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Manual Lincoln Electric SVM101-B

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  • Lincoln Electric SVM101-B - page 1

    INVERTEC V300-I SVM101-B January , 2007 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND ...

  • Lincoln Electric SVM101-B - page 2

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC i SAFETY i FOR ENGINE powered equipment. 1.a. T urn 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 a ...

  • Lincoln Electric SVM101-B - page 3

    Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I st ...

  • Lincoln Electric SVM101-B - page 4

    SAFETY iii iii Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufactu ...

  • Lincoln Electric SVM101-B - page 5

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L ? ...

  • Lincoln Electric SVM101-B - page 6

    V300-I v v MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Operation . . . . . . . . . . . . . . . . . . ...

  • Lincoln Electric SVM101-B - page 7

    Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC V300-I Section A-1 Section A-1 T ABLE OF CONTENTS - INST ALLA TION SECTION - Installation ..............................................................................................................Section A T echnical Specifications .. ...

  • Lincoln Electric SVM101-B - page 8

    V300-I Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-2 INST ALLA TION A-2 TECHNICAL SPECIFICA TIONS - V300-I (K1363-8, K1363-9) Height W idth Depth W eight 18.7 in. 10.8 in. 22.2 in. 64 lbs. 475 mm 274 mm 564 mm 29 Kg PHYS ...

  • Lincoln Electric SVM101-B - page 9

    V300-I INST ALLA TION A-3 A-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. . . . . Do not touch electrically live parts. Only qualified persons should install, use or service ...

  • Lincoln Electric SVM101-B - page 10

    V300-I INST ALLA TION A-4 A-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER INPUT CONNECTION Connect terminal marked to earth ground per any existing local or national electrical codes. Single Phase Input Connect the s ...

  • Lincoln Electric SVM101-B - page 11

    V300-I INST ALLA TION A-5 A-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC LN-9 GMA Connection Instructions (Not applicable to machines with only 42V Aux.) 1. T urn the Invertec power switch “off”. 2. Connect the K596 o ...

  • Lincoln Electric SVM101-B - page 12

    3 . Slide the copper tube into the brass plug. 4. Insert cable into copper tube. 5. T ighten set screw to collapse copper tube. Screw must apply pressure against welding cable. The top of the set screw will be well below the surface of the brass plug after tightening. 6. Slide rubber boot over brass plug. The rubber boot must be positioned to compl ...

  • Lincoln Electric SVM101-B - page 13

    Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC V300-I Section B-1 Section B-1 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ................................................................................................................Section B Operating Instructions........... ...

  • Lincoln Electric SVM101-B - page 14

    V300-I OPERA TION B-2 B-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TING INSTRUCTIONS DUTY CYCLE The Invertec is rated at 300 amps, 60% duty cycle for 3 phase inputs (based on a 10 minute cycle). It is also rated a ...

  • Lincoln Electric SVM101-B - page 15

    V300-I OPERA TION B-3 B-3 Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T O C Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC MODE SWITCH GT A W Optimized for both scratch start and Hi- Freq kit use. CC SOFT Best for EXX18 ...

  • Lincoln Electric SVM101-B - page 16

    V300-I OPERA TION B-4 B-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC METER POLARITY SWITCH The wire feeder polarity switch is located at the rear of the machine. The switch provides a work connection for wire feeder voltm ...

  • Lincoln Electric SVM101-B - page 17

    Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC V300-I Section C-1 Section C-1 T ABLE OF CONTENTS - ACCESSORIES SECTION - Accessories ............................................................................................................Section C Options/Accessories .............. ...

  • Lincoln Electric SVM101-B - page 18

    V300-I ACCESSORIES C-2 C-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPTIONS / ACCESSORIES CABLE PLUGS Cable Plug Kit for 1/0-2/0 cable (K852-70) attaches to welding cable to provide quick disconnect from machine. Cable ...

  • Lincoln Electric SVM101-B - page 19

    Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC V300-I Section D-1 Section D-1 T ABLE OF CONTENTS - MAINTENANCE SECTION - Maintenance ...........................................................................................................Section D Input Filter Capacitor Discharge Pr ...

  • Lincoln Electric SVM101-B - page 20

    V300-I MAINTENANCE D-2 D-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 5. Locate the two capacitor terminals (large hex head capscrews)shown in Figure D.1. 6. Use electrically insulated gloves and insulated pli- ers. Hold ...

