English dropdown-ico

Lincoln Electric SVM151-A manual

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119

Go to page of

Similar user manuals

A good user manual

The rules should oblige the seller to give the purchaser an operating instrucion of Lincoln Electric SVM151-A, along with an item. The lack of an instruction or false information given to customer shall constitute grounds to apply for a complaint because of nonconformity of goods with the contract. In accordance with the law, a customer can receive an instruction in non-paper form; lately graphic and electronic forms of the manuals, as well as instructional videos have been majorly used. A necessary precondition for this is the unmistakable, legible character of an instruction.

What is an instruction?

The term originates from the Latin word „instructio”, which means organizing. Therefore, in an instruction of Lincoln Electric SVM151-A one could find a process description. An instruction's purpose is to teach, to ease the start-up and an item's use or performance of certain activities. An instruction is a compilation of information about an item/a service, it is a clue.

Unfortunately, only a few customers devote their time to read an instruction of Lincoln Electric SVM151-A. A good user manual introduces us to a number of additional functionalities of the purchased item, and also helps us to avoid the formation of most of the defects.

What should a perfect user manual contain?

First and foremost, an user manual of Lincoln Electric SVM151-A should contain:
- informations concerning technical data of Lincoln Electric SVM151-A
- name of the manufacturer and a year of construction of the Lincoln Electric SVM151-A item
- rules of operation, control and maintenance of the Lincoln Electric SVM151-A item
- safety signs and mark certificates which confirm compatibility with appropriate standards

Why don't we read the manuals?

Usually it results from the lack of time and certainty about functionalities of purchased items. Unfortunately, networking and start-up of Lincoln Electric SVM151-A alone are not enough. An instruction contains a number of clues concerning respective functionalities, safety rules, maintenance methods (what means should be used), eventual defects of Lincoln Electric SVM151-A, and methods of problem resolution. Eventually, when one still can't find the answer to his problems, he will be directed to the Lincoln Electric service. Lately animated manuals and instructional videos are quite popular among customers. These kinds of user manuals are effective; they assure that a customer will familiarize himself with the whole material, and won't skip complicated, technical information of Lincoln Electric SVM151-A.

Why one should read the manuals?

It is mostly in the manuals where we will find the details concerning construction and possibility of the Lincoln Electric SVM151-A item, and its use of respective accessory, as well as information concerning all the functions and facilities.

After a successful purchase of an item one should find a moment and get to know with every part of an instruction. Currently the manuals are carefully prearranged and translated, so they could be fully understood by its users. The manuals will serve as an informational aid.

Table of contents for the manual

  • Page 1

    SVM151-A September , 2002 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 in- creased by proper installation . . . and thoughtful operation on your part. DO NO T INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANU AL AND THE SAFETY PR[...]

  • Page 2

    i i SAFETY 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 areas or vent the engine exhaust fumes outdoors. ____________________________________[...]

  • Page 3

    ii ii SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 standards. 4.b. U[...]

  • Page 4

    iii iii SAFETY 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[...]

  • Page 5

    iv iv SAFETY 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 [...]

  • Page 6

    v v - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - MUL TI-WELD 350 Page Safety .................................................................................................................................................i-iv Installation ............................................................................................................[...]

  • Page 7

    Installation ................................................................................................................... ..........Section A T echnical Specifications ..............................................................................................................A-2 Safety Precautions ..........................................[...]

  • Page 8

    A-2 A-2 INST ALLA TION MUL TI-WELD 350 Return to Section TOC Retur n 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 SPECIFICA TIONS Amps (DC+) V olts (DC+) Output Rating @ 50°C (122°F) 350 34 Input Rating @ 50°C (122°F) 165 80 Max. Input R[...]

  • Page 9

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. Only qualified personnel should install, use, or ser- vice this[...]

