Lincoln Electric CITOTIG 315DC Service Manual
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Lincoln Electric CITOTIG 315DC Service Manual

Lincoln Electric CITOTIG 315DC Service Manual

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SVM 3082
Rev.00 12-2018
CITOTIG 315DC & 415DC
For use with machines having code numbers: 50402 & 50404
LINCOLN ELECTRIC EUROPE
www.lincolnelectric.eu
1

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Summary of Contents for Lincoln Electric CITOTIG 315DC

  • Page 1: Index Of Contents

    SVM 3082 Rev.00 12-2018 CITOTIG 315DC & 415DC For use with machines having code numbers: 50402 & 50404 LINCOLN ELECTRIC EUROPE www.lincolnelectric.eu...

  • Page 2: Table Of Contents

    INDEX OF CONTENTS INDEX OF CONTENTS ..............................2 TECHNICAL SPECIFICATIONS ............................. 3 MAINTENANCE ................................19 MAJOR COMPONENTS LOCATION ........................... 20 THEORY OF OPERATION ............................22 TROUBLESHOOTING AND REPAIR SECTION ......................28 CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE ..........32 DISCHARGE PROCEDURE ............................

  • Page 3: Technical Specifications

    TECHNICAL SPECIFICATIONS INPUT Input Power at Rated Output EMC Class 6.5kW @ 100% Duty Cycle (Stick) 5.1kW @ 100% Duty Cycle (TIG) 8.8kW @ 60% Duty Cycle (Stick) 315DC 6.1kW @ 60% Duty Cycle (TIG) 9.8kW @ 40% Duty Cycle (Stick) Input Voltage Frequency 8.1kW @ 40% Duty Cycle (TIG)
  • Page 4 Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible for damages caused by improper installation, improper care or abnormal operation.
  • Page 5 SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in an environment with increased hazard of electric shock. EQUIPMENT WEIGHT OVER 30kg: Move this equipment with care and with the help of another person. Lifting may be dangerous for your physical health. CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used.
  • Page 6 First determine the proper electrode polarity for the If a COOLER unit listed above is connected to the electrode to be used. Consult the electrode data for this Machine, it will be automatically turned ON and OFF information. Then connect the output cables to the output in order to ensure the torch cooling.
  • Page 7 NOTE: If a COOLER TIG torch cooling unit is ignored). connected to the machine, it will be turned ON/OFF by the Green Mode feature. Gas Inlet: Connector for the TIG shielding gas. Use the supplied connector to connect the machine to the gas source line.
  • Page 8 Trigger Mode Pushbutton: Keep pushed for 4s The Memory pushbuttons are disabled during welding. See “List of parameters and Factory stored programs” section below for a complete list of factory stored programs. This pushbutton changes the trigger sequence in Pulsing Mode Pushbutton: TIG welding mode: 2-step / 4-step with restart This option is not selectable by the Trigger Pushbutton and, if...
  • Page 9 mapped the Arc Force levels. The control measure in each instant the output voltage and it determines the amount of the peak of current to apply; that FREQUENCY DUTY CYCLE value is enough to breaks the metal drop that is being transferred from the electrode to the workpiece as to guarantee the arc stability, but not BACKGROUND...
  • Page 10 the set current without any upslope/downslope. The welding time can be either linked to the trigger or Before to start a TIG welding, a gas circuit purge set with the spot time control. is recommended. If the spot time (“option 11” of the Setup Menu) is To purge the gas circuit and torch: enabled from the setup menu, in order to change the spot time:...
  • Page 11 TIG Welding Sequences During welding the “Sel” pushbutton is enabled for At each pressure of the SEL push the following functions: button the LEDs lights up in the Output current following order: Only if Pulse Function is active: is possible operates on the values of Duty (%), Frequency (Hz) and Background current (A).
  • Page 12 turned OFF. machine is turned OFF. 4-Step Trigger Sequence After the arc is turned OFF, the gas valve will To select 4-Step sequence: remain open to continue the flow of the shielding Action Visualization gas to the hot electrode and work piece. Press several times until the LED above lights up With the 4-step trigger mode and a TIG welding mode selected, the following welding sequence will occur.
  • Page 13 turn OFF. As shown here, again This sequence operation, 4-step with restart disabled, after the TIG torch trigger is quickly is the default setting from the factory. pressed and released 4-Step Trigger Sequence with Restart Option from step 3A, it is To select 4-Step with restart sequence: possible to quickly Action...
  • Page 14 Then release the SEL” pushbutton seconds, then turn ON again. If the error remains, a maintenance is required. Please contact the nearest technical service center or Lincoln Electric and report the error code displayed on the meter of the Front Panel. Error code table...
  • Page 15 List of parameters and Factory stored programs List of parameters and Factory Configuration program: Selectable Value Range Displayed parameter Displayed name value Factory Configuration Parameter (P99) Current Preflow 0.1s 0 - 5s (step 0.1s) selected value Lift TIG 2-step: 22A Not adjustable Current Lift TIG 4-step: 30%...
  • Page 16 Lincoln Electric. The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system.
  • Page 17 For any repair operations, modifications or maintenances, it is recommended to contact the nearest Technical Service Center or Lincoln Electric. Repairs and modifications performed by unauthorized service or personnel will cause, that the manufacturer’s warranty will become null and void.

