Lincoln Electric Vantage 520SD Service Manual
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Lincoln Electric Vantage 520SD Service Manual

Lincoln Electric Vantage 520SD Service Manual

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Vantage
520SD
™
Service Manual - SVM261
Code(s): 12297
Last update: 7/15/15

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Summary of Contents for Lincoln Electric Vantage 520SD

  • Page 1 Vantage 520SD ™ Service Manual - SVM261 Code(s): 12297 Last update: 7/15/15...

  • Page 2: Table Of Contents

    LINCOLN ELECTRIC Vantage 520SD Service Manual Theory of Operation ............................. 1 GENERAL DESCRIPTION ..........................2 ENGINE, ROTOR, STATOR, ECU ........................3 POWER BOARD ............................4 CHUI (CHOPPER USER INTERFACE) BOARD ....................5 WELD WINDINGS, RECTIFIER, POWER MODULE AND FEEDBACK ..............6 Troubleshooting ..............................

  • Page 3: Theory Of Operation

    Vantage 520SD Service Manual Theory of Operation 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 4: General Description

    General Description The Vantage 520SD is a diesel engine driven welding power source capable of producing 520amps at 30VDC at a 60% duty cycle. The engine is coupled to a brush-type AC generator. The welding output is rectified and controlled through Chopper Technology to produce DC current for multiple welding processes.

  • Page 5: Engine, Rotor, Stator, Ecu

    LINCOLN ELECTRIC Vantage 520SD Service Manual Engine, Rotor, Stator, ECU The 12VDC battery powers the Engine Control Unit which controls all of the engine functions. The ECU communicates with the CHUI board for idle speed. When the engine, which is mechanically coupled to the rotor, starts running, the 12VDC battery voltage is applied to the rotor via the CHUI board.

  • Page 6: Power Board

    LINCOLN ELECTRIC Vantage 520SD Service Manual Power Board The power board receives approximately 60VDC which is supplied by a dedicated, 42VAC winding in the stator. This is rectified and filtered, then supplied to the power board. This board in turn creates 40VDC supplies for the Smart...

  • Page 7: Chui (Chopper User Interface) Board

    LINCOLN ELECTRIC Vantage 520SD Service Manual CHUI (Chopper User Interface) Board The CHUI is powered by the DC bus for the weld output. It receives the operator commands and, via Arclink communication, tells the Smart Chopper the desired process and output. It is also responsible for the rotor and...

  • Page 8: Weld Windings, Rectifier, Power Module And Feedback

    LINCOLN ELECTRIC Vantage 520SD Service Manual Weld Windings, Rectifier, Power Module and Feedback The three phase weld windings feed a three phase rectifier bridge. The resulting DC voltage is filtered by capacitors on the Chopper boards. This is the bus for our weld output and power supply for the Slave Chopper board as well as the Chopper User Interface (CHUI) board.

