN N.H. "CE" MODELS DO NOT HAVE A RECONNECT SWITCH. POS LEAD R=RED EX. 12 PIN CONNECTORU=BLUE CONNECTS DIRECTLY TO (+) OF C4. LEAD C CONNECTS W=WHITE126(-) OF C4 TO (+) C5 AND NEG LEAD CONNECTS TO (-) OF C5. COMPONENT VALUES: CAPACITORS=MFD/VOLTS N.J. THE "CE" MODELS DO NOT HAVE A RECONNECT PANEL. INSTEAD RESISTORS=OHMS/WATTS 7 12

RIGHT SIDE OF MACHINE LEAD H4B CONNECTS H4 TO SW1. LATCH

N.K. ON CE MODELS LEADS T1, T2 AND T3 ARE REPLACED BY LEADS ELECTRICAL SYMBOLS PER E1537 VIEW OF CONNECTOR ON PC BOARD A, B AND C. LEADS A, B AND C ARE CONNECTED TO THE INPUT RECTIFIER TERMINALS RATHER THAN CR1.

C

G4923PRINT NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

FRONT OF MACHINE

1 3201 2 3202 3 3207 4 3212 5 3213 6 3216 7 3215 12 3204 13 3203 14 3206 15 3205 5 10 5 104949383827271616+ 1 414 1 514 2 418 2 518 3 403 3 503 4 404 4 504 5 405 5 505 6 406 6 506 + +

REAR OF MACHINE

+,

G-3 ELECTRICAL DIAGRAMS G-3 SCHEMATIC - COMPLETE MACHINE - (G4875 SHEET 1)

ENGINEERING CONTROLLED CHANGE DETAIL: CB2 AND FUSE, REVISED AMPS MANUFACTURER: No REVISED NOTE N.B. Heatsink isolated from Switch Boards

SWITCH BOARD #1 MAINTRANSFORMER T1

Undervoltage = 200V Schematic: L11385 ( Located Front Center of Machine) Overvoltage = 467V (Located on left side of Machine) 13 S OUTPUT DIODES C6 + D1-D4 Top Rear 3500uF A (Located above Main transformer) 500V

RECONNECT C4 .022u 2.7

N.B. 11 10WINPUT 800V Conductive Heatsink 206D 206D TO 14-PIN AMPHENOLSWITCH 414 F R2 See Page 2RECTIFIER 380-575V 208-230V 8 Hertz per Volt J40-1 RED(-) 206N.C. 325 Volts = 2600 Hertz CT J40-2 418 14 SWHITE(+) 2.7C5 .022u 10W + ELECTRODE800V (Located bottom AC3 POS HARMONIC frequency = 20 kHz B R3 right side) POS FILTER 404 J40-4 V/F (+) +15 405 J40-5 V/F (-) } 12 C6 2.7 403 } 0 F .022u 10W 206A C2 TP2J40-3 IGBT DRIVE (+) 800V19 19C .05uF 320VAC2 NEG 406 J40-6 IGBT DRIVE (-) -15 R4 (Located Middle 600V 160JFront side) 2.7 CURRENT R1 TP3 AC1 NEG 20C SWITCH BOARD #2 15 S C7 .022u 10W TRANSDUCER 50 150V800V 125:1 80J (Located right of Work stud) TO 14-PIN AMPHENOL Schematic:L11385 C R5 202C 202C NEG 20 Located on right side of machine + See Page 2N.B. 202A 20D 17 Located on rear 202 Located behind horizontal baffle F WORK reconnect panel -MAIN (Located bottomleft side) 16 S CHOKE C6 + L1 3500uF D (Located Behind C1 TP1 500V Work Stud) .05uF 320V160J P91 600V 18 F N.A. 514

INPUT LINE J50-1 RED(-)CT J50-2 518 FILTER 8 Hertz per Volt WHITE(+)325 Volts = 2600 Hertz

frequency = 20 kHz 505 J50-5 V/F (-) } +15504 J50-4 V/F (+) 503 0J50-3 IGBT DRIVE (+) 506 J50-6 IGBT DRIVE (-) } -15 216 212 Located on rear 213 211 Toroid from N.A. horizontal panel main harness

INPUT BOARD 224 224A

G Located behindreconnect panel Schematic: M19528 Not recommended for CR1 Located in reconnect single phase operation. N.C. cavity in rear of machine L1 T1 220+13V J60-3 238 224A U 224 SINGLE PHASE DETECT OUTPUT RECTIFIER CHOKE (LOW=1 PHASE) J60-8 231 THERM THERM L1B T1 J61-2 (Bolted (Connected with 206 L2 T2 220 Connection) epoxy) 202 V T2 J61-4 PRECHARGE frequency = 20 kHz T3 J61-10 RELAY +15 L3 T3 W +13V 4V=500AMPS CURRENT FEEDBACK0 +15V SWITCH L3B -15 -15V +ELECTRODE CR1 VOLTAGE SENSELEAD CONTROL BOARD COMMON - ELECTRODE FILTER 24Vac (Located right VOLTAGE SENSEL3 H1D J61-8 THERMOSTATof Contactor) N.B. (NORMALLY CLOSED)J60-4 604 THERMOSTAT 612 J61-6 225 J4-12 +15V 601 X4 222 J4-10 CONTROL BOARD COMMONMAIN CONTACTOR CONTROL N.A. 504 J6-5 V/F (+) Switch Board 2 C8 C9 L1A L3A 505 J6-10 V/F (-) 8 Hertz per Volt+13V J60-5 232 CONTROL BOARD405 J6-8 V/F (-) 325 Volts = 2600 Hertz Switch Board 1} Schematic: G3789 LEDS - 10 TOTAL Additional input / outputsareV/F (+) .0047uF 404 J6-16 Located on left side of control box DIP Switch -1, Bank of 8 440 601 J60-1 J60-2 (See page 3 for detail) 238 J6-9 +13V Single phase is 570A Max Output illustratedonschematicpage2. limited to 325amps Fold Back = 100A X3 231 J6-1 SINGLE PHASE DETECT (LOW=1 PHASE) Remove Load to reset