  • Page 10

    Be sure to follow the safety practice to use the female connector on the cable which would normally be electrically "hot" (supply lead) if disconnected when the system is energized, and the male on the normally “cold” (load lead) side. If practical, shut off power before connecting or disconnecting terminals. WORK CONNECTION Each Conv[...]

  • Page 11

    A-5 A-5 INST ALLA TION MUL TI-WELD 350 Return to Section TOC Retur n 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 DAISY CHAIN OPERATION FIXED PARALLEL OPERATION TO WORK TO POWER SOURCE TO WORK TO ELECT. TO POWER SOURCE TO WORK TO ELECT. TO WORK TO ELEC[...]

  • Page 12

    For Converters (operating at rated output) less than 200 ft. (61 m) from the power source, the following min- imum cable sizes are recommended for the indicated quantity of Converters supplied by the input cable run to keep cable temperature and voltage drop within acceptable limits: Converters Cable Size on Cable A WG (mm2 ) 1 1/0 (50) 2 2/0 (70) [...]

  • Page 13

    Operation ............................................................................................................................... Section B Safety Instructions .......................................................................................................................B-2 Product Description .......................................[...]

  • Page 14

    OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. FUMES AND G[...]

  • Page 15

    PRODUCT DESCRIPTION The Multi-Weld 350 Arc Converter (K1735-1) is part of a Multi-Weld system, ideally suited for construction site welding. It uses a single DC power source as the only input supply and provides independent, full-range control of up to 350A continuous with each Converter arc for + polarity stick and wire processes, as well as for a[...]

  • Page 16

    Simple • Easy installation with 10 ft. (3 m) work clip lead and user preference quick-connect “pig-tails” for input and electrode weld cables. • Easy setup with only a few intuitive welding controls and lit displays. This includes a single Power/Mode switch with Input level light, and a single presettable Output Control with separate digita[...]

  • Page 17

    REMOTE OUTPUT CONTROL OPTIONS The Multi-Weld 350 is provided with a 6-pin remote receptacle to permit use with the 25 ft.(7.6 m) K857 or 100 ft. (30.4 m) K857-1 Remote Output Control options. The remote receptacle can also be used with the LN-25 equipped with the K444-1 Remote Control option. These remotes have single-turn resolution on a Minimum t[...]

  • Page 18

    FRONT P ANEL CONTROLS The numbered items of Figure B.2 match the num- bered items described below: These few instruments and controls are basic to the operation and monitoring of the Converter . They are intuitively laid out so that the panel left side is weld cur- rent related, and the right side is weld voltage related: (1) Input Power/ Mode Swit[...]

  • Page 19

    Average AMPS for about 7 seconds after welding stops in CC and CV modes only . • The 5 second memory display is indicated by the display’s left-most decimal point blinking, and is interrupted if arc is restarted. Accuracy of Actual AMPS is within 3%, and typical- ly within 10 amps of Preset. • An Actual AMPS meter calibration adjustment trimm[...]

  • Page 20

    Disconnecting the Remote plug from this recepta- cle automatically transfers output control back to the panel Output Control (item (2) above). Remote output On/Off switching can also be done through this Remote Control receptacle by per- forming the following wiring changes: 1. Making sure the input to the Converter is removed, remove the case wrap[...]

  • Page 21

    TRANSPORTING The Converter may be carried by one or two persons using the front and rear top and bottom handles. It can also be set vertically on a two wheel cart, or horizon- tally on a wagon, to move it longer distances. STORAGE The Multi-Weld 350 may be set on a floor , or shelf, hor- izontally on its skid, or vertically standing on its rear top[...]

  • Page 22

    B-10 B-10 NOTES MUL TI-WELD 350 Return to Section TOC Retur n 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[...]

  • Page 23

    Accessories .................................................................................................................... ......Section C Options/Accessories ...................................................................................................................C-2 Field Installed Options ..........................................[...]

