Lincoln Electric Tomahawk 1500 Service Manual
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Lincoln Electric Tomahawk 1500 Service Manual

Lincoln Electric Tomahawk 1500 Service Manual

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Tomahawk ® 1500
For use with machines having Code Numbers:
Tomahawk 1500: 12549, 12588
SERVICE MANUAL
SVM274
| Issue D ate 17-Mar
© Lincoln Global, Inc. All Rights Reserved.

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Summary of Contents for Lincoln Electric Tomahawk 1500

  • Page 1 Tomahawk ® 1500 For use with machines having Code Numbers: Tomahawk 1500: 12549, 12588 SERVICE MANUAL SVM274 | Issue D ate 17-Mar © Lincoln Global, Inc. All Rights Reserved.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).
  • Page 4 S FETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Tomahawk® 1500 Service Manual Last update: 2017/03/01 TOMAHAWK® 1500 ..........................1 Service Manual................................1 Theory of Operation ..............................3 INPUT SWITCH AND BUCK / BOOST BOARD ..................... 3 INVERTER BOARD, INPUT BOARD AND CONTROL / DISPLAY BOARD ............4 MAIN TRANSFORMER, OUTPUT BOARD AND TORCH CONNECTOR ............
  • Page 7 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual RECTIFIER BOARD REMOVAL AND REPLACEMENT PROCEDURE .............. 51 INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE ..............54 CONTROL / DISPLAY BOARD REMOVAL AND REPLACEMENT PROCEDURE ..........56 INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE .............. 59 OUTPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE ..............

  • Page 8: Theory Of Operation

    Input Switch and Buck / Boost Board The single or three phase input power is applied to the Tomahawk 1500 through the main input switch located on the back panel of the machine. When the switch is closed the AC input power is applied to the rectifier board where it is rectified to a DC voltage.

  • Page 9: Inverter Board, Input Board And Control / Display Board

    The input board also monitors the torch parts-in-place and trigger circuits and will not send a PWM signal to the inverter board if the safety circuits are not whole and complete. Thus, no output from the Tomahawk 1500. The input board also sends control signals to the buck / boost board and powers the gas solenoid and cooling fan.

  • Page 10: Main Transformer, Output Board And Torch Connector

    LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure E.3 – Main transformer, output board and torch connector Main Transformer, Output Board and Torch Connector The 400 volt pulsed DC output of the full wave bridge inverter (located on the inverter board) is coupled to the primary winding of the main transformer.

  • Page 11: Troubleshooting & Repair

    Troubleshooting & Repair HOW TO USE TROUBLESHOOTING GUIDE 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 and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 12: Pc Board Troubleshooting Procedures

    ELECTRIC SHOCK can kill. remove them until installation is complete. • If you return a PC board to The Lincoln Electric Company • Have an electrician install and service this for credit, it must be in the static-shielding bag. This will equipment.

  • Page 13: Troubleshooting Guide

    Technical Specifications in the Operators Manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 14 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 1-888-935-3877.
  • Page 15 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 1-888-935-3877.
  • Page 16 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 1-888-935-3877.
  • Page 17 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 1-888-935-3877.
  • Page 18 Operators Manual and verify the outlet gas pressure through the regulator knob. 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 1-888-935-3877.
  • Page 19 • Turn the machine ON again. 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 1-888-935-3877.
  • Page 20 • Press again the release the Torch Trigger pushbutton. 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 1-888-935-3877.
  • Page 21 Gas Error Parts In Place Error 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 1-888-935-3877.

  • Page 22: Test Procedures

    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 1-888-935-3877.
  • Page 23 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual 11. Locate the two terminals labeled DCIN+ and DCIN- on the buck / boost board. See Figure F.6. Carefully check for any voltage present at the terminals. 12. If any voltage is present, discharge the capacitors using the high wattage resistor (25-1000 Ohms @ 25 watts minimum), electrically insulated gloves and pliers.
  • Page 24 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.2 – Case cover mounting screw locations Figure F.3 – Capacitor location...
  • Page 25 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.4 – Capacitor discharge procedure Figure F.5 – Buck / boost board location...
  • Page 26 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.6 – Buck / boost board discharge...