  • Lincoln Electric SVM101-B - page 21

    V300-I MAINTENANCE D-3 D-3 Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T OC Re tur n to Se ct io n T OC Re tur n to Se ct io n T O C Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC OVERLOAD PROTECTION T he machine is electrically protected from producing high output currents. ...

  • Lincoln Electric SVM101-B - page 22

    V300-I MAINTENANCE D-4 D-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE D.2 — LOCA TION OF MAINTENANCE COMPONENTS. ITEM COMPONENT QTY , NO. PC BOARDS CONTROL 1 1 DRIVER 1 2 PROTECTION 1 3 SWITCH 2 7 POWER 1 10 INPU ...

  • Lincoln Electric SVM101-B - page 23

    Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC V300-I Section E-1 Section E-1 Theory of Operation ...............................................................................................Section E Power Supply Operation ........................................................... ...

  • Lincoln Electric SVM101-B - page 24

    V300-I THEOR Y OF OPERA TION INPUT LINE VOL T AGE & AUXILIAR Y TRANSFORMER The V300-I can be connected for a variety of three phase or single phase input voltages. Power is applied through the Line Switch to the Input Rectifier and the Auxiliary T ransformer . The Reconnect Panel has switches to select high or low operating voltage. The “A” ...

  • Lincoln Electric SVM101-B - page 25

    V300-I THEOR Y OF OPERA TION PRECHARGE & PROTECTION CIRCUITS The DC voltage from the Input Rectifier is applied to the Driver Board to begin charging the Switch Board capacitors at a slow rate. When the pre-charge level is achieved, the input relays close, applying the full DC voltage to the capacitors. Depending on the Code Number of the machi ...

  • Lincoln Electric SVM101-B - page 26

    V300-I THEOR Y OF OPERA TION SWITCH BOARDS The Switch Boards contain the the Field Effect T ransistors (FET s) which, when switched ON, supply power to the primary windings of the main transformer . Each Switch Board powers a separate, oppositely wound primary winding. The opposite direction of cur - rent flow in those windings and a slight of fset ...

  • Lincoln Electric SVM101-B - page 27

    V300-I THEOR Y OF OPERA TION OUTPUT AND CONTROL CIRCUITS The AC output of the transformer is changed to DC by the Output Rectifier . The Output Choke between the negative side of the rectifier and the negative output stud provides the necessary filtering for DC welding. The two smaller chokes and their series diodes are the OCV boost circuit used t ...

  • Lincoln Electric SVM101-B - page 28

    V300-I THEOR Y OF OPERA TION An FET is a type of transistor . FET s are semiconduc- tors well suited for high-frequency switching because they are capable of going from full off to full on much more quicklfy than other types of semi-conductors. Drawing A above shows an FET in a passive mode. There is no gate signal, zero volts relative to the sourc ...

  • Lincoln Electric SVM101-B - page 29

    V300-I THEOR Y OF OPERA TION E-7 E-7 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Since only 2 microseconds of the 50-microsecond time period is devoted to conducting, the output power is minimized. MAXIMUM OUTPUT By holdin ...

  • Lincoln Electric SVM101-B - page 30

    V300-I THEOR Y OF OPERA TION E-8 E-8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THERMAL PROTECTION Thermostats protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of c ...

  • Lincoln Electric SVM101-B - page 31

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC V300-I Section F-1 Section F-1 T ABLE OF CONTENTS - TROUBLESHOOTING & REP AIR SECTION - Tr oubleshooting & Repair Section ........................................................................Section F How to Use T roubleshooting Guide .................... ...

  • Lincoln Electric SVM101-B - page 32

    HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may r esult 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 safet ...

  • Lincoln Electric SVM101-B - page 33

    V300-I Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-3 F-3 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connectio ...

  • Lincoln Electric SVM101-B - page 34

    V300-I TROUBLESHOOTING & REP AIR INPUT FIL TER CAP ACITOR CONDITION- ING Capacitor conditioning may be required if the machine will not produce output after power is applied and the following two conditions exist:: The machine is connected to a supply of 380 v .a.c. or higher and Power has not been applied to the machine for an extended period ...

  • Lincoln Electric SVM101-B - page 35

    Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T O C Re tur n to Se ct io n T O C Re t ur n to Se ct io n T OC Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC TROUBLESHOOTING & REP AIR F-5 F-5 PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTIO ...