AUX. RECONNECT 604 J6-12 PRECHARGE CONTROL (Max Output = 325A)ON H1D

N.B. Located behind control board 232 J6-2 MAIN CONTACTOR CONTROLS1 POWER H2 (left side) Located on top 200-208V + right of case front OFF H3 Located in rear of machine 220-230V behnid reconnect panel. X3A 3R J7-15 FAN CONTROL (+15 VDC)} Fan comes on whenA H5 output is enable440-460V TP4 3W J7-16CR2 FAN CONTROL (-) H6 LEGEND 550-575V DASHED = " " OPTION AUXILIARY 444 PHANTOM = " " PC BOARDS TRANSFORMER T3 - Toroid from Toroid from (left, rear, on base) SOLID STATE main harness main harness FAN RELAY LEAD COLOR CODE: 612B H6 115V X5 Located in Rear of B-BLACK H6A (550-575) PowerSource 41B POWER BD. RECT. J41-2Located on center baffle right of lift bale G-GREEN H5 NTC O-ORANGE (440-460) 24V X4 POS POS J41-4 POWER BOARD R-RED H4 Located near Auxiliary 65VDC C3 + Schematic: G3631 U-BLUE Located on rear of control box (left)612 (380-415) X30V Transformer X8 24000uF/100VW-WHITE X3H3 Y-YELLOW NEG NEGN.A. (220-230) J41-1 LABELS: 42VACH2 X9 J59-3 42 3J41 28VAC COMMON (200-208) X8 24VAC X7 J59-4 24 located on lower TO 14-PINH1 CB1 AMPHENOL CONTROL CAN RS232 SPI LEDS - 2 TOTAL FRAME GROUND H1 center case front (See page 3 for detail) 0V EARTH GROUND X6 J59-2 51 10 ALocated on the right side of 41B J59-1 41A Harmonic Filter 51 41 41 41A 42 COMPONENT VALUE UNITS: H6 352A J51-6 24 TO 14-PIN AMPHENOL Located on FUSE 10A H6A 5 230V 32A See Page 2 CAPACITOR: MFD/VOLTS (550-575)reconnect area 352 J52-2 31A RESISTOR: OHMS/WATTS opposite of contactor 33A J52-4 Not used115V 350 J52-1

CB2 located on lower CB2center case front

CONNECTOR PIN NUMBERS: AUXILIARY 352A 3515A N.A.15A EX. 12 PIN CONNECTOR TRANSFORMER T2 34 J51-4 34 H1B (right, rear, on base) 0V N.B. NOTES: Schematic numbers are given for reference only. 126J51-1 31

CB3 located on 31 J51-1 32 N.A. CE MACHINE ONLY.

reconnect panel N.B.31 J54 N.B. NON-CE MACHINE ONLY. (EARLIER MODELS USED 10A CIRCUIT BREAKERS). PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATEDTO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 7 3.5 A 220V N.C. ON CE MODELS LEADS T1, T2 AND T3 ARE REPLACED BY LEADS12 H1 J54 32A UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND SCALE: LATCH H1A 1 RECEPTACLE A, B AND C. LEADS A, B AND C ARE CONNECTED TO THE INPUT EQUIPMENT TYPE: 3 ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE INVERTEC V450-PRO PAGE _1_ OF _ 115V RECTIFIER TERMINALS RATHER THAN CR1. ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: DsnellLocated on the right side of Located on the left side of ON ALL ANGLES IS ± .5 OF A DEGREE IF PRINTED SUBJECT: MACHINE SCHEMATIC DOCUMENT DOCUMENT@ A1 SIZE NUMBER: REVISION:VIEW OF CONNECTOR ON PC BOARD Harmonic Filter Harmonic Filter RECEPTACLE 31A located on case front MATERIAL TOLERANCE ("t ") TO AGREE ENGINEER: J.O'ConnorWITH PUBLISHED STANDARDS. UNITS: 31A MATERIALLocated on case front APPROVAL PROJECT REFERENCE: DO NOT SCALE THIS DRAWING APPROVED: . INCH DISPOSITION: UF DATE: 7-13-2007 NUMBER: CRM36847

G4875

G4421 C

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

IGBT DRIVE (+) J6-6 503 IGBT DRIVE (-) J6-14 403 IGBT DRIVE (+) J6-15 506 IGBT DRIVE (-) J6-7 406 212 J91-1 +15V CT CURRENT (-) J10A-1 414 213 J91-2 -15V CT CURRENT (+) J10A-2 418 211 J91-3 I OUT 216 J91-4 GND CT CURRENT (-) J10B-1 514 CT CURRENT (+) J10B-2 518 +15V J42-1 225 COM J42-5 222 +5V J42-3 221 J4-8 +5V -15V J42-2 223 J4-11 -15V +5V J43-5 J11-4 +5V ARCLINK +5V COM J43-10 J11-3 ARCLINK COM POWER DOWN INTERUPT J42-4 227 J4-7 POWER DOWN +5V J43-4 226 J4-6 RS232 +5V COM J43-9 228 J4-5 RS232 COM +15V J43-6 266 J4-2 + 15V SPI COM J43-11 267 J4-1 SPI COM +5V J43-3 268 J4-3 +5V SPI COM J43-12 J8-1 J8-2 J8-3 J8-6 J5-2 J5-3 J9 -1 J9 -3 { } G4875,

G-4 ELECTRICAL DIAGRAMS G-4 SCHEMATIC - COMPLETE MACHINE - (G4875 SHEET 2)

ENGINEERING CONTROLLED CHANGE DETAIL: CB2 AND FUSE, REVISED AMPS MANUFACTURER: No REVISED NOTE N.B.

NOTES: OR N.E. THE REMOTE UI PCB ALWAYS RESPONDS AS A REMOTESPI BOARD. CONNECTING PINS 1 & 2 OF J333 TOGETHER WILL ENABLE THE REMOTE UI PCB TO RESPOND AS A STATUS SPI. CONNECTING PINS 11 & 14 OF J332 TOGETHER WILL ENABLE THE REMOTE UI PCB TO RESPOND AS A MODE PCB.

LEDS - 10 TOTAL DIP SWITCH - 1 BANK OF 8 SEE PAGE 3 FOR DETAILS

CONTROL BOARD

Schematic: G3789 Located on left side of control box Additional input / outputs are illustrated on schematic # 1. SPI CIRCUIT 206D Positive Output Studs See page 1 Factory Install OR 202C Negative Polarity Switch for wire feeder meter Field InstallS2 Located next to 14 pin amphenol LED 1 +15V CC-Stick soft 3212 J61-4 13 3207 J61-3 +10V N.D.25 LED 2 +15V 3206 J61-14 13 25 CC-Stick crisp 3202 J61-2 3204 J61-12 +15V +15V HOTLED 3 +10V ARC +10V251 Tig Gtaw START CONTROL 3201 251J61-1 J61-5 J61-13 J61-15 254 LED 4 +15V 3213 MODE CV - wire SWITCH 254 253 14 3216 J61-6 +15V 3203 32051 LED 5 253 14 ADVANCED PROCESS PANEL CV - Innershield MODE PANEL 1 3215 J61-7 Schematic: S25258-1B0 (OPTIONAL)Schematic: G3872-1B1 SPI CIRCUIT See page 1 41 42 24 76A 4 76 41 75A 77 2 77 4A 75 +15V +15V21 76A +15V +15V +15V 42 N.D. 3313 J60B-1 +15V 3303 J60A-1 3316 REMOTEF ONH J60B-2 3315 J60A-2GF4J333-16 3316 3314 J60B-3 LOCALIAE3312

REMOTE

J60A-3 N 76 J333-15 3315 +15V +15V To 115v Case Front Recepticle (For Domestic used only) 31A J