  • Page 27: Rectifier Board Test Procedure

    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 1-888-935-3877.
  • Page 28 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Table F.1 – Rectifier board resistance tests POSITIVE TEST PROBE NEGATIVE TEST PROBE EXPECTED RESULT DCIN+ 0.3V – 0.7V DCIN+ 0.3V – 0.7V DCIN+ 0.3V – 0.7V DCIN+ OPEN DCIN+ OPEN DCIN+ OPEN DCIN- 0.3V –...
  • Page 29 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.8 – Rectifier board test point locations...

  • Page 30: Input Board Test Procedure

    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 1-888-935-3877.
  • Page 31 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Table F.3 – Input board voltage checks AC INPUT VOLTAGE EXPECTED TEST POINTS COMMENTS / CONDITIONS SINGLE PHASE READING MACHINE AT IDLE NO LOAD. 240 VAC PLUG J6 PIN 3(+) TO PIN 7(-) 225 VDC RECTIFIED AC INPUT LINE.
  • Page 32 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.9 – Input board location Figure F.10 – Input board LED and plug locations...
  • Page 33 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.11 – Input board lead locations...

  • Page 34: Control / Display Board Test Procedure

    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 1-888-935-3877.
  • Page 35 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Table F.4 – Control / display board status LED light table NORMAL FAULT LED IDENTITY COMMENTS / CONDITIONS STATUS STATUS ON-GREEN INDICATION OF 15VDC SEC. SUPPLY IS PRESENT. ON-GREEN INDICATION OF 5VDC SEC. SUPPLY IS PRESENT.
  • Page 36 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.12 – Control / display board location Figure F.13 – Control / display board plug and LED locations...
  • Page 37 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.14 – Control / display board plug J22 test point locations...

  • Page 38: Inverter Board Test Procedure

    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 1-888-935-3877.
  • Page 39 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Table F.6 – Inverter board voltage tests AC INPUT EXPECTED VOLTAGE TEST POINTS COMMENTS / CONDITIONS READING SINGLE PHASE POSITIVE TEMINAL TO FILTERED DC FROM BUCK/BOOST BOARD. 240 VAC 400 VDC NEGATIVE TERMINAL MACHINE AT IDLE – NO LOAD.
  • Page 40 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.15 – Inverter board location Figure F.16 – Inverter board test point locations...
  • Page 41 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.17 – Inverter board plug J11 test point locations...

  • Page 42: Output Board Test Procedure

    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 1-888-935-3877.
  • Page 43 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual If any of the tests fail, the output board may be faulty. If faulty, perform the Output Board Removal And Replacement Procedure. 14. Perform the Case Cover Replacement Procedure. Table F.8 – Output board voltage tests...
  • Page 44 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Table F.10 – Output board resistance tests COMMENTS / AC INPUT VOLTAGE TEST POINTS EXPECTED READING CONDITIONS MACHINE DISCONNECTED LOW RESISTANCE – B5 (POSITIVE TEST PROBE) TO CHECKING DIODE FROM INPUT VOLTAGE AND FORWARD DIODE B7 (NEGATIVE TEST PROBE) MODULE A1.
  • Page 45 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.18 – Output board location Figure F.19 – Output board test point and resistor module location...
  • Page 46 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.20 – Output board lead locations...

  • Page 47: Torch Test Procedure

    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 1-888-935-3877.
  • Page 48 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.21 – Torch connection point Figure F.22 – Torch pin locations...

  • Page 49: Buck / Boost Board & Igbt Test Procedure

    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 1-888-935-3877.
  • Page 50 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Table F.12 - Forward voltage drop tests SECTION TO BE TEST POINTS EXPECTED READING +/- 10% TOLERANCE MEASURED SECTION A POSITIVE TO NEGATIVE .355 VDC +/- 10% .320 TO .391 SECTION B POSITIVE TO NEGATIVE .305 VDC +/- 10%...
  • Page 51 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.23 – Buck / boost board location Figure F.24 – Forward voltage drop test points...
  • Page 52 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.25 – DC voltage test points...

  • Page 53: Air / Gas Solenoid Test Procedure

    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 1-888-935-3877.
  • Page 54 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.26 – Air / gas solenoid location Figure F.27 – Input board location...
  • Page 55 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.28 – Input board plug and lead locations...