  • Lincoln Electric SVM101-B - page 36

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMEN ...

  • Lincoln Electric SVM101-B - page 37

    Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T O C Re tur n to Se ct io n T O C Re t ur n to Se ct io n T OC Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC TROUBLESHOOTING & REP AIR F-7 F-7 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this ...

  • Lincoln Electric SVM101-B - page 38

    Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T O C Re tur n to Se ct io n T O C Re t ur n to Se ct io n T OC Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC TROUBLESHOOTING & REP AIR F-8 F-8 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this ...

  • Lincoln Electric SVM101-B - page 39

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMEN ...

  • Lincoln Electric SVM101-B - page 40

    V300-I NOTES F-10 F-10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric SVM101-B - page 41

    V300-I TROUBLESHOOTING & REP AIR F-11 F-11 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this e ...

  • Lincoln Electric SVM101-B - page 42

    V300-I TROUBLESHOOTING & REP AIR INPUT FIL TER CAP ACITOR DISCHARGE PROCEDURE 1. T urn off input power or disconnect input power lines. 2. Remove 14 5/16” hex head screws from side and top of machine (6 screws on each side and 2 screws on top) and remove wrap-around machine cover . 3. Be careful not to make contact with the capacitor terminal ...

  • Lincoln Electric SVM101-B - page 43

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed t ...

  • Lincoln Electric SVM101-B - page 44

    V300-I F-14 F-14 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. T urn Input Power Switch OFF 2. Perform Input Capacitor Discharge test as described in the Maintenance Section. 3 ...

  • Lincoln Electric SVM101-B - page 45

    V300-I F-15 F-15 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR FIGURE F .3 – CONTROL BOARD TEST POINTS OUTPUT PILOT CIRCUIT TEST (cont.) 7. Measure voltage fr om Lead #210 (J2/Pin 4) to Lead # ...

  • Lincoln Electric SVM101-B - page 46

    V300-I NOTES F-16 F-16 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric SVM101-B - page 47

    V300-I TROUBLESHOOTING & REP AIR F-17 F-17 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this e ...

  • Lincoln Electric SVM101-B - page 48

    V300-I TROUBLESHOOTING & REP AIR F-18 F-18 Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T O C Re tur n to Se ct io n T O C Re t ur n to Se ct io n T OC Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC TES T PROCEDURE 1. TURN POWER SWITCH OFF 2. Remove sheetmetal wraparound. ...

  • Lincoln Electric SVM101-B - page 49

    V300-I TROUBLESHOOTING & REP AIR F-19 F-19 Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T O C Re tur n to Se ct io n T O C Re t ur n to Se ct io n T OC Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC PROTECTION BOARD OUTPUT TEST(cont.) TEST PROCEDURE 8. With power OFF , di ...

  • Lincoln Electric SVM101-B - page 50

    V300-I TROUBLESHOOTING & REP AIR F-20 F-20 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROTECTION BOARD OUTPUT TEST(cont.) TEST PROCEDURE 12. Open S4 and T urn Power OFF 13. Move probes to test between leads 306 (+) an ...

  • Lincoln Electric SVM101-B - page 51

    V300-I TROUBLESHOOTING & REP AIR F-21 F-21 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this e ...

  • Lincoln Electric SVM101-B - page 52

    V300-I TROUBLESHOOTING & REP AIR F-22 F-22 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TIC CAP ACITOR TEST TEST PROCEDURE: 1. With Output T erminal Switch S4 in REMOTE (OFF) position, turn Power Switch ON. 2. T es ...

  • Lincoln Electric SVM101-B - page 53

    V300-I TROUBLESHOOTING & REP AIR F-23 F-23 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .7 - SWITCH BOARD TEST POINTS L8 604- 1 L8604-1 SW I T CH SWITCH 9 9R W 12 WR 401/ 403 1/ 8 4/ 5 402/ 404 12 CAP ACITOR BA ...

  • Lincoln Electric SVM101-B - page 54

    V300-I NOTES F-24 F-24 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric SVM101-B - page 55

    V300-I TROUBLESHOOTING & REP AIR F-25 F-25 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this e ...

  • Lincoln Electric SVM101-B - page 56

    V300-I TROUBLESHOOTING & REP AIR F-26 F-26 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SWITCH BOARD TEST (cont.) TEST PROCEDURE 1. Disconnect power to the machine and perform Input Filter Capacitor Discharge Procedure ...