  • Page 9: Troubleshooting

    Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 10 Problem (Symptoms) Possible Areas of Misadjustment(s) Recommended Course of Action Output Problems Major mechanical or electrical 1. Contact the Lincoln Electric Service 1. Contact your local Lincoln damage is evident Department at 1.888.935.3877 Authorized Field Service Facility No Welding output or auxiliary 1.
  • Page 11 LINCOLN ELECTRIC Vantage 520SD Service Manual Problem (Symptoms) Possible Areas of Misadjustment(s) Recommended Course of Action No auxiliary power at one or 1. PERFORM THE STATOR VOLTAGE 1. Check for loose or faulty more receptacles or at the 14 TEST.
  • Page 12 LINCOLN ELECTRIC Vantage 520SD Service Manual Problem (Symptoms) Possible Areas of Misadjustment(s) Recommended Course of Action The machine will weld but the 1. The engine RPM may be too low. 1. Make sure the machine is welding arc is “COLD”. The Perform the.
  • Page 13 LINCOLN ELECTRIC Vantage 520SD Service Manual Problem (Symptoms) Possible Areas of Misadjustment(s) Recommended Course of Action The machine welds but it will 1. If the engine will not maintain the 1. This condition may be normal not maintain a steady output.
  • Page 14 LINCOLN ELECTRIC Vantage 520SD Service Manual Problem (Symptoms) Possible Areas of Misadjustment(s) Recommended Course of Action The arc quality is poor with 1. Check that the weld circuit isn't 1. The ARC CONTROL may be set excessive spatter. The arc heat grounded.
  • Page 15 LINCOLN ELECTRIC Vantage 520SD Service Manual Problem (Symptoms) Possible Areas of Misadjustment(s) Recommended Course of Action An Across-the-Arc type wire 1. Use a voltmeter to check for the 1. Check that the welding feeder does not function when presence of about 58 VDC open...
  • Page 16 LINCOLN ELECTRIC Vantage 520SD Service Manual Problem (Symptoms) Possible Areas of Misadjustment(s) Recommended Course of Action The engine cranks when the CONTACT DEUTZ - (800) 241-9886 1. The battery voltage may be low start button is pressed but will (normally results in slow not start.
  • Page 17 LINCOLN ELECTRIC Vantage 520SD Service Manual Problem (Symptoms) Possible Areas of Misadjustment(s) Recommended Course of Action The engine will not go to high 1. Check that leads #3 and #6 are 1. The load on the auxiliary idle when using auxiliary properly routed through the receptacle may be too low.

  • Page 18: Test Procedures

    Vantage 520SD Service Manual Test Procedures 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 19: Case Cover Removal And Replacement Procedure

    Vantage 520SD Service Manual CASE COVER REMOVAL AND REPLACEMENT PROCEDURE 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 20 LINCOLN ELECTRIC Vantage 520SD Service Manual Figure F.1 REPLACEMENT PROCEDURE 1. Install components in reverse order of removal. 2. Be sure components align correctly. 3. Reconnect battery and replace battery door F-18...

  • Page 21: Chopper Module Capacitor Discharge Procedure

    Vantage 520SD Service Manual CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE 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 22 LINCOLN ELECTRIC Vantage 520SD Service Manual Figure F.2 F-20...

  • Page 23: Engine Alternator Test

    Vantage 520SD Service Manual ENGINE ALTERNATOR TEST 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 24 LINCOLN ELECTRIC Vantage 520SD Service Manual Figure F.7 F-22...

  • Page 25: Brush And Slip Ring Service Procedure

    Vantage 520SD Service Manual BRUSH AND SLIP RING SERVICE PROCEDURE 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 26 LINCOLN ELECTRIC Vantage 520SD Service Manual Figure F.8 F-24...

  • Page 27: Rotor Resistance And Ground Test (Static)

    Vantage 520SD Service Manual ROTOR RESISTANCE AND GROUND TEST (STATIC) 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 28: Rotor Resistance And Ground Test (Dynamic) (Also Referred To As Flying Resistance Test)

    (Also referred to as flying resistance test) 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 29: Flashing Voltage Test

    FLASHING VOLTAGE TEST (Engine Off) 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 30: Rotor Voltage Test

    Vantage 520SD Service Manual ROTOR VOLTAGE TEST 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 31 LINCOLN ELECTRIC Vantage 520SD Service Manual 17. All of these disconnected leads should be insulated, and/or positioned so they cannot come in contact with any other wiring or chassis ground and cannot be damaged by moving parts when the engine is running.

  • Page 32: Stator Voltage Tests

    Vantage 520SD Service Manual STATOR VOLTAGE TESTS 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 33 LINCOLN ELECTRIC Vantage 520SD Service Manual Figure F.11 To test the 120 VAC auxiliary winding: 1. Connect the volt/ohmmeter probes to either 120 VAC receptacle as follows. 2. For the upper receptacle, place the probes directly into receptacle, or connect to leads #3D and #5A. See FIGURE F.11.
  • Page 34 LINCOLN ELECTRIC Vantage 520SD Service Manual To test the 42 VAC wire feeder winding: 1. Connect the voltmeter probes to pins “I” (lead 41A) and “K” (lead #42A) of the 14 pin Amphenol. SEE FIGURE F.11. 2. Start the engine and run it at high idle (1800 RPM).