M

K E 77A J333-14 3314 3305 J60B-4 3304 J60A-4 Not on CE ModelsLDD2J333-13 331332AABBJ333-12 3312 OUTPUT CONTROL WELD TERMINALSC Led select pc board Led select pc board75A C J333-8 276 Schematic: S25259-1 R6 Schematic: S25259-1 J333-7 275 com 10K/2W 4A J333-6 277 +10V 2B 2A 6 PIN REMOTE 75 J333-5 3305J333-4 3304 276 J333-3 3303 277 275+10V com WIRE FEEDER REMOTE J333-2J333-1 SPI CIRCUIT AMPHENOLS ARE VIEWED FROM FRONT OF MACHINE +10 Volts J332-16 3216 J332-15 3215 N.E. J332-14 N.D. J332-13 3213 J332-12 3212 J332-11 3211 graphical representation J332-7 3207 of potentiometer connection J332-6 3206 Open view of Control Panel J332-5 3205 REMOTE BOARD J332-4 3204 AMPS VOLTS Schematic: G4017-1D0 J332-3 3203 Average actual current Average actual voltage+_ 3% +_ .5V J332-2 3202 J332-1 3201 DISPLAY PANELSchematic: L11108-3 LEAD COLOR CODE: LAST No. USED COMPONENT VALUE UNITS: B-BLACK R- 6 C - 9 CAPACITOR: MFD/VOLTSG-GREEN O-ORANGE S - 2 RESISTOR: OHMS/WATTS R-RED TP - 4 Located in the middle of U-BLUE J-Numbers CONNECTOR PIN NUMBERS: J2,J3,J4,J5,J6,J7,J8, Control PanelW-WHITE EX. 12 PIN CONNECTOR Y-YELLOW J9,J10A,J10B,J11,

LEGEND

J40,J50,J42,J43,J51, 126Schematic numbers are given for reference only. DASHED = " " OPTION LABELS: J52,J54,J59, PHANTOM = " " PC BOARDS COMMON J60 andJ61(InputPCB), J61(Mode PCB), 7 12 FRAME GROUND J60A,J60B LATCH PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. EARTH GROUND J91,J331, VIEW OF CONNECTOR ON PC BOARD MANUFACTURING TOLERANCE PER E2056J332,J333 UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND SCALE: EQUIPMENT TYPE: 3 ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE INVERTEC V450-PRO PAGE _2_ OF _ ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: Dsnell ON ALL ANGLES IS ± .5 OF A DEGREE IF PRINTED MATERIAL TOLERANCE ("t ") TO AGREE J.O'Connor @ A1 SIZE SUBJECT: MACHINE SCHEMATIC DOCUMENT DOCUMENTNUMBER: REVISION: ENGINEER: WITH PUBLISHED STANDARDS. UNITS: MATERIAL APPROVAL PROJECT REFERENCE: G4875 DO NOT SCALE THIS DRAWING APPROVED: . INCH DISPOSITION: UF DATE: 7-13-2007 NUMBER: CRM36847 G4421 C

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

"2" LEAD J331-11 "77" LEAD J331-10 14 PIN'S "76" LEAD J331-9 SOLENOID COIL (+) J331-8 14 PIN'S "4" LEAD J331-6 6 PIN'S "4" LEAD J331-5 "75" LEAD J331-4 6 PIN'S "76" LEAD J331-3 SOLENOID COIL (-) J331-2 J3-1 (+)15 VOLT SPI J3-2 (+)5 VOLT SPI J3-3 /SS J3-4 CS1 J3-5 CS2 J3-6 CS3 N.D. J3-7 MISO J3-8 SCK RS232 COMMON J2-1 251 J3-9 MOSI RECEIVE J2-3 253 J3-10 GROUND SPI TRANSMIT J2-4 254

THERMAL

} } } G4875,

G-5 ELECTRICAL DIAGRAMS G-5 SCHEMATIC - COMPLETE MACHINE - (G4875 SHEET 3)

ENGINEERING CONTROLLED CHANGE DETAIL: CB2 AND FUSE, REVISED AMPS MANUFACTURER: No REVISED NOTE N.B.

CONTROL BOARD

Error codes for the Invertec V450-PRO 1. STD DISPLAY PC BOARD ASSEMBLY 2. SPI ASSEMBLY J5 J6 J7 J8 J9 The following is a list of possible error codes that the Power Wave can output via the status light3. REMOTE PC BOARD ASSEMBLY 4. LED SELECT PC BOARD ASSEMBLY 5. FACTORY MODE PANEL ASSEMBLY Error Code # Indication LED1 21 Unprogrammed Weld Mode. Contact the Service Department for instructions on reloading the Welding Software. LED9

J4 22 Empty Weld Table. Contact the Service Department for instructions on LED10 reloading the Welding Software.

Contact the Service Department for instructions on LED2 23 Weld Table checksum error. reloading the Welding Software. LED5 31 Primary overcurrent error. Excessive Primary current present. May be related to a switch board or output rectifier failure.

J3 LED3 32 Capacitor “ A” under voltage(Left side facing machine) Low voltage on the main capacitors. May be caused by

33 Capacitor “ B” under voltage improper input configuration, or an open/short circuit LED4 J10B (Right side facing machine) in the primary side of the machine.

LED6 S1 (S1 is not used) 34 Capacitor “ A” over voltage(Left side facing machine) Excess voltage on the main capacitors. May be caused

J2 35 Capacitor “ B” over voltage by improper input configuration, or an open/short J10A (Right side facing machine) circuit in the primary side of the machine. Indicates over temperature. Usually accompanied by 36 Thermal error Thermal LED. Check fan operation. Be sure process does not exceed duty cycle limit of the machine.

J1 37 Softstart error Capacitor precharge failed. Usually accompanied by J11 codes 32-35.

4 The secondary (weld) current limit has been exceeded. LED7 When this occurs the machine output will phase back234541 Secondary overcurrent error to 100 amps, typically resulting in a condition refered1 LED8 to as “ noodle welding” The maximum voltage difference between the main 43 Capacitor delta error capacitors has been exceeded. May be accompanied by

Control Panel errors 32-35.Indicates machine is running on single phase input

49 Single phase error power. Usually caused by the loss of the middle leg (L2). Other Use Snap Shot to interpret other errors or Diagnostic Sofware

Description of LED functions on the Invertec V450-PRO

Factory Mode Panel For reference only RS232 L11088 Digital Control PC Board LED # COLOR FUNCTION WELD MODE Hot Arc Control 1 Green Indicates +15VDC from power supply board is present Start2Green Indicates –15VDC from power supply board is present C-C Stick Soft503Green Indicates +5VDC for +5SPI from power supply board is present C-C Stick crisp 4 Green Indicates +15VDC for +15SPI from power supply board is present Tig Gtaw 5 Green Indicates +5VDC for +5V from power supply board is present6 Green Indicates +5VDC for +5VRS232 from power supply board is present CV Wire 1 10 -10 +10 7 Red FAULT Signal (See software group for coding) CV Innershield Select Touch Hi-Freq Crisp 8 Green Indicates +5VDC for +5CAN from power supply board is presentStart TIG SoftTIG 9 Green ArcLink Status Indicators (Main System Master ArcLink Connection) Solid 10 Red Green only when functional (See software for error codes) Alpha Numeric RS232 Advance Process Panel Display 1 10 (Optional) 1. Power Switch 2. 24V-42V 10 Amp Wire Feeder Circuit Breaker 3. 115V Auxiliary Power & Select Adjust Wire Feeder Circuit Breaker Memory 4. 6 pin Remote