  • Page 24

    OPTIONS/ACCESSORIES The following options/accessories are available for your Multi-Weld 350 from your local Lincoln Distributor . FIELD INST ALLED OPTIONS K1736-1 DISTRIBUTION BOX - Makes connecting up to 10 Multi-Weld 350s quick and easy . Contains cop- per bus bar for connecting multiple “ pig-tails. ” Four “ pig-tails ” included. K857 25[...]

  • Page 25

    CONNECTION OF THE LN-25 TO THE MUL TI-WELD 350 “ACROSS THE ARC” (SEE FIGURE C.1.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-25 to the “ + ” terminal of the welder . NOTE: Welding cable must be sized for current and duty cycle of application. 3. Attach the single lead from the LN-25 to the work using the spring clip [...]

  • Page 26

    C-4 C-4 NOTES MUL TI-WELD 350 Return to Section TOC Retur n 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[...]

  • Page 27

    Maintenance .................................................................................................................... ......Section D Safety Precautions ............................................................................................................. .........D-2 Maintenance....................................................[...]

  • Page 28

    SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. Have qualified personnel do the maintenance work. Always use the greatest care when working near mov- ing parts. If a problem cannot be correc[...]

  • Page 29

    SER VICE The Multi-Weld 350 was designed for easy service using quick-to-replace components and assembly modules that can be simply swapped out at the job site to minimize down time. More prolonged troubleshoot- ing and repair of the module may be done later on the service bench. Figure D.2 shows the three assembly modules of the Converter which ar[...]

  • Page 30

    D-4 D-4 NOTES MUL TI-WELD 350 Return to Section TOC Retur n 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[...]

  • Page 31

    General Description .......................................................................................................................E-2 Input Power Source, Contactor and DC Buss Power Supply Board ..........................................E-2 Power Modules and Feedback .........................................................................[...]

  • Page 32

    GENERAL DESCRIPTION The MUL TI-WELD 350 Converter uses a single DC input power source to provide up to 350 continuous amps for positive polarity stick, wire processes, and arc-air gouging. The machine converts higher volt- age/lower current DC input power to lower voltage/higher current DC output power with over 90% efficiency . This DC output is c[...]

  • Page 33

    POWER MODULES AND FEED- BACK The external DC source voltage is applied to parallel capacitors incorporated within each of the two Power (Chopper) Modules. These capacitors function as fil- ters and as power supplies for the IGBT s. See IGBT Operation in this section. The IGBT s act as high- speed switches operating at 20KHZ. These devices are switc[...]

  • Page 34

    ANALOG CONTROL POWER SUPPL Y BOARD AND WELD CONTROL BOARD The Analog Control Power Supply Board, which is pow- ered by 40 VDC delivered from the DC Buss Power Supply Board, supplies various regulated DC voltages to operate the Weld Control Board circuitry . It also pro- vides two regulated 20 VDC supplies to operate the electronics on the Chopper M[...]

  • Page 35

    MODE SELECT OR AND OUTPUT CONTROLS In CC mode, machine output is at open circuit voltage. The OUTPUT control presets amps in the 30 to 350 A range and then adjusts actual welding current to match the preset when welding. In CV mode, machine output is at the voltage level set at the OUTPUT control. The OUTPUT control presets volts, then adjusts the [...]

  • Page 36

    PROTECTION FEA TURES The Multi-Weld 350 design features electronic protec- tion systems to help assure reliable operation even under adverse conditions. These systems include: F AN AS NEEDED (F .A.N.) The cooling fan will turn on when the arc starts and remain on for about a minute after the arc is out to cool down the power components. This featur[...]

  • Page 37

    INSULA TED GA TE BIPOLAR TRANSIST OR (IGBT) OPERA TION An IGBT is a type of transistor . IGBT s are semicon- ductors well suited for high frequency switching and high current applications. Drawing A shows an IGBT in a passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow . The drain terminal of the[...]

  • Page 38

    PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION is used to describe how much time is devoted to conduction in the cycle. Changing the pulse width is known as MODU- LA TION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine. MINIMUM OUTPUT By controlling the [...]

