Lincoln Electric WELD PAK 2000 Service Manual
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Lincoln Electric WELD PAK 2000 Service Manual

Lincoln Electric WELD PAK 2000 Service Manual

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SVM 3051
Rev.00 07-2015
TM
WELD PAK
2000
For use with machines having code number: 50291
LINCOLN ELECTRIC EUROPE
www.lincolnelectric
Page1

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  • Page 1 SVM 3051 Rev.00 07-2015 WELD PAK 2000 For use with machines having code number: 50291 LINCOLN ELECTRIC EUROPE www.lincolnelectric Page1...

  • Page 2: Table Of Contents

    INDEX OF CONTENTS INDEX OF CONTENTS ..............................2 TECHNICAL SPECIFICATIONS ............................. 3 Safety ....................................6 Installation and Operator Instructions ......................... 7 MAINTENANCE ................................16 MAJOR COMPONENTS LOCATION ........................... 17 THEORY OF OPERATION ............................17 GENERAL DESCRIPTION ............................19 MAIN BOARD ................................20 (INVERTER CIRCUIT –...

  • Page 3: Technical Specifications

    TECHNICAL SPECIFICATIONS NAME INDEX WELD PAK™2000 K14134-1 INPUT Input Voltage U EMC Class Frequency 230V ± 10% 50 / 60Hz 1 – phase Input Amperes Input Power at Rated Cycle 1max 7,6 kVA @ 20 % Duty Cycle (40°C) 33 A 0,66 RATED OUTPUT Duty Cycle 40°C...
  • Page 4 Accessories K10429-15-3M The gas-cooled gun LGS150 to GMAW process - 3m K10429-15-4M The gas-cooled gun LGS150 to GMAW process - 4m K10429-15-5M The gas-cooled gun LGS150 to GMAW process - 5m KP10461-1 Gas nozzle conical Ø12mm KP10440-06 Contact Tip M6x25mm ECu 0.6mm KP10440-08 Contact Tip M6x25mm ECu 0.8mm KP10440-09...

  • Page 5: Electromagnetic Compatibility (Emc)

    If any electromagnetic disturbances are detected the operator must put in place corrective actions to eliminate these disturbances with, if necessary, assistance from Lincoln Electric Before installing the machine, the operator must check the work area for any devices that may malfunction because of electromagnetic disturbances.

  • Page 6: Safety

    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 7: Installation And Operator Instructions

    SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in an environment with increased hazard of electric shock. 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 8: Input Supply Connection

    output terminals will lived. Input Supply Connection WARNING WARNING During SMAW process, the output terminals are still Only a qualified electrician can connect the welding lived. machine to the supply network. Installation had to be made in accordance with the appropriate National Electrical Code and local regulations.
  • Page 9 6. LED Indicator Power switch: This LED lights up when the welding machine is ON and is ready to work 7. Thermal Overload Indicator: It indicates that the machine is overloaded or that the cooling is not sufficient. WARNING If the welding current exceed 200 A, output power will be turned off after 5 seconds.
  • Page 10 Table 1. Table 2. Page10...

  • Page 11: Wire Spool Loading

    Wire Spool Loading Wire spool type S300 and BS300 can be installed on the Wire Spool Type S200 Loading wire spool support without adapter. ® Wire spool type S200, B300 or Readi-Reel can be WARNING installed, but the applicable adapter must be purchased. Turn the input power OFF at the welding power source The applicable adapter can be purchased before installation or changing a wire spool.
  • Page 12 Wire Spool Type B300 Loading Place the spool type B300 [29] on the adapter [26]. • Set one of the B300 inside cage wires [30] on the slot [28] in the retaining spring tab [27] and slide the WARNING spool onto the adapter. Turn the input power OFF at the welding power source before installation or changing a wire spool.

  • Page 13: Loading The Electrode Wire

    fastening cap again. Re-install the locking nut [19]. Make sure that the • locking nut is tightened. Adjusting of Force of Pressure Rotate the spindle and adapter so the retaining • spring [32] is at the 12 o'clock position. Roll Force ®...

  • Page 14: Changing Driving Rolls

    Changing Driving Rolls WARNING Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. ® WELD PAK™ 2000 is equipped with drive roll V0.8/V1.0 for steel wire. For others wire sizes, is available the proper drive rolls kit (see "Accessories"...

  • Page 15: Welding Smaw (Mma) Process

    • maintenances, it is recommended to contact the nearest Inductance • Technical Service Center or Lincoln Electric. Repairs and modifications performed by unauthorized service or Welding SMAW (MMA) Process personnel will cause, that the manufacturer’s warranty WELD PAK™2000 does not include the electrode will become null and void.

