Summary of Contents for Lincoln Electric Flextec 350X Power Connect
Page 1
Service Manual Flextec 350X Power Connect ® For use with machines having Code Numbers: 12822, 12946 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...
Table of Contents Flextec > Flextec 350X Power Connect - 12822 USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS ..................5 TROUBLESHOOTING GUIDE ..............................7 General Description................................10 Input Section ................................... 11 Insulated Gate Bipolar Transistor (IGBT) Operation......................12 Inverter Control Board And Switchboard ..........................13 Main Transformer...................................
0000178409 USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. Errors are displayed on the user interface. In addition, there are status lights on the User Interface board and the Switchboard that contain error sequences. Included in this section is information about the status lights and some basic troubleshooting charts for both machine and weld performance.
Page 7
0000178409 ERROR DESCRIPTION POSSIBLE CAUSE CORRECTIVE ACTION CODE NUMBER cable connections. Verify proper connections of main internal power components. Power must be cycled to the machine to reset the error. Thermal Fault. Machine shut off output Check for material blocking due to elevated internal intake or exhaust louvers.
FUNCTION PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION Major mechanical or Contact your local Lincoln Authorized Contact the Lincoln Electric electrical damage is Field Service Facility. Service Department at evident. 1-888-935-3877. The machine is “dead”. Make sure the line switch is in the ON...
Page 9
0000178481 PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION Perform the Mode Select Switch Test Procedure. The thermal LED is “ON”. The welding application may be Perform the Thermostat #1 The machine regularly exceeding the duty cycle and/or limits of and #2 Circuit Test overheats.
Page 10
0000178481 WELDING PROBLEMS PROBLEMS POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION (SYMPTOMS) There is a general Make sure the correct input power is Perform the Choke Test degradation of the being applied to the machine. Procedure. welding performance. Make sure the machine’s controls are Perform the Current Transducer set correctly for the welding process (LEM) Test Procedure.
Using CrossLink the operator can adjust the open circuit voltage on the Flextec 350X Power Connect™ from the compatible wire feeder. This is accomplished by sending a 1000 Hz pulse through the welding cables.
0000178340 Input Section Input section LECOL_EMBEDDEDIMG_0000178341_x.png Figure 1. Input section When a single or three phase input voltage is applied through the line switch to the input / precharge SCR bridge board the AC input voltage is rectified and controlled. This rectified voltage is applied, via the PFC boost board, to the auxiliary power board.
0000178335 Insulated Gate Bipolar Transistor (IGBT) Operation Insulated gate bipolar transistor (IGBT) operation LECOL_EMBEDDEDIMG_0000178336_x.png Figure 1. Insulated gate bipolar transistor (IGBT) operation An IGBT is a type of transistor. IGBT are semiconductors well suited for high frequency switching and high current applications.
The inverter control board also controls the cooling fans speed. The inverter control board also monitors the thermostat and thermistor circuits. In addition, it monitors the Crosslinc circuit and turns on the green LED when the Flextec 350X Power Connect™ is connected to a compatible crosslinc wirefeeder.
0000178350 Main Transformer Main transformer LECOL_EMBEDDEDIMG_0000178351_x.png Figure 1. Main transformer The main transformer is a step-down transformer. The primary windings receive the high voltage pulse width modulated power from the switch board. The 25 KHz AC output that is created on the center tapped weld secondary winding is applied to the output rectifiers.
0000178348 Output Rectifier And Choke Output rectifier, choke and current transducer LECOL_EMBEDDEDIMG_0000178349_x.png Figure 1. Output rectifier, choke and current transducer There are two output diode modules mounted to a heatsink. The AC output of the center tapped weld secondary winding, of the main transformer, is full wave rectified by the output rectifier. The resultant DC output has a 50 KHz ripple content.
0000178337 Pulse Width Modulation Typical IGBT outputs LECOL_EMBEDDEDIMG_0000178338_x.png Figure 1. Typical IGBT outputs The term Pulse Width Modulation is used to describe how much time is devoted to conduction in the positive and negative portions of the cycle. Changing the pulse width is known as modulation. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine.