  • Lincoln Electric SVM101-B - page 57

    V300-I TROUBLESHOOTING & REP AIR F-27 F-27 Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T O C Re tur n to Se ct io n T O C Re t ur n to Se ct io n T OC Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC SWITCH BOARD TEST (CONT .) Apply Positive Apply Negative T est Probe to T ...

  • Lincoln Electric SVM101-B - page 58

    V300-I TROUBLESHOOTING & REP AIR F-28 F-28 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SWITCH BOARD TEST (CONT .) Apply Positive Apply Negative T est Prove to T est Probe to T erminal T erminal T est Result Conclusion ...

  • Lincoln Electric SVM101-B - page 59

    V300-I TROUBLESHOOTING & REP AIR F-29 F-29 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this e ...

  • Lincoln Electric SVM101-B - page 60

    V300-I TROUBLESHOOTING & REP AIR 5. T est for 25 ohms resistance from lead 401 to termi- nal 12 on Switch Board. a. If 25 ohms is measured, Resistor R4 is OK. b. If 30 ohms or more is measured, Resistor R4 is faulty and must be replaced. c. If 20 ohms or less is measured, Resistor R4 is faulty and must be replaced. 6. Repeat same procedures to ...

  • Lincoln Electric SVM101-B - page 61

    V300-I TROUBLESHOOTING & REP AIR F-31 F-31 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST DESCRIPTION This procedur e will determine if the Output Diodes are defective. MA TERIALS NEEDED Vo lt/Ohm Meter (multi-meter) ...

  • Lincoln Electric SVM101-B - page 62

    V300-I TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Locate the Output T erminals on front panel. 2. Remove any cables from Output T erminals. 3. T est for more than 200 ohms resistance between positive and negative Output T erminals: positive meter lead to the positive terminal, negative meter lead to the negative terminal. NOTE: Polarity of tes ...

  • Lincoln Electric SVM101-B - page 63

    V300-I TROUBLESHOOTING & REP AIR TEST DESCRIPTION This procedur e will determine if the Input Rectifier is defective. MA TERIALS NEEDED ANALOG Vo lt/Ohm Meter (multi-meter) Misc. Hand T ools Wiring Diagram (Section G) F-33 F-33 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to ...

  • Lincoln Electric SVM101-B - page 64

    V300-I TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Perform Input Filter Capacitor Discharge Procedure as detailed in this section. 2. Locate Input Rectifier (Component D-13). 3. Locate leads needed to perform tests shown in Figure F .1 1. 4. Use ohmmeter to perform tests shown in T able F .5. Replace the Inpit Rectiferif readings are not as ind ...

  • Lincoln Electric SVM101-B - page 65

    V300-I TROUBLESHOOTING & REP AIR F-35 F-35 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OVERCURRENT PROTECTION CURRENT TRIGGER TEST W ARNING Service and repair should be performed by only Lincoln Electric factory traine ...

  • Lincoln Electric SVM101-B - page 66

    V300-I TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. Perform Input Filter Capacitor Discharge Procedure detailed in this section. 2. Remove front panel from machine to access Control Board. 3. Arrange wires so there is ample room to work on the board. 4. T urn main power ON. 5. T est for 15 VDC between leads 302 and 275D. a. If 15 VDC is present, ...

  • Lincoln Electric SVM101-B - page 67

    V300-I TROUBLESHOOTING & REP AIR 6. T urn main power OFF . 7. Perform Input Filter Capacitor Discharge Procedure detailed in this section. T est resistance of the Black and White leads from 1J3 and 2J3 to the shunt. See Figure F .14. a. If zero ohms resistance (continuity) is shown, test is OK. b. If resistance of any value is shown, check wire ...

  • Lincoln Electric SVM101-B - page 68

    V300-I TROUBLESHOOTING & REP AIR F-38 F-38 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OVER VOL T AGE PROTECTION DC TRIGGER CIRCUIT TEST W ARNING Service and repair should be performed by only Lincoln Electric factory ...

  • Lincoln Electric SVM101-B - page 69

    V300-I TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. T urn main power OFF . 2. Perform Input Filter Capacitor Discharge procedure detailed in Maintenance section. 3. Detach the following PC boards so you can gain access to and have ample room to perform the tests: (Do not disconnect from wiring harness.) • Control Board • Protection Board • ...