POWER BOARDS 5. Work StudSelect 6. Electrode Stud7. 14 Pin Wire feeder Remote Description of LED functions on the Invertec V450-PRO 11 8. Auxiliary Output (110V or 220V)9. STD Display Board

For reference only 10. Weld Terminal /Remote ON 8 Memory Select weld process Select Hot Start Adjust Hot Start & 14 Arc control 11. Output Control /Remote Local (encoder) or Arc Weld (encoder) G3632 Digital Power Supply Board 12. Wire Feeder Polarity Switch LED # COLOR FUNCTION 13. Control Knob 1 Red Indicates +5VDC SPI supply is present 14. Mode Panel or (optional) Advance 2 Red Indicates +5VDC control supply is present Process Panel found underneath Front Panel Door. 15. Thermal Light Invertec V450- PRO Case frontDetail45283712 6 PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATEDTO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND SCALE: EQUIPMENT TYPE: 3 ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE INVERTEC V450-PRO PAGE _3_ OF _ ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: Dsnell DOCUMENT DOCUMENT ON ALL ANGLES IS ± .5 OF A DEGREE IF PRINTED SUBJECT: NUMBER: REVISION: MATERIAL TOLERANCE ("t ") TO AGREE ENGINEER: J.O'Connor @ A1 SIZE MACHINE SCHEMATIC WITH PUBLISHED STANDARDS. UNITS: MATERIAL APPROVAL PROJECT REFERENCE: DO NOT SCALE THIS DRAWING APPROVED: . INCH DISPOSITION: UF

G4875

DATE: 7-13-2007 NUMBER: CRM36847 G4421 C

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

G4875,

G-6 ELECTRICAL DIAGRAMS G-6 SCHEMATIC - DIGITAL CONTROL PC BOARD - (G3789 SHEET 1)

ENGINEERING CONTROLLED CHANGE DETAIL: PAGE 3, R65, REVISED VALUE MANUFACTURER: Yes PROPRIETARY & CONFIDENTIAL:THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATEDTO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: INVERTER WELDER PAGE _1 4ON 2 PLACE DECIMALS IS ± .02 _ OF _ ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: FEI G3789-1E2 DOCUMENT DOCUMENT ON ALL ANGLES IS ± .5 OF A DEGREE MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: SCALE: SUBJECT: SCHEMATIC DIGITAL CONTROL NUMBER: REVISION: WITH PUBLISHED STANDARDS. MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING APPROVED: . NONE DISPOSITION: UF DATE: 10/26/2006 NUMBER: CRM22115-GA

G3789-2FO B NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

G3789-2FO,

G-7 ELECTRICAL DIAGRAMS G-7 SCHEMATIC - DIGITAL CONTROL PC BOARD - (G3789 SHEET 2)

ENGINEERING CONTROLLED CHANGE DETAIL: PAGE 3, R65, REVISED VALUE MANUFACTURER: Yes PROPRIETARY & CONFIDENTIAL:THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATEDTO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: INVERTER WELDER PAGE _21 4ON 2 PLACE DECIMALS IS ± .02 _ OF _ ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: FEI G3789-1E2 DOCUMENT DOCUMENT ON ALL ANGLES IS ± .5 OF A DEGREE MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: SCALE: SUBJECT: SCHEMATIC DIGITAL CONTROL NUMBER: REVISION: WITH PUBLISHED STANDARDS. MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING APPROVED: . NONE DISPOSITION: UF DATE: 10/26/2006 CRM22115-GA

G3789-2FO

NUMBER: B

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

G3789-2FO,

G-8 ELECTRICAL DIAGRAMS G-8 SCHEMATIC - DIGITAL CONTROL PC BOARD - (G3789 SHEET 3)

ENGINEERING CONTROLLED CHANGE DETAIL: PAGE 3, R65, REVISED VALUE MANUFACTURER: Yes 47.5K PROPRIETARY & CONFIDENTIAL:THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATEDTO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: ON 2 PLACE DECIMALS IS ± .02 INVERTER WELDER PAGE _31_ OF _4_ ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: FEI G3789-1E2 DOCUMENT DOCUMENT ON ALL ANGLES IS ± .5 OF A DEGREE SUBJECT: MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: SCALE: SCHEMATIC DIGITAL CONTROL NUMBER: REVISION: WITH PUBLISHED STANDARDS. MATERIAL UF APPROVAL PROJECTAPPROVED: . NONE 10/26/2006 CRM22115-GA G3789-2FODO NOT SCALE THIS DRAWING DISPOSITION: DATE: NUMBER: B

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

G3789-2FO,

G-9 ELECTRICAL DIAGRAMS G-9 SCHEMATIC - DIGITAL CONTROL PC BOARD - (G3789 SHEET 4)

ENGINEERING CONTROLLED CHANGE DETAIL: PAGE 3, R65, REVISED VALUE MANUFACTURER: Yes PROPRIETARY & CONFIDENTIAL:THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATEDTO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: ON 2 PLACE DECIMALS IS ± .02 INVERTER WELDER PAGE _41_ OF _4_ ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: FEI G3789-1E2 DOCUMENT DOCUMENT ON ALL ANGLES IS ± .5 OF A DEGREE SUBJECT: MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: SCALE: SCHEMATIC DIGITAL CONTROL NUMBER: REVISION: WITH PUBLISHED STANDARDS. MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING APPROVED: . NONE

G3789-2FO

DISPOSITION: UF DATE: 10/26/2006 NUMBER: CRM22115-GA B

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

G3789-2FO, G-10 ELECTRICAL DIAGRAMS G-10 SCHEMATIC - DIGITAL POWER SUPPLY PC BOARD - (G5631) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual., G-11 ELECTRICAL DIAGRAMS G-11 SCHEMATIC - INPUT PC BOARD - (M19528) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.,

G-12 ELECTRICAL DIAGRAMS G-12 PC BOARD ASSEMBLY - INPUT PC BOARD - (L11396)

ENGINEERING CONTROLLED CHANGE DETAIL: REVISED NOTE N.B. No REFERENCES QTY PART NO. DESCRIPTIONMANUFACTURER: C1 1 S16668-5 .022/50 CR1, CR2 2 S14293-18 DPST RELAY D1, D3 2 T12199-1 1N4004 D2 1 T12705-58 DIODE,1.0A,1500V N.C. J60 1 S24020-8 HEADER,VERTICAL N.C. J61 1 S24020-10 HEADER,VERTICAL OCI1 1 S15000-22 OPTO ISOLATOR R1, R2, R3, R6, R7, R8, R9, R10 8 S24376-3 100/1OW R4 1 S19400-2673 267K 1/4W

P.C. BOARD BLANK INFORMATION R5 1 S19400-4750 475 1/4W BUY COMPLETE AS L11396-B R11, R12, R13, R14, R15, R16, 15 S19400-3011 3.01K 1/4WR17, R18, R19, R20, R21, R22,