  • Page 18: Maintenance

    MAINTENANCE WARNING INPUT FILTER CAPACITOR DISCHARGE PROCEDURE Remove main input power to the CITOTIG 315DC or 415DC ELECTRIC SHOCK can kill Remove the cover following the case removal procedure available in this Service manual. Have an electrician install and service this equipment...

  • Page 19: Major Components Location

    If the fan is not turning or the air intake louvers were obstructed , then the power must be switched off and the fan problem or air obstruction must be corrected. MAJOR COMPONENTS LOCATION CITOTIG 315DC Input Board Switch...
  • Page 20 CITOTIG 415DC Input Board Inverter Board Input rectifier Output Board HF Board 10. Output Transformer Hall Current Sensor 11. Display Board 12. Control Board Gas Solenoid 13. DC BUS Capacitor Switch...

  • Page 21: Theory Of Operation

    THEORY OF OPERATION  General description  Input Line Voltage, Auxiliary Voltage, Pre-charge  Inverter Board and Main Transformer  Output Board and Output Choke  Control Board, Display Board and HF Board  Protection Circuits  IGBT operation BLOCK DIAGRAM (showing 315DC block diagram)
  • Page 22 During this phase a signal called GENERAL DESCRIPTION READY_OK signals to the control The CITOTIG 315DC & 415DC are inverter based board that the machine is not still welding power sources that offers multi-mode working; the green led on the (TIG and Stick) constant current welding.
  • Page 23 INVERTER AND MAIN TRANSFORMER INVERTER AND MAIN TRANSFORMER disabling the machine’s output. A thermal When the input filter capacitors are fully charged protector is also present, to the inverter heat-sink, they act as power supplies for the IGBT switching to protect the IGBTs from overheating conditions. circuit.
  • Page 24 OUTPUT BOARD AND OUTPUT CHOKE OUTPUT BOARD AND OUTPUT CHOKE The output board receives the AC output waveform from the main transformer secondary winding and rectifies it to a DC voltage level. Since the output choke is in series with the positive leg of the output rectifier and also in series with the welding load, a filtered DC output current is applied through the machine’s output...
  • Page 25 CONTROL BOARD, DISPLAY BOARD AND HF BOARD Display Boards functions as the interface between CONTROL BOARD , DISPLAY the user and the machine. BOARD AND HF BOARD The control board receives status and feedback signals from the input board, inverter board, The HF Board generates a set of 40-60Hz pulses output board and various sensors.
  • Page 26 OVERLOAD PROTECTION The thermal protection devices are self-resetting once the machine cools sufficiently. If the CITOTIG 315DC & 415DC are electrically shutdown was caused by excessive output or duty protected from producing higher than normal cycle and the fan is operating normally, the power output currents.

  • Page 27: Troubleshooting And Repair Section

    TROUBLESHOOTING AND REPAIR SECTION  How to use troubleshooting Guide  Troubleshooting Guide  Case cover removal and capacitor discharge procedure...
  • Page 28 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 29 WARNING 4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board. NOTE: Allow the machine to heat up so that all ELECTRIC SHOCK can kill electrical components can reach their operating temperature. Have an electrician install and service this •...
  • Page 30 TROUBLESHOOTING !! WARNING !! BEFORE CONNECT POWER SUPPLY, MAKE A CAREFUL VISUAL INSPECTION INSIDE THE MACHINE , CHECK ALL THE BOARDS AND HARNESSES. POSSIBLE AREAS OF RECOMMENDED COURSE PROBLEMS / SYMPTOMS CHECK MISADJUSTMENT(S) OF ACTION • INPUT POWER BRIDGE IS IN SHORT CIRCUIT •...