  • Lincoln Electric SVM101-B - page 70

    V300-I TROUBLESHOOTING & REP AIR 7. T est for 0 VDC between leads 31 1 and 313 on Protection Board. a. If 0-1 VDC is present, the Protection Board is OK. Go to step 8. b. If 15 VDC is present, go to step 1 1. F-40 F-40 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master T ...

  • Lincoln Electric SVM101-B - page 71

    V300-I TROUBLESHOOTING & REP AIR 8. T est for 15 VDC supply voltage between leads 302 and 275D on Power Board. a. If 15 VDC is present, test is OK. Go to step 9. b. If 15 VDC is not present, the Power Board may be faulty . Check for 18 V AC input voltage at lead 501 and 504 (J7). If 18 V AC is present the Power Board is faulty and must be repla ...

  • Lincoln Electric SVM101-B - page 72

    V300-I TROUBLESHOOTING & REP AIR 11 . If 15 VDC is present at step 7, test Capacitor volt- ages using leads shown in Figure F .19. If voltage does not match table, check reconnect switches for proper operation and proper position for voltage applied. Perform Capacitor Balance T ests. F-42 F-42 Return to Section TOC Return to Section TOC Return ...

  • Lincoln Electric SVM101-B - page 73

    V300-I TROUBLESHOOTING & REP AIR F-43 F-43 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THERMAL PROTECTION AC TRIGGER CIRCUIT W ARNING Service and repair should be performed by only Lincoln Electric factory trained pers ...

  • Lincoln Electric SVM101-B - page 74

    V300-I TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. T urn main power OFF . 2. Perform Input Filter Capacitor Discharge proce- dure detailed in this section. 3. Detach the following PC boards so you can gain access to and have ample room to perform the tests. (Do not disconnect from wiring harness.) • Power Board • Control Board NOTE: Do not ...

  • Lincoln Electric SVM101-B - page 75

    V300-I TROUBLESHOOTING & REP AIR 4. Locate the Auxiliary T ransformer T1 and leads used for test. See Figure F .21. 5. T urn main power ON. 6. T est Auxiliary T ransformer voltage for 24 V AC between leads 503 and 212D. See Figure F .21. a. If 24 V AC is present, transformer is OK. Go to step 7. b. If 0 V AC is present, test input voltage to Au ...

  • Lincoln Electric SVM101-B - page 76

    V300-I NOTES F-46 F-46 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric SVM101-B - page 77

    V300-I TROUBLESHOOTING & REP AIR F-47 F-47 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER BOARD TEST W ARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized r ...

  • Lincoln Electric SVM101-B - page 78

    V300-I TROUBLESHOOTING & REP AIR . TEST PROCEDURE NOTE: Perform T est A before disassembling the unit T est A 1. T urn main power OFF . 2. Position yourself at Switch Board area of the machine (near Case Back) so as to hear the oper- ation of the control relays. 3. T urn main power ON. 4. Listen for control relays to operate (audible click of c ...

  • Lincoln Electric SVM101-B - page 79

    V300-I TROUBLESHOOTING & REP AIR 6. T est for 18 V AC input from Auxiliary T ransformer between leads 504 and 501 (J7-pin 5 & pin6) on Power Board. If 18 V AC is not correct, check the 3 amp fuse, the Auxiliary T ransformer and associated wires. 7. T est for 15 VDC output between leads 275D (-) and 302 (+) (J6-pin1 & pin 6) on Power Boa ...

  • Lincoln Electric SVM101-B - page 80

    V300-I TROUBLESHOOTING & REP AIR F-50 F-50 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER BOARD TEST (cont.) FIGURE F .24 - SIMPLIFIED TRIGGER CICUIT FROM PROTECTION BOARD OVERVOLTAGE PWM OUTPUTS TO POWER BOARD 7J6 ...

  • Lincoln Electric SVM101-B - page 81

    V300-I TROUBLESHOOTING & REP AIR F-51 F-51 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAP ACIT OR REMOV AL AND REPLACEMENT PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory tra ...

  • Lincoln Electric SVM101-B - page 82

    V300-I TROUBLESHOOTING & REP AIR PROCEDURE NOTE: When replacing capacitors, remove the entire FET Heat Sink Assembly as a unit. Remove and reassemble one side at a time, using the other side as a model to insure that all parts are reinstalled prop erly 1. Perform the Input Filter Capacitor Discharge Procedure. 2. Remove the two 3/8” hex nuts ...