  • Page 39

    CHOPPER TECHNOLOGY FUNDAMENT ALS The new era of welding machines such as the Multi- Weld 350 employ a technology whereby a DC source is turned on and off (chopped up) at high speed, then smoothed through an inductor to control an arc. Hence the name “ Chopper . ” The biggest advantage of chopper technology is the high-speed control of the arc, [...]

  • Page 40

    E-10 E-10 NOTES MUL TI-WELD 350 Return to Section TOC Retur n 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[...]

  • Page 41

    T roubleshooting & Repair Section ......................................................................................Section F How to Use T roubleshooting Guide ...........................................................................................F-2 PC Board T roubleshooting Procedures ..................................................[...]

  • Page 42

    This T roubleshooting Guide is provided to help you locate and repair possible machine malfunc- tions. Simply follow the three-step procedure list- ed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “ PROBLEM ” (SYMP- TOMS). This column describes possible symp- toms that the machine may exhibit. Find the list- ing that [...]

  • Page 43

    ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. T urn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting an[...]

  • Page 44

    Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 45

    TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 46

    Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 47

    TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 48

    Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 49

    TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 50

    Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 51

    TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 52

    Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. PROBLEMS ([...]

  • Page 53

    TROUBLESHOOTING & REP AIR F-13 F-13 MUL TI-WELD 350 CASE COVER ASSEMBL Y REMOV AL AND REPLACEMENT PROCEDURE W ARNING 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 facto[...]

  • Page 54

    TROUBLESHOOTING & REP AIR F-14 F-14 MUL TI-WELD 350 Return to Section TOC Retur n 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 MUL MUL TI-WELD 350 TI-WELD 350 MULTI-WELD 350 L IN COLN ELECTR IC A M P S V O L T S A V ELECTRODE IN PUT WORK CHOPPER T [...]

  • Page 55

    TROUBLESHOOTING & REP AIR F-15 F-15 MUL TI-WELD 350 POWER MODULE CAP ACITOR DISCHARGE PROCEDURE W ARNING 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 [...]

  • Page 56

    TROUBLESHOOTING & REP AIR F-16 F-16 MUL TI-WELD 350 Return to Section TOC Retur n 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 MUL TI-WELD 350 LINCOLN ELECTRIC AMPS VOL TS A V ELECTRODE INPUT WORK CHOPPER TECHNOLOGY POWER MODULE CAP ACITOR TERMINAL[...]

  • Page 57

    TROUBLESHOOTING & REP AIR F-17 F-17 MUL TI-WELD 350 INPUT CONT ACTOR COIL RESIST ANCE AND SUPPL Y VOL T AGE TEST W ARNING 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 [...]

  • Page 58

    TROUBLESHOOTING & REP AIR F-18 F-18 MUL TI-WELD 350 Return to Section TOC Retur n 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 LEADS #303A #330 FIGURE F .3 – INPUT CONT ACTOR DET AILS INPUT CONT ACTOR COIL RESIST ANCE AND SUPPL Y VOL T AGE TEST ([...]

  • Page 59

    TROUBLESHOOTING & REP AIR F-19 F-19 MUL TI-WELD 350 Return to Section TOC Retur n 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 INPUT CONT ACTOR COIL RESIST ANCE AND SUPPL Y VOL T AGE TEST (CONTINUED) ELECTRIC SHOCK can kill. With the input power ON[...]

  • Page 60

    TROUBLESHOOTING & REP AIR F-20 F-20 MUL TI-WELD 350 ANALOG CONTROL POWER SUPPL Y PC BOARD TEST W ARNING 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 .[...]

  • Page 61

    TROUBLESHOOTING & REP AIR F-21 F-21 MUL TI-WELD 350 Return to Section TOC Retur n 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 MUL TI-WELD 350 LINCOLN ELECTRIC AMPS VOLTS A V ELECTRODE IN PUT WORK CHOPPER T ECHNOLOGY P42 P41 ANALOG CONTROL POWER SU[...]