Page 18
0000178337 By controlling the duration of the gate signal, the IGBT is turned on and off for different durations during the cycle. The top drawing in Figure E.7 shows the minimum output signal possible over a 40-microsecond time period. The positive portion of the signal represents one IGBT group1 conducting for one microsecond. The negative portion is the other IGBT group1.
If the temperature continues to rise and exceeds a set limit then the welding output will be disabled and the thermal symbol will illuminate. Protective Circuits Protective circuits are designed into the Flextec 350X Power Connect™ to sense trouble and shut down the machine before damage occurs to the machine’s internal components. 1(1)
0000178352 User Interface (UI) Board User interface (UI) board LECOL_EMBEDDEDIMG_0000178353_x.png Figure 1. User interface (UI) board The UI board is powered by the 42 VDC received from the auxiliary power board. LED 5 indicates that the on- board power supply if functioning. Led 4 is the Arclink status indicator. The user controls, switches, and connectors allow the operator to communicate to the UI board the desired processes and welding requirements.
Page 21
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 23
0000178375 Auxiliary power board voltage tests TEST POINT TEST POINT EXPECTED READING PLUG J49 PIN 1 (LEAD B2C) PLUG J49 PIN 6 (LEAD B1C) 860 VDC PLUG J49 PIN 12 (LEAD 444) PLUG J49 PIN 11 (LEAD 441) 18 VDC PLUG J45 PIN 2 (LEAD 465) PLUG J45 PIN 1 (LEAD 466) 5 VDC...
Page 24
0000178375 Auxiliary power board location LECOL_EMBEDDEDIMG_0000178378_x.png Figure 1. Auxiliary power board location 3(5)
Page 25
0000178375 Auxiliary power board plug locations LECOL_EMBEDDEDIMG_0000178377_x.png Figure 2. Auxiliary power board plug locations 4(5)
Page 26
0000178375 Auxiliary power board lead locations LECOL_EMBEDDEDIMG_0000178376_x.png Figure 3. Auxiliary power board lead locations 5(5)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 28
0000178482 Table F.1 - Boost rectifier diode drop tests TEST POINT TEST POINT EXPECTED READING AC TERMINAL (LEAD X21) POSITIVE TERMINAL (POS) 0.3 VDC – 1.0 VDC NEGATIVE TERMINAL (NEG) AC TERMINAL (LEAD X21) 0.3 VDC – 1.0 VDC NEGATIVE TERMINAL (NEG) AC TERMINAL (LEADS 202A AND 202B) 0.3 VDC –...
Page 30
0000178482 Transformer and positive boost lead connection locations LECOL_EMBEDDEDIMG_0000178464_x.png Figure 2. Transformer and positive boost lead connection locations 4(5)
Page 31
0000178482 Boost rectifier terminal and lead locations LECOL_EMBEDDEDIMG_0000178483_x.png Figure 3. Boost rectifier terminal and lead locations 5(5)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 36
0000178359 SCR (pre-charge) board, input rectifier and main capacitor board locations LECOL_EMBEDDEDIMG_0000178362_x.png Figure 1. SCR (pre-charge) board, input rectifier and main capacitor board locations 2(4)
Page 37
0000178359 Input rectifier terminals B5 and B6 LECOL_EMBEDDEDIMG_0000178361_x.png Figure 2. Input rectifier terminals B5 and B6 3(4)
Page 38
0000178359 Main capacitor board terminals B1 and B2 LECOL_EMBEDDEDIMG_0000178360_x.png Figure 3. Main capacitor board terminals B1 and B2 4(4)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 42
0000178455 14. Perform the Case Cover Replacement Procedure. Table F.1 - DC supply voltages from inverter control board DESCRIPTION TEST POINT (POS) TEST POINT (NEG) EXPECTED READING POSITIVE VOLTAGE SUPPLY PLUG J11 PIN 4 (LEAD 216A) PLUG J11 PIN 9 (LEAD 218A) +15 VDC NEGATIVE VOLTAGE PLUG J11 PIN 5 (LEAD 217A)
Page 43
0000178455 Inverter control board location LECOL_EMBEDDEDIMG_0000178458_x.png Figure 1. Inverter control board location 3(5)
Page 44
0000178455 Plug J11 location on inverter control board LECOL_EMBEDDEDIMG_0000178457_x.png Figure 2. Plug J11 location on inverter control board 4(5)
Page 45
0000178455 Plug J11 lead locations LECOL_EMBEDDEDIMG_0000178456_x.png Figure 3. Plug J11 lead locations 5(5)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 47
0000178461 Table F.1 - Fan voltage tests TEST TEST POINT TEST POINT CONDITIONS EXPECTED DESCRIPTION READING BOTTOM FAN PLUG J13 PLUG J13 PIN FAN NOT RUNNING 0 VDC PIN 4 (RED 3 (BLACK WIRE +) WIRE -) TOP FAN PLUG J14 PLUG J14 PIN FAN NOT RUNNING 0 VDC...