  • Lincoln Electric SVM101-B - page 83

    V300-I TROUBLESHOOTING & REP AIR 4. Remove the two 1/4-28 hex head bolts that hold the Capacitor to the PC board. See Figure F .27. 5. Loosen the set screw of the Capacitor clamp ring and remove the Capacitor from the clamp ring. See Figure F .28. F-53 F-53 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC ...

  • Lincoln Electric SVM101-B - page 84

    V300-I TROUBLESHOOTING & REP AIR NOTE: Proper capacitor polarity must be noted when attaching the capacitor to the Switch Board assembly . 6. Install the new Capacitor and tighten the two bolts to a torque of 55 inch-pounds (6 Nm). Hand tight- en first, then tighten the bolts in increments of 10 inch-pounds, alternating between the two. See Fig ...

  • Lincoln Electric SVM101-B - page 85

    V300-I TROUBLESHOOTING & REP AIR F-55 F-55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SWITCH BOARD REMOV AL AND REPLACEMENT PROCEDURE W ARNING Service and repair should be performed by only Lincoln Electric factory tr ...

  • Lincoln Electric SVM101-B - page 86

    V300-I TROUBLESHOOTING & REP AIR NOTE: If a test indicates that a Switch Board is defec- tive, unless their part number is L10958-[ ] both Switch Boards must be replaced at the same time. In addition to replacing the Switch Boards, Capacitors C1 and C2 (plus C14 and C15 on 575 V AC models) must also be replaced if the following conditions exist ...

  • Lincoln Electric SVM101-B - page 87

    V300-I TROUBLESHOOTING & REP AIR F-57 F-57 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST AFTER SWITCH BOARD OR CAP ACIT OR REPLACEMENT W ARNING Service and repair should be performed by only Lincoln Electric factory ...

  • Lincoln Electric SVM101-B - page 88

    B300-I TROUBLESHOOTING & REP AIR TEST PROCEDURE 1. T urn main power OFF . 2. Perform Input Filter Capacitor Dis-charge proce- dure detailed in Mainten-ance section.. 3. Connect a shorting conductor across terminals 14 and 53 of Protection Board. 4. Set an ohmmeter to X1000 range and place probes on terminals 9 (+) and 12 (-) of one Switch Board ...

  • Lincoln Electric SVM101-B - page 89

    V300-I TROUBLESHOOTING & REP AIR F-59 F-59 Re t ur n t o Se ct io n T OC Re tu r n to Se ct io n T O C Re tur n to Se ct io n T O C Re t ur n to Se ct io n T OC Re t ur n t o Ma ste r T OC Re tur n to Ma st e r T OC Re tu r n to Ma st e r T O C Re t ur n t o Ma ste r T OC OUTPUT DIODE REPLACEMENT PROCEDURE W ARNING Service and repair should be ...

  • Lincoln Electric SVM101-B - page 90

    V300-I TROUBLESHOOTING & REP AIR PROCEDURE (Paralleled IndividualDiodes) 1. T urn main power OFF . 2. Perform Input Filter Capacitor Discharge proce- dure detailed in Maintenance section.. 3. Detach and remove both Switch Board assemblies and attached capacitors. See Switch Board Removal and Replacement procedure 4. Detach the fan shroud to gai ...

  • Lincoln Electric SVM101-B - page 91

    V300-I TROUBLESHOOTING & REP AIR PROCEDURE (Diode Modules) 1. T urn main power OFF . 2. Perform Input Filter Capacitor Discharge proce- dure detailed in Maintenance section.. 3. Detach and remove both Switch Board assemblies and attached capacitors. See Switch Board Removal and Replacement procedure 4. Detach the fan shroud to gain access to th ...

  • Lincoln Electric SVM101-B - page 92

    V300-I TROUBLESHOOTING & REP AIR F-62 F-62 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RETEST AFTER REP AIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could ...

  • Lincoln Electric SVM101-B - page 93

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC V300-I Section G-1 Section G-1 T ABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagrams ...............................................................................................Section G Wiring Diagram (L8657 for Code 9826) . . . . . . . . . . . ...

  • Lincoln Electric SVM101-B - page 94

    ELECTRICAL DIAGRAMS G-2 V300-I WIRING DIAGRAM - ENTIRE MACHINE - CODE 9826 (L8657) G-2 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. Return to Section TOC Return to Section TOC Return to ...