  • Page 62

    TROUBLESHOOTING & REP AIR F-22 F-22 MUL TI-WELD 350 Return to Section TOC Retur n 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 T ABLE F .1 ANALOG CONTROL POWER SUPPL Y PC BOARD VOL T AGE T ABLE Positive Meter Probe Negative Meter Probe Acceptable V[...]

  • Page 63

    TROUBLESHOOTING & REP AIR F-23 F-23 MUL TI-WELD 350 DC BUSS POWER SUPPL Y PC BOARD TEST W ARNING 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 yo[...]

  • Page 64

    TROUBLESHOOTING & REP AIR F-24 F-24 MUL TI-WELD 350 Return to Section TOC Retur n 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 MUL TI-WELD 350 LINCOLN ELECTRIC AMPS VOL TS A V ELECTRODE INPUT WORK CHOPPER TECHNOLOGY DC BUSS POWER SUPPL Y PC BOARD P[...]

  • Page 65

    TROUBLESHOOTING & REP AIR F-25 F-25 MUL TI-WELD 350 Return to Section TOC Retur n 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 DC BUSS POWER SUPPL Y PC BOARD TEST (CONTINUED) 8. Check the DC Buss Power Supply PC Board input and output voltages acco[...]

  • Page 66

    TROUBLESHOOTING & REP AIR F-26 F-26 MUL TI-WELD 350 CHOPPER PC BOARD INPUT VOL T AGES AND RESIST ANCE TEST W ARNING 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 factor[...]

  • Page 67

    TROUBLESHOOTING & REP AIR F-27 F-27 MUL TI-WELD 350 Return to Section TOC Retur n 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 MUL TI-WELD 350 LINCOLN ELECTRIC AMPS VOL TS A V ELECTRODE INPUT WORK CHOPPER TECHNOLOGY COPPER CAP ACITOR NEGA TIVE STRA[...]

  • Page 68

    TROUBLESHOOTING & REP AIR F-28 F-28 MUL TI-WELD 350 Return to Section TOC Retur n 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 CHOPPER PC BOARD INPUT VOL T AGES AND RESIST ANCE TEST (CONTINUED) T est Procedure for the Left Side Power Module 1. Loca[...]

  • Page 69

    Return to Section TOC Retur n 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-29 F-29 MUL TI-WELD 350 This is the typical CC open circuit out- put voltage generated from a properly operating machine. Note that each vertical[...]

  • Page 70

    Return to Section TOC Retur n 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-30 F-30 MUL TI-WELD 350 This is the typical CV output voltage generated from a properly operating machine. Note that each vertical division repre[...]

  • Page 71

    Return to Section TOC Retur n 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-31 F-31 MUL TI-WELD 350 This is the typical CC output voltage generated from a properly operating machine. Note that each vertical divi- sion rep[...]

  • Page 72

    Return to Section TOC Retur n 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-32 F-32 MUL TI-WELD 350 NORMAL WELD VOL T AGE W A VEFORM MACHINE LOADED TO 350 AMPS A T 34 VOL TS – CV MODE This is the typical CV output volta[...]

  • Page 73

    Return to Section TOC Retur n 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-33 F-33 MUL TI-WELD 350 This is the typical CV open circuit out- put voltage generated from a properly operating machine. Note that each vertical[...]

  • Page 74

    TROUBLESHOOTING & REP AIR F-34 F-34 MUL TI-WELD 350 CASE FRONT ASSEMBL Y REMOV AL AND REPLACEMENT W ARNING 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 warrant[...]

  • Page 75

    TROUBLESHOOTING & REP AIR F-35 F-35 MUL TI-WELD 350 Return to Section TOC Retur n 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 BASE SCREWS (2) ACCESS FROM BOTTOM PLUG ASSEMBLIES (3) MUL TI-WELD 350 LINCOLN ELECTRIC AMPS VOL TS A V ELECTRODE INPUT W[...]