  • Page 16: Input Filter Capacitor Discharge Procedure

    MAINTENANCE WARNING Board to check if capacitors are discharged is not possible without removing the board from the machine. For this reason ALL operations to remove the Main Board have to be done in a safer way using electrically insulate gloves and insulate tools (pliers, screwdrivers etc..) ELECTRIC SHOCK can kill Remove the Main Board from the machine...

  • Page 17: Thermal Protection

    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 WELD PAK 2000 1. Gas solenoid 2. Fan 3.

  • Page 18: Theory Of Operation

    THEORY OF OPERATION General description Main Board Output choke – Polarity change – User Interface Protection Circuits IGBT operation BLOCK DIAGRAM Page18...

  • Page 19: General Description

    MOTOR BLACK hardened to an IP23 rating for operating in difficult GENERAL DESCRIPTION environments. The WELD PAK 2000 is an industrial arc welding power source which utilizes single phase EMI FILTER input power, to produce constant voltage or constant current output. The welding response of...

  • Page 20: Main Board

    BUS capacitors. The 25 ohm PTC will be “shorted OUTPUT CIRCUIT, WIRE DRIVE CIRCUIT) out” by the relay K1 contacts when pre-charge The WELD PAK 2000 can be connected to a phase is finish. Command to K1 is coming from 230Vac +/- 10% single phase input voltage.
  • Page 21 MAIN BOARD (INVERTER CIRCUIT – OUTPUT CIRCUIT – WIRE DRIVE CIRCUIT) (continued) OUTPUT MAIN CORD POLARITY CHOKE CHANGE T5-1 T5-2 230V AC R-5041-338-1 50/60 Hz T5-3 T5-4 R-6042-069-1R R-5041-338-1 MAIN BOARD R-5041-338-1 VALVE LIFT PLATE MAIN R-5041-338-1 SWITCH DL-1 R-5041-339-1 512 (LED_THERM) 516 (LED ON-OFF) 502 (3V3_A)

  • Page 22: Output Choke - Polarity Change - User Interface

    OUTPUT CHOKE – POLARITY CHANGE – USER INTERFACE OUTPUT MAIN CORD POLARITY CHOKE CHANGE T5-1 T5-2 230V AC R-5041-338-1 50/60 Hz T5-3 T5-4 R-6042-069-1R R-5041-338-1 MAIN BOARD R-5041-338-1 VALVE LIFT PLATE MAIN R-5041-338-1 SWITCH DL-1 R-5041-339-1 512 (LED_THERM) 516 (LED ON-OFF) 502 (3V3_A) 511 (SPEED_POT) 501 (GND_A)

  • Page 23: Overload Protection

    If excessive OVERLOAD PROTECTION operating temperature should occur, the Thermal LED indicator on the control board, will turn ON WELD PAK 2000 is electrically protected from and the thermostat will prevent output current. producing higher than normal output currents. An...

  • Page 24: Pulse Width Modulation

    negative portion is the other IGBT group. The PULSE WIDTH dwell time (off time) is 12 microseconds (both MODULATION IGBT groups off). Since only 2 microseconds of The term PULSE WIDTH MODULATION (PWM the 25 microsecond time period are devoted to is used to describe how much time is devoted to conducting, the output power is minimized.

  • Page 25: Troubleshooting And Repair Section

    TROUBLESHOOTING AND REPAIR SECTION How to use troubleshooting Guide Troubleshooting Guide Case cover removal and capacitor discharge procedure Page25...
  • Page 26 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 27 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 28: Troubleshooting

    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 THE LINE CIRCUIT BREAKER •...

  • Page 29: 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 30: Necessary Tool

    WELD PAK 2000 - CASE COVER REMOVAL Necessary tool: 8 mm Nut driver Procedure: 1. Turn on/off switch to off position. 2. Disconnect Input Power from the machine ! 3. Remove the 5 screws (A) from the upper side of the unit.

  • Page 31: Input Filter Capacitors Discharge Procedure

    DISCHARGE PROCEDURE WARNING Board to check if capacitors are discharged is not possible without removing the board from the machine. For this reason ALL operations to remove the Main Board have to be done in a safer way using electrically insulate gloves and insulate tools (pliers, screwdrivers etc..) ELECTRIC SHOCK can kill Remove the Main Board from the machine...