  • Lincoln Electric SVM101-B - page 95

    ELECTRICAL DIAGRAMS G-3 V300-I WIRING DIAGRAM - ENTIRE MACHINE CODE 9827 (L8938) L G-3 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. Return to Section TOC Return to Section TOC Return to ...

  • Lincoln Electric SVM101-B - page 96

    ELECTRICAL DIAGRAMS G-4 V300-I WIRING DIAGRAM - ENTIRE MACHINE CODE 10036 (L9299) G-4 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. Return to Section TOC Return to Section TOC Return to ...

  • Lincoln Electric SVM101-B - page 97

    ELECTRICAL DIAGRAMS G-5 V300-I WIRING DIAGRAM - ENTIRE MACHINE CODE 10037 (L9300) G-5 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. Return to Section TOC Return to Section TOC Return to ...

  • Lincoln Electric SVM101-B - page 98

    ELECTRICAL DIAGRAMS G-6 V300-I WIRING DIAGRAM - ENTIRE MACHINE CODE 10132 (L9567) G-6 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. Return to Section TOC Return to Section TOC Return to ...

  • Lincoln Electric SVM101-B - page 99

    ELECTRICAL DIAGRAMS G-7 V300-I WIRING DIAGRAM - ENTIRE MACHINE CODE 10133 (L9568) G-7 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. Return to Section TOC Return to Section TOC Return to ...

  • Lincoln Electric SVM101-B - page 100

    ELECTRICAL DIAGRAMS G-8 V300-I WIRING DIAGRAM - ENTIRE MACHINE CODE 10258 (L10189) G-8 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. Return to Section TOC Return to Section TOC Return to ...

  • Lincoln Electric SVM101-B - page 101

    ELECTRICAL DIAGRAMS G-9 V300-I WIRING DIAGRAM - ENTIRE MACHINE CODE 10336, 10450 (L10205) G-9 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. Return to Section TOC Return to Section TOC Re ...

  • Lincoln Electric SVM101-B - page 102

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-10 V300-I SCHEMA TIC - ENTIRE MACHINE G-10 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. BOARD ...

  • Lincoln Electric SVM101-B - page 103

    ELECTRICAL DIAGRAMS G-11 V300-I SCHEMA TIC - DRIVER PC BOARD - (S20216) G-11 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Maste ...

  • Lincoln Electric SVM101-B - page 104

    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 troub ...

  • Lincoln Electric SVM101-B - page 105

    ELECTRICAL DIAGRAMS G-13 V300-I SCHEMA TIC - DRIVER PC BOARD (S20799) G-13 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master ...

  • Lincoln Electric SVM101-B - page 106

    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 troub ...

  • Lincoln Electric SVM101-B - page 107

    ELECTRICAL DIAGRAMS G-15 V300-I SCHEMA TIC - SWITCH PC BOARD (L8440) G-15 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master T ...

  • Lincoln Electric SVM101-B - page 108

    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 troub ...

  • Lincoln Electric SVM101-B - page 109

    ELECTRICAL DIAGRAMS G-17 V300-I SCHEMA TIC - SWITCH PC BOARD (L10956) G-17 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master ...

  • Lincoln Electric SVM101-B - page 110

    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 troub ...

  • Lincoln Electric SVM101-B - page 111

    ELECTRICAL DIAGRAMS G-19 V300-I SCHEMA TIC - CONTROL PC BOARD (G2525) G-19 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master ...

  • Lincoln Electric SVM101-B - page 112

    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 troub ...

  • Lincoln Electric SVM101-B - page 113

    ELECTRICAL DIAGRAMS G-21 V300-I G-21 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. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Maste ...

  • Lincoln Electric SVM101-B - page 114

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-22 V300-I SCHEMA TIC - PROTECTION PC BOARD (M16097) G-22 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this ...

  • Lincoln Electric SVM101-B - page 115

    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 troub ...

  • Lincoln Electric SVM101-B - page 116

    ELECTRICAL DIAGRAMS G-24 V300-I SCHEMA TIC - POWER PC BOARD (M16018) G-24 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master T ...

  • Lincoln Electric SVM101-B - page 117

    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 troub ...

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A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Lincoln Electric SVM101-B by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Lincoln Electric SVM101-B.

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