  • Page 76

    TROUBLESHOOTING & REP AIR F-36 F-36 MUL TI-WELD 350 WELD CONTROL OR PERIPHERAL PC BOARD REMOV AL AND REPLACEMENT W ARNING 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 [...]

  • Page 77

    TROUBLESHOOTING & REP AIR F-37 F-37 MUL TI-WELD 350 Return to Section TOC Retur n 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 PERIPHERAL PC BO ARD JUMPER PLUG P3 PLUG P31 SCREWS (7) WELD CONTROL PC BO ARD NUTS HOT START ARC FORCE OTE CC SLOPE P IP[...]

  • Page 78

    TROUBLESHOOTING & REP AIR F-38 F-38 MUL TI-WELD 350 Return to Section TOC Retur n 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 WELD CONTROL OR PERIPHERAL PC BOARD REMOV AL AND REPLACEMENT (CONTINUED) 7. Carefully label and remove the 12 molex plugs[...]

  • Page 79

    TROUBLESHOOTING & REP AIR F-39 F-39 MUL TI-WELD 350 AMPS/VOL TS DIGIT AL METER AND POTENTIOMETER REMOV AL AND REPLACEMENT W ARNING 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 invalid[...]

  • Page 80

    TROUBLESHOOTING & REP AIR F-40 F-40 MUL TI-WELD 350 Return to Section TOC Retur n 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 DIGIT AL METER OUTPUT CONTROL PO TENTIOMETER BEZEL LENS KNOB SP ACER SEAL HO T STA RT ARC FO RCE OTE 4 4 2 2 0 6 6 10 5 4[...]

  • Page 81

    TROUBLESHOOTING & REP AIR F-41 F-41 MUL TI-WELD 350 Return to Section TOC Retur n 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 AMPS/VOL TS DIGIT AL METER AND POTENTIOMETER REMOV AL AND REPLACEMENT (CONTINUED) 7. Carefully remove the Amps or V olts [...]

  • Page 82

    TROUBLESHOOTING & REP AIR F-42 F-42 MUL TI-WELD 350 INPUT CONT ACTOR REMOV AL AND REPLACEMENT W ARNING 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 . [...]

  • Page 83

    TROUBLESHOOTING & REP AIR F-43 F-43 MUL TI-WELD 350 Return to Section TOC Retur n 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 LEADS #303A #330 LEADS #X1A #X1 #XBP5 INPUT CONT ACTOR LEAD #331 COPPER STRAP HEA T SINK BOL TS & NYLON INSULA TORS ([...]

  • Page 84

    TROUBLESHOOTING & REP AIR F-44 F-44 MUL TI-WELD 350 Return to Section TOC Retur n 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 INPUT CONT ACTOR REMOV AL AND REPLACEMENT (CONTINUED) 7. Using the 17 mm wrench, remove the nuts from the input contactor[...]

  • Page 85

    TROUBLESHOOTING & REP AIR F-45 F-45 MUL TI-WELD 350 INPUT DIODE REMOV AL AND REPLACEMENT W ARNING 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 y[...]

  • Page 86

    TROUBLESHOOTING & REP AIR F-46 F-46 MUL TI-WELD 350 Return to Section TOC Retur n 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 { } INPUT TERMINAL STRAP BOL T THERMOST A T (LEADS #306 &#307) MYLAR CHOKE A TT A CHMENT POINT DIODE PIGT AILS MYLAR [...]

  • Page 87

    TROUBLESHOOTING & REP AIR F-47 F-47 MUL TI-WELD 350 Return to Section TOC Retur n 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 INPUT DIODE REMOV AL AND REPLACEMENT (CONTINUED) 10. Disconnect thermostat leads #306 and #307. 1 1. Carefully remove the[...]

  • Page 88

    TROUBLESHOOTING & REP AIR F-48 F-48 MUL TI-WELD 350 F AN MOTOR ASSEMBL Y REMOV AL AND REPLACEMENT W ARNING 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 warrant[...]