Page 48
0000178461 Inverter control board location LECOL_EMBEDDEDIMG_0000178463_x.png Figure 1. Inverter control board location 3(4)
Page 49
0000178461 Inverter control board plugs J13 and J14 locations LECOL_EMBEDDEDIMG_0000178462_x.png Figure 2. Inverter control board plugs J13 and J14 locations 4(4)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 51
0000178382 Table F.1 - Input rectifier diode drop tests TEST POINT TEST POINT EXPECTED READING TERMINAL L1 POSITIVE TERMINAL (B6) 0.3 VDC – 1.0 VDC TERMINAL L2 POSITIVE TERMINAL (B6) 0.3 VDC – 1.0 VDC TERMINAL L3 POSITIVE TERMINAL (B6) 0.3 VDC –...
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 55
0000178418 DESCRIPTION LOCATION MEANING LED 2 INVERTER ARCLINK SUPPLY ON CONTROL BOARD LED 1 DAUGHTER ARCLINK STATUS INDICATOR STEADY GREEN = SYSTEM OK BLINKING GREEN BOARD = OCCURS DURING STARTUP. NORMAL FOR FIRST 1 TO 30 SECONDS AFTER POWER IS APPLIED. ALTERNATING GREEN AND RED = READ THE ERROR CODE BEFORE THE MACHINE IS POWERED OFF.
Page 56
0000178418 Inverter control board location LECOL_EMBEDDEDIMG_0000178422_x.png Figure 1. Inverter control board location 3(5)
Page 57
0000178418 Inverter control board test points LECOL_EMBEDDEDIMG_0000178421_x.png Figure 2. Inverter control board test points 4(5)
Page 58
0000178418 Inverter control board lead locations LECOL_EMBEDDEDIMG_0000178419_x.png Figure 3. Inverter control board lead locations 5(5)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 60
0000178371 Table F.1 - Line switch resistance tests TEST POINT (POS) TEST POINT (NEG) EXPECTED READING SWITCH POSITION WHITE LEAD VERY LOW RESISTANCE (LESS THAN ONE OHM) “ON” POSITION RED LEAD VERY LOW RESISTANCE (LESS THAN ONE OHM) “ON” POSITION BLACK LEAD VERY LOW RESISTANCE (LESS THAN ONE OHM) “ON”...