( 2 LAYER BOARD PER E3281) R23, R24, R25 (MAKES 8 BOARDS PER PANEL, SEE ELECTRONIC FILE TP1, TP2, TP3, TP4 4 T13640-23 MOV,250J,660V FOR ADDITIONAL INFORMATION) N.D. N.A. N.D. 4.50 ±.04

XXXXXXXX INPUT XXXXXXX

ITEM REQ'D PART NO. IDENTIFICATION11SEE BLANK INFO. P.C. BD. BLANK J61 J60 2 1.0 OZ. E2861 SEALANT D132S14020-7 PLASTIC EXPANSION NUT R22 TP4 TP3 D2 R24 R11 OCI1 R25 R12 TP2 R23 R13 R21 R14 R20 R15 CAPACITORS = MFD / VOLTS1 TP1 R19 R16

XXX R18 R17X X RESISTORS = OHMS/WATTS X R7

CR1

X CR2 X X NOTES:

R6

X X N.A. THIS AREA TO BE COVERED ON BOTH SIDES OF BOARD WITH ITEM 2 PRIOR TO

R9XXENCAPSULATION. MATERIAL MUST BE APPLIED THRU SLOTS FROM BOTTOMR8 SIDE TO COMPLETELY FILL TO UNDERSIDE OF DEVICE ON COMPONENT SIDE.

X X XXXXN.B. P.C. BOARD HOLES TO BE FREE OF ENCAPSULATION MATERIAL AND RTV FORR3 A DIAMETER OF .40 ON COMPONENT AND NON-COMPONENT SIDES OF BOARD XXXR1 X (6 PLACES).

N.B. XXX X R10XXR2 X N.C. DO NOT COAT WITH ENCAPSULATION MATERIAL.

XXXXN.D. APPLY ITEM 2 AS SHOWN, ALL EXPOSED LEADS MUST BE COVERED. MATERIAL

L11396-2 MUST BE APPLIED PRIOR TO ENCAPSULATION. N.E. APPLY ITEM 2 ON NON-COMPONENT SIDE OF BOARD PRIOR TO N.D. N.D. ENCAPSULATION. ALL EXPOSED PINS MUST BE COVERED.0 6.00 ±.04

MAKE PER E1911-ROHS ENCAPSULATE WITH E1844 MANUFACTURED AS: TEST PER E3647-I SCHEMATIC REFERENCE: M19528-2B0 L11396-2B0 IDENTIFICATION CODE

ALL COMPONENTS AND MATERIALS USED IN THIS ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253. PROPRIETARY & CONFIDENTIAL:THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATEDTO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND SCALE: EQUIPMENT TYPE: ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) 1:1 INVERTER WELDERS PAGE _1_ OF _1_ ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: fivory IF PRINTED SUBJECT: INPUT P.C. BOARD ASSEMBLY DOCUMENT DOCUMENTON ALL ANGLES IS ± .5 OF A DEGREE @ A2 SIZE NUMBER: REVISION: MATERIAL TOLERANCE ("t ") TO AGREE ENGINEER: WITH PUBLISHED STANDARDS. UNITS: MATERIAL UF APPROVAL 2-8-2008 PROJECT REFERENCE: APPROVED: - INCH CRM39233 L11396-2DO NOT SCALE THIS DRAWING DISPOSITION: DATE: NUMBER: L11396-1 C NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may 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. C1 R4 D3 R5 L11396-2,

G-13 ELECTRICAL DIAGRAMS G-13 SCHEMATIC - SWITCH PC BOARD - (L11385)

ENGINEERING CONTROLLED CHANGE DETAIL: NEW. MANUFACTURER: No PROPRIETARY & CONFIDENTIAL:THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATEDTO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND SCALE: EQUIPMENT TYPE: ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE PW-455 PAGE _1_ OF _1_ ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: fivory IF PRINTED DOCUMENT DOCUMENT ON ALL ANGLES IS ± .5 OF A DEGREE @ A2 SIZE SUBJECT: ENGINEER: - SCHEMATIC, SWITCH PCB NUMBER: REVISION:MATERIAL TOLERANCE ("t ") TO AGREE WITH PUBLISHED STANDARDS. UNITS: MATERIAL APPROVAL PROJECT REFERENCE: DO NOT SCALE THIS DRAWING APPROVED: DRS INCH NA 11-6-2009 CRM41517

L11385-2D1

DISPOSITION: DATE: NUMBER: - A

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

L11385-2D1,

G-14 ELECTRICAL DIAGRAMS G-14 PC BOARD ASSEMBLY - SWITCH PC BOARD - (G3734)