  • Page 35: Stator Short Circuit & Ground Test

    Vantage 520SD Service Manual STATOR SHORT CIRCUIT & GROUND TEST 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 36 LINCOLN ELECTRIC Vantage 520SD Service Manual 5) Disconnect the #5H and #6 leads from the field bridge rectifier. SEE WIRING DIAGRAM. 6) Using an ohmmeter, check the resistance between chassis ground and each of the following points; Resistance should read very high, 500,000 (500K) ohms minimum.

  • Page 37: Output Rectifier Bridge Test

    Vantage 520SD Service Manual OUTPUT RECTIFIER BRIDGE TEST 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 38 LINCOLN ELECTRIC Vantage 520SD Service Manual Figure F-15 Electrically isolate the DC output terminals of the rectifier: 1. Mark the leads connected to the positive and negative terminals of the output bridge rectifier to assure that they can be reconnected properly.
  • Page 39 LINCOLN ELECTRIC Vantage 520SD Service Manual Table F.1 Test Measured + Meter Lead - Meter Lead Component Tested Point Value Terminal AC1 Positive Terminal ~.45VDC Terminal AC2 Positive Terminal ~.45VDC Terminal AC3 Positive Terminal ~.45VDC Output Rectifier Negative Terminal Terminal AC1 ~.45VDC...

  • Page 40: Chopper Module Function Test

    Vantage 520SD Service Manual CHOPPER MODULE FUNCTION TEST 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 41 LINCOLN ELECTRIC Vantage 520SD Service Manual Figure F.16 9. If the correct DC voltage is not present at terminals B1- to B2+ and B4- to B5+, check for damaged conductors or faulty connections between the chopper module, the output rectifier, and the stator weld winding. SEE FIGURE F.17.

  • Page 42: Smart Chopper Feedback Test

    Vantage 520SD Service Manual SMART CHOPPER FEEDBACK TEST 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 43 LINCOLN ELECTRIC Vantage 520SD Service Manual 17. Connect the millivolt meter probes between lead #206S+ (P20-2) and lead 204S- (P20-1). SEE WIRING DIAGRAM. If the machine is currently producing 200 amps the millivolt meter should read about 25 millivolts. 18. If the machine cannot produce 200 amps of weld current, the correct millivolt signal will need to be calculated by dividing the reading displayed on the external ammeter by 8.

  • Page 44: Mode Board Test

    Vantage 520SD Service Manual MODE BOARD TEST 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 45: Remote Receptacle Resistance Test

    Vantage 520SD Service Manual REMOTE RECEPTACLE RESISTANCE TEST 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 46 LINCOLN ELECTRIC Vantage 520SD Service Manual F-44...

  • Page 47: Output Rectifier Bridge And Choke Removal And Replacement

    OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVAL AND REPLACEMENT 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 48 LINCOLN ELECTRIC Vantage 520SD Service Manual Replacing the Rectifier 1. Place the Rectifier into the machine so that its mounting studs fit into the holes in the bracket. Place a lock washer and a nut on each stud and tighten.

  • Page 49: Chopper Module Removal And Replacement

    Vantage 520SD Service Manual CHOPPER MODULE REMOVAL AND REPLACEMENT 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 50: Rotor Removal And Replacement Procedure

    Vantage 520SD Service Manual ROTOR REMOVAL AND REPLACEMENT PROCEDURE 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 51 LINCOLN ELECTRIC Vantage 520SD Service Manual STATOR REMOVAL PROCEDURE 1. Remove the brush holder bracket assembly 2. Remove the 3/4-10 hex nut and lockwasher from the end of the rotor shaft and remove the fan blade assembly. 3. Remove the two bolts holding the stator to the shock mounts.
  • Page 52 LINCOLN ELECTRIC Vantage 520SD Service Manual RE-ASSEMBLY PROCEDURE 1. Slide the Stator Fan Guard into place and fasten it to the base. 2. Install the left side rail and carefully swing the front panel back into place and fasten it to the base.

  • Page 53: Retest After Repair

    Vantage 520SD Service Manual RETEST AFTER REPAIR 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 54 LINCOLN ELECTRIC Vantage 520SD Service Manual F-52...

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