  • Page 31: Case Cover Removal And Dc Link Capacitor Discharge Procedure

    DISCHARGE PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 32 CITOTOTIG 315DC - CASE COVER REMOVAL Necessary tool: Screwdriver type PH2 Procedure: 1. Turn on/off switch to off position. 2. Disconnect Input Power from the machine ! 3. Remove the 4 screws on the top of the machine (A). 4. Remove the 6 screws on the left and 6 screws on the right side of the machine (B). 5.
  • Page 33 CITOTIG 415DC - CASE COVER REMOVAL Necessary tool: Screwdriver type PH2 Procedure: 1. Turn on/off switch to off position. 2. Disconnect Input Power from the machine ! 3. Remove the 4 screws on the top of the machine (A). 4. Remove the 8 screws on the left and 8 screws on the right side of the machine (B). 5.

  • Page 34: Discharge Procedure

    DISCHARGE PROCEDURE WARNING INPUT FILTER CAPACITOR DISCHARGE PROCEDURE ELECTRIC SHOCK can kill CITOTIG Remove main input power to the 315DC or 415DC Have an electrician install and service this Remove the cover following the case removal equipment procedure available in this Service manual. Turn the input power off at the fuse box before The capacitors are discharged by discharge working on equipment...

  • Page 35: Input Board Resistance Test

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact your Local Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
  • Page 36 W05X1328 used on 315DC (picture above) W05X1328-2 used on 415DC TEST PROCEDURE 1. Remove main input power to the CITOTIG 315DC or 415DC 2. Perform the Discharge procedure 3. Visually check for burned or damaged components. If any components are physically damaged the input board should be replaced 4.

  • Page 37: Inverter Board Resistance Test

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact your Local Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
  • Page 38 W05X1327-1 used on 315DC W05X1327-2 used on 415DC TEST PROCEDURE 1. Remove main input power to the CITOTIG 315DC or 415DC 2. Perform the Discharge procedure 3. Visually check for burned or damaged components. If any components are physically damaged the inverter board and damaged components should be replaced 4.

  • Page 39: Output Board Resistance Test

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact your Local Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
  • Page 40 Output resistor W05X1326-2 used on 315DC TEST PROCEDURE 1. Remove main input power to the CITOTIG 315DC 2. Perform the Discharge procedure 3. Visually check for burned or damaged components. If any components are physically damaged the output board should be replaced 4.
  • Page 41 OUTPUT BOARD RESISTANCE TEST (continued) for CITOTIG 415DC Connector for thermostat TH1 Output diode modules D14,D15 Output resistor Doubler circuit diode bridge module D3 Output diode modules D12,D13 W05X1442 used on 415DC TEST PROCEDURE 1. Remove main input power to the CITOTIG 415DC 2.

  • Page 42: Input Board Voltage Test

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact your Local Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
  • Page 43 TEST PROCEDURE Use always electrically insulate gloves during this test procedure 1. Apply 400Vac +/- 15% to the CITOTIG 315DC or 415DC 2. Turn the machine input switch to ON position, soft start operation starts and power LED on front panel starts to blink.
  • Page 44 INPUT BOARD VOLTAGE TEST (continued) J2: Input/Control connector Pin# Description Value (use SGND as 0V ref.) Notes +15V +15Vdc +15Vdc generated by input board SGND SGND Secondary GND for power supply (0V ref.) • 0Vdc=Water flow OK FLOW Water flow signal from coolarc->input board •...
  • Page 45 INPUT BOARD VOLTAGE TEST (continued) J3: Input/Output connector Pin# Description Value (use SGND as 0V ref.) Notes • 6Vdc +/- 10% in stick mode in OCV condition MIS_V Output voltage feedback • 0,6 Vdc +/- 10% TIG modes in OCV condition Not used Not used...

  • Page 46: Inverter Board Voltage Test

    INVERTER BOARD VOLTAGE TEST WARNING 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 precautions detailed throughout this manual.
  • Page 47 Use always electrically insulate gloves during this test procedure 1. Apply 400Vac +/- 15% to the CITOTIG 315DC or 415DC 2. Turn the machine input switch to ON position, and wait till the power LED on front panel is steady green.

  • Page 48: Output Board Voltage Test

    OUTPUT BOARD VOLTAGE TEST WARNING 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 precautions detailed throughout this manual.
  • Page 49 TEST PROCEDURE Use always electrically insulate gloves during this test procedure 1. Apply 400V +/- 15% to the CITOTIG 315DC 2. Turn the machine input switch to ON position, and wait till the power LED on front panel is steady green.
  • Page 50 OUTPUT BOARD VOLTAGE TEST (continued) for CITOTIG 415DC to “HALL1” to Input bd (output current transducer) TEST PROCEDURE Use always electrically insulate gloves during this test procedure 1. Apply 400V +/- 15% to the CITOTIG 415DC 2. Turn the machine input switch to ON position, and wait till the power LED on front panel is steady green. 3.