  • Page 32: Test Description

    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 33: Test Procedure

    DC - a&b TEST PROCEDURE 1. Remove main input power to the WELD PAK 2000 2. Perform the Discharge procedure 3. Follow the Main Board disassembly operations available in this Service Manual. 4. Visually check for burned or damaged components. If any components are physically damaged the main board should be replaced 5.
  • Page 34 MAIN BOARD RESISTANCE TEST (continued) IGBT pinout V6 – V5 V9 – V10 TEST PROCEDURE 7. Check Inverter IGBT V5-V6 and V9-V10, using the Volt-Ohmmeter (diode test mode), following the Table tests 2 IGBT V5-V6-V9-V10 - Table tests 2 Positive Probe (RED) Negative Probe (BLACK) Value Emitter (E)
  • Page 35 MAIN BOARD RESISTANCE TEST (continued) Output Diode Anode pinout Cathode Anodes Cathode TEST PROCEDURE 7. Check the output diodes V3,V4,V7,V8 with multi meter in diode test mode, for short, following the Table tests 3 8. Using the Volt-Ohmmeter (ohm mode) check thermal sensor B1 (Output Diodes heat sink) value, shall be 0 Ohms.

  • Page 36: Main 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 37 TEST PROCEDURE Use always electrically insulate gloves during this test procedure 1. Remove main input power to the WELD PAK 2000 2. Follow the case removal procedure available in this Service Manual 3. Apply 230Vac +/- 15% to the WELD PAK 2000 4.
  • Page 38 X3: Main Board to User Interface connector Pin # Description Value Notes GND_A GND_A 3V3_A +3,3Vdc Versus GND_A 0Vdc= Volt/Amp pot at min value Volt/Amp Pot. +3,3Vdc= Volt/Amp pot at max value Induct/Arc Force 0Vdc= Volt/Amp pot at min value Pot.

  • Page 39: Led Information

    MAIN BOARD VOLTAGE TEST (continued) V64 (red) LED INFORMATION: • V64 (red) = + 15Vdc auxiliary supply present Note: The V64 LED can be checked without removing the PCB from the machine. If V64 is lit the red light reflection can be seen on the machine divider panel. Page39...

  • Page 40: User Interface Board 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 41 TEST PROCEDURE Use always electrically insulate gloves during this test procedure 1. Remove main input power to the WELD PAK 2000 2. Follow the case removal procedure available in this Service Manual 3. Follow the User Interface board removal procedure 4.

  • Page 42: Error Codes

    ERROR CODES Thermal Overload & Error indicator The Yellow Thermal overload LED, when lit, could indicate one of the following error conditions: 1. Output bridge thermal sensor is activated 2. The output current exceed 200A for more than 6 seconds 3.

  • Page 43: Removal Procedure

    Phillips screwdriver PH02 8mm nut driver 1. Remove main input power to the WELD PAK 2000 2. Using the 8mm nut driver, remove the screw (A) 3. With a 2 mm Allen Wrench loosen the Allen screws until you’ll be able to remove the 3 knobs 4.
  • Page 44 8mm wrench 14mm wrench 1. Remove main input power to the WELD PAK 2000 2. Using the 8 mm wrench remove the screw (A) and remove the change polarity cover 3. Using the 8 mm wrench remove the screw (B) and (C).
  • Page 45 DISASSEMBLY OPERATIONS WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continue) 5. Remove the fixing cap screw (E) that lock the drive roll and remove the drive roll and drive roll support 6. Using a 14 mm wrench remove the nut (F) and washer 7.

  • Page 46: Fan Removal And Replacement Procedure

    Necessary tool: 8 mm Nut Driver/wrench 1. Remove main input power to the WELD PAK 2000 2. Follow the case removal procedure available in this Service Manual 3. Locate the fan on the back side of the machine. See Figure 1 4.
  • Page 47 Phillips screwdriver PH02 8 mm nut driver 2x 13mm wrench 1. Remove main input power to the WELD PAK 2000 2. Follow the case removal procedure available in this Service Manual 3. Disconnect from the main board all connectors X1,X2, X3,X4,X5 4.
  • Page 48 DISASSEMBLY OPERATIONS MAIN BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) REMOVAL PROCEDURE (continued) 7. Using the two 13mm wrenches unscrew the nuts (C) and (D). Label the two cables and remove the two bolts. 8. Using the Phillips screwdriver PH02 remove the 4 screws (E) at the corners of the main board. 9.

  • Page 49: Retest After Repair

    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 Input Voltage Input Current...

  • Page 50: Electrical Schematics

    ELECTRICAL SCHEMATICS Block Diagram Page50...
  • Page 51 ELECTRICAL SCHEMATICS Main Board Schematic Y039. Page 1/2 Page51...
  • Page 52 ELECTRICAL SCHEMATICS Main Board Schematic Y039. Page 2/2 Page52...
  • Page 53 ELECTRICAL SCHEMATICS User Interface Schematic Y031-1 Page53...

  • Page 54: Note

    NOTE Page54...

This manual is also suitable for:

K14134-1

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