ENGINEERING CONTROLLED CHANGE DETAIL: ADDED ITEM 6 AND NOTE N.Y. ITEM (USED WITH)* QTY PART NUMBER DESCRIPTION MANUFACTURER: No REVISED MANUFACTURED AS, IDENTIFICATION CODE AND SCHEMATIC REFERENCE PART NUMBERS P.C. BOARD BLANK REFERENCE INFORMATION11G3734-E PC BOARD BLANK N.D. 2 (B11, B19, B20)* 3 T9147-11 CONNECTOR,EYELET,POWER,FEMALE NOTES : N.X. 3 1 S24869-2 PC BOARD SHIELDBUY COMPLETE AS G3734-E (4 LAYER BOARD PER E3281) 4 280 g. E2527 EPOXY ENCAPSULATING RESIN N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC51S24869-1 PC BOARD SHIELD ELECTRICITY. SEE E2454 BEFORE HANDLING. (SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION) 6 1 oz. E2861 SEALANT N.D. FEMALE EYELET TO BE AGAINST THE COPPER SIDE AS SHOWN. N.D. REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW EYELET MUST NOT SPIN AFTER CLINCHING. REFERENCES QTY PART NUMBER DESCRIPTION N.E. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET AND 2 N.A.,N.J.,N.R. A1, A2 2 M21214-2 ELECTRONIC MODULE,5-T12704-84 IGBT'S ALL AROUND EYELET ON COPPER SIDE ONLY. NO ICICLES OR B11, B19, B20 3 T9147-15 CONNECTOR,EYELET,POWER,MALE SOLDER BLOBS PERMITTED. MUST BE SMOOTH AND EVEN WITHIN .020" OVER SURFACE. N.Q. B13 1 S24866 BRACKET,POWER-HOLDER N.Q. B14 1 S23006 CONNECTOR,TERMINAL,POWER N.H. MOLEX CAVITIES AND AREA AROUND LOCKING TAB TO BE FREE OF ENCAPSULATION MATERIAL. R .045 .275 C1 1 S20500-14 CAPACITOR,PPMF,.022,100V,BOX,5% MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS. .285 C2 1 S16668-11 CAPACITOR,CEMO,0.1, 50V,10% MAX. C3 1 S16668-5 CAPACITOR,CEMO,.022,50V,20% N.J. ELECTRONIC MODULES TO BE ASSEMBLED, SOLDERED, AND SEALED TO PC BOARD PER E3875. .116 CRIMP HEIGHT C4, C6, C7 3 S16668-6 CAPACITOR,CEMO,4700pF,50V,10% C5 1 S13490-93 CAPACITOR,TAEL,27,35V,10% N.M. DO NOT COAT THE TOP SURFACES OR THE THREADS WITH ENCAPSULANT MATERIAL (1 TERMINAL). COPPER SIDE C8, C9, C10, C11, C12, 10 S20500-1 CAPACITOR,PPMF,0.1,1000V,10%,BOX MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS. C13, C14, C15, C16, C17 D1, D2 2 T12705-44 DIODE,AXLDS,1A,1000V,FR, 818 N.Q. BRACKET MUST HAVE FULL MATING CONTACT WITH POWER TERMINAL AND HAVE HOLES ALIGNED. D3, D4, D5, D6, D7, D8, 10 T12705-32 DIODE,TO220,15A,600V,FR,MUR1560 D9, D10, D11, D12 N.R. ELECTRONIC MODULES ON A COMMON P.C. BOARD ASSEMBLY TO EYELET DETAIL DZ1 1 T12702-4 ZENER DIODE,1W,20V,5%,1N4747A HAVE THE SAME VENDOR CODE. DZ2, DZ3, DZ5, DZ6 4 T12702-29 ZENER DIODE,1W,15V,5%,1N4744A e.g. M21214-2 X XX XXX... DZ4, DZ7 2 T12702-40 ZENER DIODE,1W,6.2V,5%,1N4735A J40 1 S24020-6 CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN VENDOR CODE L1, L2, L3, L4, L5, L6, L7, 10 T12218-15 CHOKE,RF,FERRITE BEAD,180 OHM VCE(SAT) L8, L9, L10 OCI1 1 S15000-22 OPTOCOUPLER,PHOTO-Q,70V,CNY17-3/VDE VGE(TH) R1 1 S16296-5 TRIMMER,MT,1/2W,10K, 10%,LINEAR N.S. AFTER SOLDERING, INSPECT TERMINAL CONNECTIONS PER E1880. R2 1 S19400-6811 RESISTOR,MF,1/4W,6.81K,1% N.T. ENCAPSULATE COMPONENT SIDE OF P.C. BOARD TO A THICKNESS OF .30 +.12/-.00 IN AREA SHOWN. R3, R8 2 S19400-1002 RESISTOR,MF,1/4W,10.0K,1%R4, R13, R14, R17, R18, N.U. ENCAPSULATE NON COMPONENT SIDE OF P.C. BOARD TO A THICKNESS OF .25 +.12/-.00. R19, R20, R21, R23, R24, 13 S19400-10R0 RESISTOR,MF,1/4W,10.0,1% R25, R26, R27 N.V. ENCAPSULATION MATERIAL MUST EXTEND BEYOND EDGES OF P.C. BOARD .12 +.12/-.00. R5, R9 2 S19400-2001 RESISTOR,MF,1/4W,2.00K,1% R6 1 S19400-2213 RESISTOR,MF,1/4W,221K,1% N.W. ENCAPSULATE OPPOSITE COMPONENT SIDE OF P.C. BOARD IN AREAS SHOWN TO A MAXIMUM THICKNESS OF .20. R7 1 S19400-1000 RESISTOR,MF,1/4W,100,1% R10, R12, R15 3 S19400-1003 RESISTOR,MF,1/4W,100K,1% N.X. BOTH P.C. BOARD SHIELDS SOLDER INTO THE SAME MOUNTING HOLES. ITEM 3 IS MOUNTED ON NON-COMPONENT SIDE N.X. R11 1 S19400-6191 RESISTOR,MF,1/4W,6.19K,1% OF P.C. BOARD. N.W. R16, R22 2 S19400-1001 RESISTOR,MF,1/4W,1.00K,1% N.Y. APPLY A BEAD OF ITEM 6 TO COVER R28, R29, R30, R31 AND R32. 5 3 N.Y. R28, R29, R30, R31, R32 5 T14648-9 RESISTOR,WW,5W,2.5K,5%,SQ T1 1 T12737-7 TRANSFORMER,PULSE,3-WINDING T2 1 M19612 CURRENT-TRANSDUCER,125-TURN 6.00 ±.04 X1 1 M13552-3 IC,CONVERTER,V/F,654 .30 +.12-.00 X2 1 S15128-10 VOLTAGE REF,ADJ, PRECISION,431I C5 C1 X2 X1 R9 R2 R10 R11 C3 A1 R5 OCI1 DZ3 DZ2 C6 DZ4 L5 L4 L3 L2 L1 R16 R13 N.H. R21 R20 R19 R18 R17 DZ5 R 1.62 C7 3.00 DZ6R30 R29 R28 R14 DZ7 N.E.N.M., N.S.,N.Q. (3 PLACES) R27 R26 R25 R24 R23 J40 L10 L9 L8 L7 L6 A2 N.Q. .30 +.12-.00 N.W. N.W.6 .00 1.20 1.38 +.12-.00 N.T.,N.U.,N.V. 2.00 ±.12 11.15 ±.04 MAKE PER E1911-ROHS POT PER E1911-E-ROHS TEST PER E3901-SW NON COMPONENT SCHEMATIC REFERENCE: L11385-3E1 SIDE ENCAPSULATION MANUFACTURED AS: ALL COMPONENTS AND MATERIALS USED IN THIS

G3734-3E1 ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.

IDENTIFICATION CODE FOR PARTS ORDERS OR SUBSIDIARY ORDERS N.W. INCLUDE ONE G3010PRINT, ONE M19661PRINT, P.C. BOARD COMPONENT SIDE ENCAPSULATION ONE S25254PRINT AND ONE T12837-1. PROPRIETARY & CONFIDENTIAL:THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATEDTO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND SCALE: EQUIPMENT TYPE: 1 ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) 1:1 INVERTER WELDERS PAGE _1_ OF _ ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: fivory ON ALL ANGLES IS ± .5 OF A DEGREE IF PRINTED DOCUMENT DOCUMENT MATERIAL TOLERANCE ("t ") TO AGREE ENGINEER: @ A1 SIZE SUBJECT: SWITCH P.C. BD ASSEMBLY NUMBER: REVISION: WITH PUBLISHED STANDARDS. UNITS: MATERIAL APPROVAL PROJECT REFERENCE: DO NOT SCALE THIS DRAWING APPROVED: DRS INCH DISPOSITION: UF DATE: 11-6-2009

G3734-3

NUMBER: CRM41517 G3734-2 E NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. G3734-3 SH1 C4 R3 R6 R7 DZ1 T2 C2 R1 R4 R8 T1 B13 R12 B14 D1 R15 D2 R22 C8 C13 D3 D8 C9 C14 D4 D9 C10 C15 D5 D10 C11 C16 D6 D11 C12 C17 D7 D12 R31 R32 B11 B20 B19 11/12

OR

20 19 SWITCH15/16 G3734-3, G-15 ELECTRICAL DIAGRAMS G-15 SCHEMATIC - SPI / REMOTE CONTROL PC BOARD - (G4017) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual., G-16 ELECTRICAL DIAGRAMS G-16 SCHEMATIC - DISPLAY PC BOARD - (L11108) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.,