Page 61
0000178371 Line switch location LECOL_EMBEDDEDIMG_0000178373_x.png Figure 1. Line switch location 3(4)
Page 62
0000178371 Line switch lead location LECOL_EMBEDDEDIMG_0000178372_x.png Figure 2. Line switch lead location 4(4)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 64
0000178389 Main capacitor board location LECOL_EMBEDDEDIMG_0000178391_x.png Figure 1. Main capacitor board location 2(3)
Page 65
0000178389 Main capacitor board terminal and LED locations LECOL_EMBEDDEDIMG_0000178390_x.png Figure 2. Main capacitor board terminal and LED locations 3(3)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 67
0000178428 TEST POINT TEST POINT EXPECTED MACHINE READING CONDITION X12 (AT OUTPUT RECTIFIER X13 (AT NEGATIVE OUTPUT 40 VAC MACHINE ON. BUSS BAR) TERMINAL) Main transformer location LECOL_EMBEDDEDIMG_0000178430_x.png Figure 1. Main transformer location 2(3)
Page 68
0000178428 Main transformer test point locations LECOL_EMBEDDEDIMG_0000178429_x.png Figure 2. Main transformer test point locations 3(3)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 70
0000178453 SWITCH TEST POINT TEST POINT EXPECTED READING POSITION SMAW PLUG J3 PIN PLUG J3 PIN VERY LOW RESISTANCE (LESS THAN ONE OHM) IN SWITCH 7 (LEAD 302) 1 (LEAD 308) POSTION. HIGH RESISTANCE (GREATER THAN 50OK OHMS) IN ALL OTHER POSITIONS. PLUG J3 PIN PLUG J3 PIN VERY LOW RESISTANCE (LESS THAN ONE OHM) IN SWITCH...
Page 71
0000178453 User interface board plug J3 location LECOL_EMBEDDEDIMG_0000178435_x.png Figure 2. User interface board plug J3 location User interface board plug J3 lead locations LECOL_EMBEDDEDIMG_0000178434_x.png Figure 3. User interface board plug J3 lead locations 3(3)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 73
0000178423 TEST POINT (POS) TEST POINT (NEG) EXPECTED READING LOWER BUSS BAR OUTPUT RECTIFIER HEATSINK 0.2 VDC – 0.7 VDC Output rectifier assembly location LECOL_EMBEDDEDIMG_0000178404_x.png Figure 1. Output rectifier assembly location 2(3)
Page 74
0000178423 Lead X11 and X12 connection point locations LECOL_EMBEDDEDIMG_0000178404_x.png Figure 2. Lead X11 and X12 connection point locations 3(3)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 76
0000178402 TEST POINT TEST POINT EXPECTED READING TERMINAL B7 TERMINAL B2 0.3 VDC – 1.0 VDC TERMINAL B7 TERMINAL B2 GREATER THAN 100K OHMS PFC boost board location LECOL_EMBEDDEDIMG_0000178384_x.png Figure 1. PFC boost board location 2(3)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 81
22. Place the #4 DIP switch in the OFF position. 23. Perform the Case Cover Replacement Procedure. Procedure Steps: Turn off the Flextec 350X Power Connect machine. Perform the Case Cover Removal Procedure. Perform the Capacitor Discharge Procedure. Locate the DIP switch on the user interface board. See Figure F.1.
Page 82
21. Place the #4 DIP switch in the OFF position. 22. Perform the Case Cover Replacement Procedure. Procedure Steps: Turn off the Flextec 350X Power Connect machine. Perform the Case Cover Removal Procedure. Perform the Capacitor Discharge Procedure. Locate the DIP switch on the user interface board. See Figure F.3.
Page 83
0000178477 14-PIN REMOTE SETTING LEFT DISPLAY RIGHT DISPLAY AT MIN. POSITION TURNING UP INCREASING AT MAX. POSITION 20. Step 3 – Machine Output Control, all models: OUTPUT CONTROL SETTING LEFT DISPLAY RIGHT DISPLAY AT MIN. POSITION TURNING UP INCREASING AT MAX. POSITION 21.
Page 84
28. Place the #8 DIP switch in the OFF position. 29. Perform the Case Cover Replacement Procedure. Procedure Steps: Turn off the Flextec 350X Power Connect machine. Perform the Case Cover Removal Procedure. Perform the Capacitor Discharge Procedure. Locate the DIP switch on the user interface board. See Figure F.3.
Page 85
32. Place the #8 DIP switch in the OFF position. 33. Perform the Case Cover Replacement Procedure. Procedure Steps: Turn off the Flextec 350X Power Connect machine. Perform the Case Cover Removal Procedure. Perform the Capacitor Discharge Procedure. Locate the DIP switch on the user interface board. See Figure F.3.