  • Page 89

    TROUBLESHOOTING & REP AIR F-49 F-49 MUL TI-WELD 350 Return to Section TOC Retur n 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 MO TOR LEADS #303A #330 F AN MO TOR SCREWS (2 ) FIGURE F .12 – F AN MOTOR ASSEMBL Y DET AILS F AN MOTOR ASSEMBL Y REMOV[...]

  • Page 90

    TROUBLESHOOTING & REP AIR F-50 F-50 MUL TI-WELD 350 Return to Section TOC Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F AN MOTOR ASSEMBL Y REMOV AL AND REPLACEMENT (CONTINUED) 3. Perform the Input Diode Removal proce- dure. 4. Disconnect t[...]

  • Page 91

    TROUBLESHOOTING & REP AIR F-51 F-51 MUL TI-WELD 350 POWER CAP ACITOR REMOV AL AND REPLACEMENT W ARNING 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 . [...]

  • Page 92

    TROUBLESHOOTING & REP AIR F-52 F-52 MUL TI-WELD 350 Return to Section TOC Retur n 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 CLAMP BRACKET ANALOG CONTROL SUPPLY PC BOARD (4 SCREWS) SCREWS (2) CHOPPER PC BOARD CAP ACITOR POSITIVE STRAP CAP ACITOR [...]

  • Page 93

    TROUBLESHOOTING & REP AIR F-53 F-53 MUL TI-WELD 350 Return to Section TOC Retur n 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 CAP ACITOR REMOV AL AND REPLACEMENT (CONTINUED) 7. Using the slot head screw driver , remove the two screws and loc[...]

  • Page 94

    TROUBLESHOOTING & REP AIR F-54 F-54 MUL TI-WELD 350 CHOPPER PC BOARD AND DIODE MODULE REMOV AL AND REPLACEMENT W ARNING 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 fa[...]

  • Page 95

    TROUBLESHOOTING & REP AIR F-55 F-55 MUL TI-WELD 350 Return to Section TOC Retur n 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 MUL TI-WELD 350 LINCOLN ELECTRIC AMPS VOLTS A V ELECTRODE INPUT WORK CHOPPER TECHNOLOGY 4 SCREWS A CCESSED FROM BO TT OM [...]

  • Page 96

    TROUBLESHOOTING & REP AIR F-56 F-56 MUL TI-WELD 350 Return to Section TOC Retur n 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 CHOPPER PC BOARD REMOV AL AND REPLACEMENT (CONTINUED) 3. Perform the Case Cover Removal proce- dure. 4. Perform the Power[...]

  • Page 97

    TROUBLESHOOTING & REP AIR F-57 F-57 MUL TI-WELD 350 Return to Section TOC Retur n 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 MUL TI-WELD 350 L IN COLN ELECTR IC AMPS VOLTS A V E L E C T R O D E IN P U T W O R K CHOPPER T ECHNOLOGY + - 3/16" [...]

  • Page 98

    TROUBLESHOOTING & REP AIR F-58 F-58 MUL TI-WELD 350 Return to Section TOC Retur n 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 DIODE MODULE REMOV AL AND REPLACEMENT (CONTINUED) 3. Perform the Case Cover Removal proce- dure. 4. Perform the Power Cap[...]

  • Page 99

    TROUBLESHOOTING & REP AIR F-59 F-59 MUL TI-WELD 350 Return to Section TOC Retur n 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 SPRING WASHER PLAIN WASHER 2 TO 3 TURNS EACH FINGER TIGHT 5.0-10 IN-LBS. 5.0-10 IN-LBS. 12-18 IN-LBS. 30-40 IN-LBS. 1 2 3[...]

  • Page 100

    TROUBLESHOOTING & REP AIR F-60 F-60 MUL TI-WELD 350 Return to Section TOC Retur n 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 Retest a machine: • If it is rejected under test for any reason that requires you to remove any me[...]