  • Page 51: Hf Board Test

    HF BOARD TEST WARNING 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 precautions detailed throughout this manual.
  • Page 52 TEST PROCEDURE Use always electrically insulate gloves during this test procedure CITOTIG 315DC or 415DC 1. Carefully apply 400Vac +/- 15% or 230Vac-3ph +/-15% to the 2. Turn the machine input switch to ON position and wait till the power LED on front panel is steady green.

  • Page 53: Control Board Test

    CONTROL BOARD TEST WARNING 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 precautions detailed throughout this manual.
  • Page 54 The following tests must be performed with the control board installed inside the machine and with all harnesses connected. 1. Apply 400V +/- 15% to the CITOTIG 315DC or 415DC 2. Turn the machine input switch to ON position, and wait till the power LED on front panel is steady green.
  • Page 55 Only when in TIG HF mode +15Vdc are applied to • +15Vdc in Stick and Lift TIG mode HVPON pin 1 of HF connector • 0Vdc in TIG HF mode • +5Vdc only during Power Up sequence READY_OK • 0V during normal operation condition •...

  • Page 56: Disassembly Operations

    DISASSEMBLY OPERATIONS INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE for CITOTIG 315DC & 415DC WARNING (pictures shown 315DC input board) Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment.
  • Page 57 REMOVAL PROCEDURE Necessary tool: Screwdriver type PH02 1. Remove main input power to the CITOTIG 315DC or 415DC 2. Follow the case removal procedure available in this Service Manual 3. Perform the Discharge procedure 4. Disconnect the connectors J1,J2,J3,J4,J5,J6,J7 and the ground connection from the input board. See Fig.1...
  • Page 58 Screwdriver type PH02 A small flat bladed screwdriver Torque wrench 1. Remove main input power to the CITOTIG 315DC or 415DC 2. Follow the case removal procedure available in this Service Manual 3. Perform the Discharge procedure 4. Disconnect the connector J11 5.
  • Page 59 See printed circuit board for reference 7 mm nut driver Torque wrench 1. Remove main input power to the CITOTIG 315DC 2. Follow the case removal procedure available in this Service Manual 3. Perform the Discharge procedure 4. Disconnect the connectors J31, J32 and J34 5.
  • Page 60 DISASSEMBLY OPERATIONS OUTPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE W05X1442 for CITOTIG 415DC PAY ATTENTION ! of how to position the open end mounting of modules to heat-sink. REMOVAL PROCEDURE Necessary tool: See printed circuit board for reference Screwdriver type PH02 A small flat bladed screwdriver 7 mm nut driver Torque wrench...
  • Page 61 REMOVAL PROCEDURE Necessary tool: 5,5 mm wrench 1. Remove main input power to the CITOTIG 315DC or 415DC 2. Follow the case removal procedure available in this Service Manual 3. Perform the Discharge procedure 4. Locate the HF board (see Fig.1) 5.
  • Page 62 Necessary tool: Screwdriver type Phillips 5,5 mm short Nut driver or wrench 1. Remove main input power to the CITOTIG 315DC or 415DC 2. Follow the case removal procedure available in this Service Manual 3. Perform the Discharge procedure 4. Remove the flat knob cap and use a screwdriver type Phillips to loosen the knob until you’ll be able to remove it (see Fig.1)
  • Page 63 Screwdriver type PH02 13 mm wrench 17 mm wrench 1. Remove main input power to the CITOTIG 315DC or 415DC 2. Follow the case removal procedure available in this Service Manual 3. Perform the Discharge procedure 4. Remove the gas pipe (A) pressing the red part (B) of the gas connector and pulling the gas pipe (see Fig.1)

  • Page 64: Retest After Repair

    Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested. Machine input and output CITOTIG 315DC Input Voltage Input Current Rated Output...

  • Page 65: Electrical Schematics

    ELECTRICAL SCHEMATICS Block Diagram : CITOTIG 315DC code 50402...
  • Page 66 ELECTRICAL SCHEMATICS Block Diagram : CITOTIG 415DC code 50404...

  • Page 67: Note

    NOTE...

This manual is also suitable for:

Citotig 415dc5040250404

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