Page 86
0000178477 13. Cycle the weld terminals switch until the left display shows “ 9”. The right display will show the last three digits of the switchboard software number (Example: S30146-07 is software, then the right display shows “607”). 14. Cycle the weld terminals switch until the left display shows “ 10”. The right display will show the last three digits of the switchboard boot code version.
Page 87
0000178477 User interface board DIP switch location and position LECOL_EMBEDDEDIMG_0000178480_x.png Figure 1. User interface board DIP switch location and position 8(10)
Page 88
0000178477 User controls locations LECOL_EMBEDDEDIMG_0000178479_x.png Figure 2. User controls locations 9(10)
Page 89
0000178477 User interface board DIP switch location and position LECOL_EMBEDDEDIMG_0000178478_x.png Figure 3. User interface board DIP switch location and position 10(10)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 91
0000178413 Table F.1 - Switchboard resistance and diode drop tests DESCRIPTION TEST POINT (POS) TEST POINT (NEG) EXPECTED READING CHECKING SWITCHBOARD TERMINAL B4 SWITCHBOARD TERMINAL B2 0.3 TO 1.0 VDC “HIGH-SIDE” IGBTs CHECKING SWITCHBOARD TERMINAL B3 SWITCHBOARD TERMINAL B2 0.3 TO 1.0 VDC “HIGH-SIDE”...
Page 92
0000178413 LED FUNCTION NUMBER COLOR GREEN INDICATES SWITCHBOARD IS RECEIVING GATE DRIVE SIGNALS FROM THE INVERTER CONTROL BOARD. GREEN INDICATES SWITCHBOARD IS RECEIVING GATE DRIVE SIGNALS FROM THE INVERTER CONTROL BOARD. GREEN INDICATES SWITCHBOARD IS RECEIVING GATE DRIVE SIGNALS FROM THE INVERTER CONTROL BOARD.
Page 93
0000178413 Inverter control board location LECOL_EMBEDDEDIMG_0000178397_x.png Figure 2. Inverter control board location 4(7)
Page 94
0000178413 Switchboard terminal and LED locations LECOL_EMBEDDEDIMG_0000178396_x.png Figure 3. Switchboard terminal and LED locations 5(7)
Page 95
0000178413 Inverter control board plug J12 location LECOL_EMBEDDEDIMG_0000178395_x.png Figure 4. Inverter control board plug J12 location 6(7)
Page 96
0000178413 Inverter control board plug J12 lead locations LECOL_EMBEDDEDIMG_0000178394_x.png Figure 5. Inverter control board plug J12 lead locations 7(7)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 98
0000178448 16. Using a volt/ohmmeter, check the resistance from plug J3 pin 5 (lead #225) to pin 13 (lead #226). See Figure F.4. Resistance should be less than one ohm. If the resistance is greater than one ohm, there is an open or high resistance connection in the thermostat circuit.
Page 99
0000178448 Inverter control board location LECOL_EMBEDDEDIMG_0000178451_x.png Figure 2. Inverter control board location 3(5)
Page 100
0000178448 Inverter control board plug J3 location LECOL_EMBEDDEDIMG_0000178450_x.png Figure 3. Inverter control board plug J3 location 4(5)
Page 101
0000178448 Inverter control board plug J3 lead locations LECOL_EMBEDDEDIMG_0000178449_x.png Figure 4. Inverter control board plug J3 lead locations 5(5)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 103
0000178405 TEST POINT TEST POINT EXPECTED READING PLUG J1 PIN 5 (LEAD PLUG J1 PIN 3 (LEAD 0 – 3.24 K OHMS DEPENDENT ON OUTPUT CONTROL KNOB 252) 253) POSITION. PLUG J1 PIN 4 (LEAD PLUG J1 PIN 2 (LEAD 0 –...