  • Page 56: Removal And Replacement Procedures

    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 1-888-935-3877.
  • Page 57 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual 5. Carefully position new rectifier board into the machine. Using a Phillips screwdriver, connect the five screws, lock washers and flat washers securing the leads to terminals DCIN+, DCIN-, AC1, AC2 and AC3 to the rectifier board. See Wiring Diagram.
  • Page 58 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.30 – Input rectifier module mounting screw locations...

  • Page 59: Input Board Removal And Replacement Procedure

    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 1-888-935-3877.
  • Page 60 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.31 – Input board lead locations Figure F.32 – Input board mounting screw locations...

  • Page 61: Control / Display Board Removal And Replacement Procedure

    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 1-888-935-3877.
  • Page 62 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.33 – Control / display board plug J22 location Figure F.34 – Output control knob location...
  • Page 63 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.35 – Control / display board mounting screw locations...

  • Page 64: Inverter Board Removal And Replacement Procedure

    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 1-888-935-3877.
  • Page 65 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual REPLACEMENT PROCEDURE 1. Clean the heat sink. 2. Apply a coating of Dow Corning 340 heat sink compound to the mating surface of the IGBT module and the heat sink. 3. Carefully position the new IGBT module into the machine. Make sure the IGBT module slot is facing the correct direction.
  • Page 66 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.36 – Inverter board plug and lead locations Figure F.37 – Inverter board mounting screws location...
  • Page 67 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.38 – IGBT module mounting screw locations Figure F.39 – IGBT module slot orientation...

  • Page 68: Output Board Removal And Replacement Procedure

    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 1-888-935-3877.
  • Page 69 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual REPLACEMENT PROCEDURE 1. Clean the heat sink surface. 2. Apply a coating of Dow Corning 340 heat sink compound to the mating surface of the modules to be replaced and the heat sink. 3. Carefully position the module into the machine. Make sure the mounting slot is facing the correct direction.
  • Page 70 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.40 – Output board plug and lead locations Figure F.41 – Output board mounting screw locations...
  • Page 71 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.42 – Output module mounting screw locations Figure F.43 – Output module slot orientation...

  • Page 72: Buck / Boost Board Removal And Replacement Procedure

    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 1-888-935-3877.
  • Page 73 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual 3. Carefully position each module into the machine. NOTE: Both modules look the same but have different functions and part numbers. Verify that the proper module has been installed in the correct location. See Figure F.47.
  • Page 74 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.45 – Buck / boost board mounting screw locations Figure F.46 – Buck / boost module lead locations...
  • Page 75 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.47 – Buck / boost module mounting orientation and mounting screw locations...

  • Page 76: Choke Assembly Removal And Replacement Procedure

    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 1-888-935-3877.
  • Page 77 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Using a Torx nutdriver (size T-20), connect the two screws, lock washers and flat washers securing the previously disconnected leads to terminals IND1 and IND2 of the buck / boost board. See Wiring Diagram. Torque to 17 – 21 in/lbs.
  • Page 78 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.49 – Buck / boost board terminal IND1 and IND2 locations Figure F.50 – Output board location...
  • Page 79 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.51 – Output board terminal B7 and B8 location Figure F.52 – Choke assembly mounting screw locations...

  • Page 80: Transformer Assembly Removal And Replacement Procedure

    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 1-888-935-3877.
  • Page 81 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.53 – Inverter board location Figure F.54 – Inverter board terminal TR3 and TR1 locations...
  • Page 82 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.55 – Output board location Figure F.56 – Output board terminal B5 and B6 location...
  • Page 83 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.57 – Transformer assembly mounting screw locations...

  • Page 84: Air / Gas Solenoid Removal And Replacement Procedure

    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 1-888-935-3877.
  • Page 85 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.58 – Air / gas solenoid mounting screw and air hose connection locations Figure F.59 – Input board location...
  • Page 86 LINCOLN ELECTRIC Tomahawk® 1500 Service Manual Figure F.60 – Input board plugs J5 and J8 location...

  • Page 87: Retest After Repair

    LED goes out pull the torch trigger and verify that a pilot arc does occur. NOTE: There may be a delay in re-strike during the post flow time. Test cut with Tomahawk 1500 at its maximum recommended cut thickness with 1.25” steel max. Turn current dial to maximum.

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