G-17 ELECTRICAL DIAGRAMS G-17 PC BOARD ASSEMBLY - DISPLAY PC BOARD - (L11130)

ENGINEERING CONTROLLED CHANGE DETAIL: REVISED NOTE N.D. No ITEM / REFERENCE DESIGNATORS QTY PART NUMBER DESCRIPTIONMANUFACTURER: 1 1 L11757-F P.C. BOARD BLANK24T15176-2 LED, SPACER, 0.140 HIGH 3 .01 OZ. E3539 ELECTRICAL INSULATING COMPOUND41L11166-2 FLEX CIRCUIT51T15067-2 LABEL FOR ITEMS BELOW REFER TO ELECTRONIC COMPONENTS DATABASE FOR COMPONET SPECIFICATIONS C1 1 S25024-7SMT CAPACITOR,SMD,TANTALUM,47MF,20V,10%,S7343 C2, C3, C4, C5, C11, C12, C19, C20 8 S25020-3SMT CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X7R,S0805 N.A., N.D. DISP1, DISP2 2 S17395-9 LED,DISPLAY,7-SEGMENT,CC,4-DIGIT J37 1 S18248-10 CONNECTOR,MOLEX,MINI,PCB,10-PIN N.A. LED1, LED2, LED3, LED4 4 T13657-6 LED,T-1,RED,HLMP-K101 N.A. LED5, LED6, LED7 3 T13657-14 LED,T-1,3/4,AMBER,HIGH-INTENSITY R6, R16 2 S25000-1501SMT RESISTOR,SMD,METAL FILM,1/10W,1.50K,1%,S0805 R9, R10, R11, R12, R13, R14 6 S25000-1212SMT RESISTOR,SMD,METAL FILM,1/10W,12.1K,1%,S0805 R20 1 S25000-2670SMT RESISTOR,SMD,METAL FILM,1/10W,267OHMS,1%,S0805 R21, R25, R26, R28, R29 5 S25000-1001SMT RESISTOR,SMD,METAL FILM,1/10W,1.00K,1%,S0805 R22, R23 2 S25000-10R0SMT RESISTOR,SMD,METAL FILM,1/10W,10.0OHMS,1%,S0805 R24 1 S25000-4751SMT RESISTOR,SMD,METAL FILM,1/10W,4.75K,1%,S0805 R27 1 S25000-4752SMT RESISTOR,SMD,METAL FILM,1/10W,47.5K,1%,S0805 N.B. X1 1 S17900-8SMT IC,SMD,CMOS,INVERTER,SCHMITT,HEX,HC14A(SS) N.B. X2 1 S17900-26SMT IC,CMOS,SMD,MUX,DAT,8-INPUT,HC151(SS) N.B. X3 1 S17900-28SMT IC,SMD,CMOS,HEX INVERTING BUFFER,3-ST (SS) N.G. N.B. X4 1 S17900-10SMT IC,SMDCMOS,REGISTER,SHFT,S-PI/SO,8-BIT(SS) 1 5 N.B. X5, X6, X7 3 S20496-1SMT IC,SMD,CMOS,DRIVER,DISPLAY,LED,CC,MCU .15 N.E. N.A. 2.95 1.75 NOTES: 1.60 R6 SPI DISPLAY L11130-5DISP1 1.45 C20 R21

N.A. DO NOT COAT WITH ENCAPSULATION MATERIAL.

LED5 N.B. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC X6 N.A. ELECTRICITY. SEE E2454 BEFORE HANDLING.R25LED X5 LED6 X2 LED1 LED2 LED7 X4 C3 LED3 C12 DISP2 N.A. C1 N.C. USE ITEM2 TO STAND LED1, LED2,LED3 AND LED4 FROM THE P.C. BOARD. THERE.50 X7 R11 2 LED4R13 R16 MUST NOT BE MORE THAN .020 GAP BETWEEN SPACER AND P.C. BOARD OR X1 R26 3 R24 N.C. 5 4R9 R28 R27 .15 BETWEEN SPACER AND LED. ENCAPSULATE P.C.BOARD, SPACER AND LOWER HALFC2 J37 R14 R10 C5 0 OF LED. TOP 1/4 OF LED BODY MUST BE FREE OF ENCAPSULATION. 2 5.65 5.90 N.D. DISP1AND DISP2MUST ALWAYS BE MATCHED BY VENDOR NAME, AND EACH MUST 0 .25 5.75 HAVE THE SAME INTENSITY LETTER CODE (G, H, J, ETC.). DO NOT MIX DIFFERENT GROUND SIDE VENDORS ON THE SAME BOARD ASSEMBLY. ENCAPSULATE LEADS AND SOLDER

CONNECTIONS OF DISPLAYS. FACE OF DISPLAYS MUST BE KEPT FREE OF ENCAPSULATION. ENCAPSULATION AROUND UPPER HALF OF DISPLAYS MUST NOT EXCEED .006 PER SIDE.

UNLESS OTHERWISE SPECIFIED: CAPACITORS = MFD/VOLTS N.E. CONNECTOR MUST BE GREASED WITH ITEM3PRIOR TO PLACING IN STOCK. MOUNT4 INDUCTANCE = HENRIES FLEX CABLE BETWEEN CONNECTOR AND BOARD ON SOLDER SIDE. RESISTANCE = OHMS N.F. IDENTIFY FINISHED ASSEMBLY WITH SERIAL NUMBER AND MANUFACTURING CODE.

PLACE LABEL ON NON-COMPONENT SIDE. N.G. PRINT "L11130-5" ON ITEM 5 AND PLACE OVER EXISTING PART NUMBER. MAKE AS:

L11757-2 MUST BE REVIEWED WHEN MODIFYING THIS BOARD. FRONT SIDE OF CONNECTOR MANUFACTURE PER E1911-ROHS ENCAPSULATE WITH HUMISEAL 1A27LU PER E1844 OR WITH EQUIVALENT AS APPROVED L11130-5F0 BY LINCOLN ELECTRIC COMPANY. (2 COATS) SCHEMATIC REFERENCE: L11108-5F0

PART NO. IDENTIFICATION CODE

ALL COMPONENTS AND MATERIALS USED IN THIS ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253. TEST PER E3856-D PROPRIETARY & CONFIDENTIAL:THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATEDTO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND SCALE: EQUIPMENT TYPE: 1 1 ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) 1:1 MISCELLANEOUS PAGE _ OF _ ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: ddietz IF PRINTED ON ALL ANGLES IS ± .5 OF A DEGREE @ A2 SIZE SUBJECT: ENGINEER: SPI DISPLAY PC BOARD ASSEMBLY DOCUMENT DOCUMENT NUMBER: REVISION: MATERIAL TOLERANCE ("t ") TO AGREE WITH PUBLISHED STANDARDS. UNITS: MATERIAL REFERENCE: DO NOT SCALE THIS DRAWING APPROVED: - INCH DISPOSITION: UF APPROVAL 10/31/2008 PROJECTDATE: NUMBER: CRM39937 L11130-5L11130-4 D NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. C19 R12 C11 C4 R22 R23 R20 X3 R29 L11130-5, G-18 ELECTRICAL DIAGRAMS G-18 SCHEMATIC - LED POTENTIOMETER PC BOARD - (S25258) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.,