Page 104
0000178405 DESCRIPTION TEST POINT TEST POINT EXPECTED CONDITIONS (POS) (NEG) READING +10 VDC PLUG J1 PIN 7 PLUG J1 PIN 1 10 VDC MACHINE ON. (LEAD #280) (LEAD #282) WELD TERMINALS SWITCH PLUG J3 PIN 9 PLUG J3 PIN 4 0 VDC WELD TERMINALS SWITCH (LEAD #212)
Page 105
0000178405 User interface board location LECOL_EMBEDDEDIMG_0000178408_x.png Figure 1. User interface board location 4(5)
Page 106
0000178405 User interface board plug and LED locations LECOL_EMBEDDEDIMG_0000178407_x.png Figure 2. User interface board plug and LED locations User interface board lead locations LECOL_EMBEDDEDIMG_0000178406_x.png Figure 3. User interface board lead locations 5(5)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 108
0000178379 Auxiliary power board plug locations LECOL_EMBEDDEDIMG_0000178381_x.png Figure 1. Auxiliary power board plug locations 2(3)
Page 109
0000178379 Auxiliary power board mounting nut locations LECOL_EMBEDDEDIMG_0000178380_x.png Figure 2. Auxiliary power board mounting nut locations 3(3)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 111
0000178466 Boost rectifier lead locations LECOL_EMBEDDEDIMG_0000178468_x.png Figure 1. Boost rectifier lead locations 2(3)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 117
0000178363 Corner cap, right case side and roof mounting screw locations LECOL_EMBEDDEDIMG_0000178345_x.png Figure 1. Corner cap, right case side and roof mounting screw locations 2(3)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 120
0000178443 REPLACEMENT PROCEDURE Procedure Steps: Carefully position the new choke into the machine. Using a 5/16” nutdriver, attach the two screws securing the choke to the base of the machine. Carefully position the output rectifier assembly into the machine. Using a 5/16” nutdriver, attach the two screws securing the bottom rectifier bracket to the base. Using a 3/8”...
Page 121
0000178443 Choke lead and POS lead connection location LECOL_EMBEDDEDIMG_0000178427_x.png Figure 1. Choke lead and POS lead connection location 3(6)
Page 122
0000178443 Choke lead and mounting hardware location LECOL_EMBEDDEDIMG_0000178426_x.png Figure 2. Choke lead and mounting hardware location 4(6)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 126
0000178459 NEG lead, X13 lead and mounting hardware locations LECOL_EMBEDDEDIMG_0000178460_x.png Figure 1. NEG lead, X13 lead and mounting hardware locations 2(2)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 128
0000178444 Using a 5/16” nutdriver, attach the four screws securing the brickwork fan guard to the rear of the machine. Perform the Case Cover Replacement Procedure. Perform the Retest After Repair Procedure. Brickwork fan guard and fan bracket mounting screw locations LECOL_EMBEDDEDIMG_0000178447_x.png Figure 1. Brickwork fan guard and fan bracket mounting screw locations 2(4)
Page 129
0000178444 Inverter control board plug J13 and J14 locations LECOL_EMBEDDEDIMG_0000178446_x.png Figure 2. Inverter control board plug J13 and J14 locations 3(4)
Page 130
0000178444 Fan mounting screw locations LECOL_EMBEDDEDIMG_0000178445_x.png Figure 3. Fan mounting screw locations 4(4)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 134
0000178420 Inverter control board plug locations LECOL_EMBEDDEDIMG_0000178422_x.png Figure 1. Inverter control board plug locations 2(3)
Page 135
0000178420 Inverter control board mounting nut locations LECOL_EMBEDDEDIMG_0000178421_x.png Figure 2. Inverter control board mounting nut locations 3(3)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 137
0000178354 Using a 5/16” nutdriver, attach the two screws and washers securing the line switch to the front panel. Using a 3/8” nutdriver, attach the nut, lock washer and flat washer securing the ground lead to the ground stud on the front panel. See Wiring Diagram. Carefully attach the cable tie, securing the plastic protective sleeve to the line switch.