  • Page 101

    G-1 ELECTRICAL DIAGRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 [...]

  • Page 102

    ELECTRICAL DIAGRAMS G-2 MUL TI-WELD 350 WIRING DIAGRAM - MUL TI-WELD 350 9-17-99A G3676 MULTI-WELD 350 WIRING DIAGRAM REMOTE RECEPT ACLE ARC FORCE FA N (LEFT) (RIGHT) L1 L2 CHOPPER PCB (LEFT) CHOPPER PCB (RIGHT) C1 C2 REVERSE DIODE D5 D4 HEA TSINK CONNECTION OFF S1 R3 S2 ON/OFF & MODE SELECT 202 231 217 218 219 202A 222 223 217 221 A A B B C C [...]

  • Page 103

    Return to Section TOC Retur n 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-3 MUL TI-WELD 350 SCHEMA TIC - CONTROL PC BOARD #1 G-3 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this m[...]

  • Page 104

    Return to Section TOC Retur n 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-4 MUL TI-WELD 350 SCHEMA TIC - CONTROL PC BOARD #2 G-4 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this m[...]

  • Page 105

    Return to Section TOC Retur n 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-5 MUL TI-WELD 350 SCHEMA TIC - CONTROL PC BOARD #3 G-5 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this m[...]

  • Page 106

    Return to Section TOC Retur n 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-6 MUL TI-WELD 350 SCHEMA TIC - CONTROL PC BOARD #4 G-6 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this m[...]

  • Page 107

    ELECTRICAL DIAGRAMS G-7 MUL TI-WELD 350 SCHEMA TIC - CONTROL PC BOARD #5 G-7 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Retur n 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 Mast[...]

  • Page 108

    SOLID EDGE EN-170 MA NUF ACT URING T OLE RAN CE PE R E20 56 UNLESS OT HERWIS E SP EC I FIED T OLER ANCE SCALE: DO N OT SCA LE T HIS DRAW ING ON 3 PLACE DECIMALS IS ±  .002 THIS SH EE T C ON TAINS P RO PR IE TAR Y IN FO RMATI O N OW NE D B Y T HE L INC OL N ELEC TRI C COM PAN Y AN D I S N OT TO BE RE PR ODU C ED, D ISC LOS ED OR U S ED WIT H OUT[...]

  • Page 109

    Return to Section TOC Retur n 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-9 MUL TI-WELD 350 SCHEMA TIC - PERIPHERAL PRINTED CIRCUIT BOARD G-9 NOTE: This diagram is for reference only . It may not be accurate for all machines cove[...]

  • 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[...]

  • Page 111

    ELECTRICAL DIAGRAMS G-11 MUL TI-WELD 350 SCHEMA TIC - POWER PRINTED CIRCUIT BOARD 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 Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retu[...]

  • 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[...]

  • Page 113

    Return to Section TOC Retur n 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-13 MUL TI-WELD 350 SCHEMA TIC - ANALOG PRINTED CIRCUIT BOARD G-13 NOTE: This diagram is for reference only . It may not be accurate for all machines covere[...]

  • Page 114

    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[...]

  • Page 115

    Return to Section TOC Retur n 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-15 MUL TI-WELD 350 SCHEMA TIC - BY -P ASS PRINTED CIRCUIT BOARD G-15 NOTE: This diagram is for reference only . It may not be accurate for all machines cov[...]

  • Page 116

    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[...]

  • Page 117

    Return to Section TOC Retur n 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-17 MUL TI-WELD 350 SCHEMA TIC - CHOPPER PRINTED CIRCUIT BOARD 50V 0.1 C1 1W 16V DZ5 D1 150V 8A Q1 B1 D2 47 35V C2 500 50V C5 + t .24 R1 4.75K R14 D3 D5 D4 [...]

  • Page 118

    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[...]

  • Page 119

    SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. W e also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information w[...]