G-19 ELECTRICAL DIAGRAMS G-19 PC BOARD ASSEMBLY - LED POTENTIOMETER PC BOARD - (M19874)

ENGINEERING CONTROLLED CHANGE DETAIL: REVISED NOTE N.B. AND ADDED NOTE N.E. MANUFACTURER: No REVISED DETAIL GRAPHICS ITEM (USED WITH)* QTY PART NUMBER DESCRIPTION11SEE BLANK INFO PC BOARD BLANK 2 (LED1, LED2, LED3, LED4, LED5)* 5 T15176 LED,SPACER,0.220 HIGH REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW

P.C. BOARD BLANK INFORMATION REFERENCES QTY PART NUMBER DESCRIPTION

BUY COMPLETE AS M19874-C (2 LAYER BOARD PER E3281). J61 1 S19365-15 CONNECTOR,PCB,WW,MALE,RT-L,15-PIN (MAKES 18 BOARDS PER PANEL. SEE ELECTRONIC FILE LED1, LED2, LED3, LED4, LED5 5 T13657-13 LED,T-1,3/4,RED,HIGH-INTENSITY,OVAL FOR ADDITIONAL INFORMATION). R1, R2 2 S19366-1 POT,SINGLE-TURN,0.5W,10K,10%,LINEAR R3, R4, R5, R6, R7 5 S19400-2211 RESISTOR,MF,1/4W,2.21K,1% S1 1 T13381-17 SWITCH,PUSHBUTTON,SPST,GREEN,W/BLACK EXTENDER N.C. N.D. N.C. N.B. RESISTANCE = OHMS 1.90

MANUFACTURE AS:

LED1 R3 J61 LED/POT R4 R5 M19874-2 LED2

M19874-2C0

.88 LED3 S1 R2 R1 LED4 R6 R7 2 LED5 PART NO. IDENTIFICATION CODE 0 ENCAPSULATE WITH E1844. (2 COATS)

BRUSH COAT ACCEPTABLE

0 1.80 5.35

MAKE PER E1911-ROHS

N.A. N.C. TEST PER E3964-MS

NOTES: N.A. DO NOT COAT WITH ENCAPSULATION MATERIAL.

N.E. N.B. THERE MUST NOT BE MORE THAN A .010 GAPBETWEEN SPACER & LED, OR BETWEEN SPACER & P.C. BOARD. LEDS MUST BE PERPENDICULAR

WITH P.C. BOARD AFTER ALL OPERATIONS ARE COMPLETE. N.C. ENCAPSULATE AROUND BASE OF COMPONENT N.D. COAT EXTERNAL PINSWITH ENCAPSULATION MATERIAL. N.E. ENCAPSULATE P.C. BOARD, SPACER AND LOWER HALF OF LED. SCHEMATIC REFERENCE: S25258-2C0 ALL COMPONENTS AND MATERIALS USED IN THIS ENLARGED DETAIL ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.

(LED ORIENTATION) PROPRIETARY & CONFIDENTIAL:THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATEDTO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: 1 1 ON 2 PLACE DECIMALS IS ± .02 INVERTERWELDERS PAGE _ OF _ ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: FEI M19874-1 SUBJECT: LED POT P.C. BOARD ASSEMBLY DOCUMENT DOCUMENTON ALL ANGLES IS ± .5 OF A DEGREEMATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: SCALE: NUMBER: REVISION: WITH PUBLISHED STANDARDS. MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING APPROVED: - 1:1 CDISPOSITION: UF DATE: 4/5/2007 NUMBER: CRM38610 M19874-2 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

CATHODE

(SQUARE)

ANODE

(ROUND) M19874-2, G-20 ELECTRICAL DIAGRAMS G-20 SCHEMATIC - LED SELECT PC BOARD - (S25259) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.,

G-21 ELECTRICAL DIAGRAMS G-21 PC BOARD ASSEMBLY - LED SELECT PC BOARD - (M19875)

ENGINEERING CONTROLLED CHANGE DETAIL: ADDED MAKE PER E1911-ROHS ITEM QTY PART NUMBER DESCRIPTION MANUFACTURER: No11SEE BLANK INFO. PC BOARD BLANK21CI001498 E3165-.25-.75-.20 REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW REFERENCES QTY PART NUMBER DESCRIPTION J60 1 S19365-5 CONNECTOR,PCB,WW,MALE,RT-L,5-PIN LED1, LED2, LED3, LED4, LED5, LED6 6 T13657-13 LED,T-1,3/4,RED,HIGH-INTENSITY,OVAL

P.C. BOARD BLANK INFORMATION R1, R2 2 S19400-7500 RESISTOR,MF,1/4W,750,1%

BUY COMPLETE AS M19875-C (2 LAYER BOARD PER E3281). S1 1 T13381-16 SWITCH,PUSHBUTTON,SPST (MAKES 63 BOARDS PER PANEL. SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION). RESISTANCE = OHMS 1 MANUFACTURE AS: .20 N.A. N.D. M19875-2C0 1.33 1.15 M19875-2 LED SELECT N.E. LED6 LED5 LED4 J60 PART NO. IDENTIFICATION CODE N.B. 2 LED3 LED2 LED1 .18 MAKE PER E1911-ROHS 0 ENCAPSULATEWITH E1844. (2 COATS) 0 N.A. 2.02 2.55 BRUSH COAT ACCEPTABLE

TEST PER E3964-ST

N.C. NOTES:

N.A. DO NOT COAT WITH ENCAPSULATION MATERIAL. N.B. INSERT ITEM 2 BETWEEN ROWS OF LED'S. ITEM 2 MUST BE FLUSHWITH LED BULB. CATHODE

(SQUARE) N.C. ENCAPSULATE PC BOARD AND LOWER HALF OF LED.

N.D. ENCAPSULATE AROUND BASE OF COMPONENT ANODE N.E. COAT EXTERNAL PINSWITH ENCAPSULATION MATERIAL.

(ROUND)

SCHEMATIC REFERENCE: S25259-2C0 ALL COMPONENTS AND MATERIALS USED IN THIS ENLARGED DETAIL ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.

(LED ORIENTATION) PROPRIETARY & CONFIDENTIAL:THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATEDTO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 DESIGN INFORMATION REFERENCE: EQUIPMENT TYPE: ON 2 PLACE DECIMALS IS ± .02 INVERTERWELDERS PAGE _1_ OF _1_ ON 3 PLACE DECIMALS IS ± .002 DRAWN BY: FEI M19875-1 ON ALL ANGLES IS ± .5 OF A DEGREE SCALE: SUBJECT:MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: LED SELECT PC BOARD ASSEMBLY DOCUMENT DOCUMENT NUMBER: REVISION: WITH PUBLISHED STANDARDS. MATERIAL APPROVAL PROJECT DO NOT SCALE THIS DRAWING APPROVED: - 1:1 DISPOSITION: UF DATE: 3/16/2007 NUMBER: CRM34409 M19875-2 B NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. R1 R2 S1 M19875-2]

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