Page 138
0000178354 Line switch mounting screw locations LECOL_EMBEDDEDIMG_0000178356_x.png Figure 2. Line switch mounting screw locations Line switch lead locations LECOL_EMBEDDEDIMG_0000178355_x.png Figure 3. Line switch lead locations 3(3)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 140
0000178392 Perform the Case Cover Replacement Procedure. Perform the Retest After Repair Procedure. Main capacitor board terminal locations LECOL_EMBEDDEDIMG_0000178374_x.png Figure 1. Main capacitor board terminal locations 2(3)
Page 141
0000178392 Main capacitor board mounting nut locations LECOL_EMBEDDEDIMG_0000178393_x.png Figure 2. Main capacitor board mounting nut locations 3(3)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 143
0000178431 13. Using a 5/16” nutdriver, remove the two screws securing the main transformer to the base of the machine. Figure F.6. See Wiring Diagram. 14. Carefully route the transformer leads to allow for the removal. See Wiring Diagram. 15. The main transformer can now be removed and replaced. REPLACEMENT PROCEDURE Procedure Steps: Carefully position the new main transformer into the machine.
Page 144
0000178431 Short transformer primary lead location LECOL_EMBEDDEDIMG_0000178417_x.png Figure 1. Short transformer primary lead location 3(7)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 150
0000178437 Perform the Case Cover Replacement Procedure. Perform the Retest After Repair Procedure. Mode select switch knob location LECOL_EMBEDDEDIMG_0000178440_x.png Figure 1. Mode select switch knob location 2(3)
Page 151
0000178437 User interface board plug J3 location LECOL_EMBEDDEDIMG_0000178439_x.png Figure 2. User interface board plug J3 location User interface board plug J3 lead locations LECOL_EMBEDDEDIMG_0000178438_x.png Figure 3. User interface board plug J3 lead locations 3(3)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 153
0000178491 13. Using a 7/16” nutdriver, remove the two screws and washers securing the bottom rectifier bracket to the heatsink. See Figure F.2. 14. The output rectifier assembly can now be removed and replaced. REPLACEMENT PROCEDURE Procedure Steps: Using a 7/16” nutdriver, attach the two screws and washers securing the bottom rectifier bracket to the heatsink.
Page 154
0000178491 Choke lead, positive boost lead, X11 and X12 lead locations LECOL_EMBEDDEDIMG_0000178493_x.png Figure 1. Choke lead, positive boost lead, X11 and X12 lead locations 3(4)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 157
0000178385 14. Label and disconnect plug J44 from the PFC boost board. See Figure F.2. See Wiring Diagram. 15. Carefully remove the PFC board bracket from the machine. Carefully route cables through the bracket as necessary. 16. Using a 3/8” nutdriver, remove the four nuts securing the PFC boost board to the PFC board bracket. See Figure F.3.
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 162
0000178368 Perform the Case Cover Replacement Procedure. Perform the Retest After Repair Procedure. Protective cover cable tie locations LECOL_EMBEDDEDIMG_0000178370_x.png Figure 1. Protective cover cable tie locations 2(3)
Page 163
0000178368 SCR (pre-charge) board plug J40 and input rectifier lead and plug locations LECOL_EMBEDDEDIMG_0000178369_x.png Figure 2. SCR (pre-charge) board plug J40 and input rectifier lead and plug locations 3(3)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 165
0000178399 Carefully position the new switchboard into the machine. Using a 3/8” nutdriver, attach the four nuts securing the switchboard to the mounting bracket. Connect plugs J42 and J43 to the switchboard. See Wiring Diagram. Using a torx nutdriver (size T-25), attach the screw and lock washer securing lead B2A to terminal B2 of the switchboard.
Page 166
0000178399 Switchboard terminal and plug locations LECOL_EMBEDDEDIMG_0000178401_x.png Figure 1. Switchboard terminal and plug locations 3(4)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 169
0000178474 Thermostat #1 lead locations LECOL_EMBEDDEDIMG_0000178476_x.png Figure 1. Thermostat #1 lead locations 2(3)
WARNING: Type of Hazard: Service and repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 172
0000178410 User interface board plug locations LECOL_EMBEDDEDIMG_0000178412_x.png Figure 1. User interface board plug locations User interface board mounting screw locations LECOL_EMBEDDEDIMG_0000178411_x.png Figure 2. User interface board mounting screw locations 2(2)
Need help?
Do you have a question about the Flextec 350X Power Connect and is the answer not in the manual?
Questions and answers