Lincoln Electric FLEXTEC 450 Service Manual
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Lincoln Electric FLEXTEC 450 Service Manual

Lincoln Electric FLEXTEC 450 Service Manual

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FLEXTEC
450
®
For use with machines having Code Numbers:
11626, 11754
SERVICE MANUAL
SVM214-A
| Issue D ate Feb - 20
© Lincoln Global, Inc. All Rights Reserved.

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Summary of Contents for Lincoln Electric FLEXTEC 450

  • Page 1 FLEXTEC ® For use with machines having Code Numbers: 11626, 11754 SERVICE MANUAL SVM214-A | Issue D ate Feb - 20 © Lincoln Global, Inc. All Rights Reserved.

  • Page 2: Electric And Magnetic Fields

    Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. explosion. 7.a. Use only compressed cylinders containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and from starting a fire.
  • Page 5 SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
  • Page 6 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.

  • Page 7: Safety

    SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda- tions.

  • Page 8: Table Of Contents

    - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN MENU Page Safety ................i-vi Installation .
  • Page 9 TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .

  • Page 10: Technical Specifications

    INSTALLATION TECHNICAL SPECIFICATIONS - FLEXTEC™ 450 POWER SOURCE-INPUT VOLTAGE AND CURRENT Model Duty Cycle Input Voltage ± 10% Input Amperes Power Factor @ Idle Power Rated Output 60% rating 72 Watts 37 / 27 / 22 K2882-1 Max. 380 / 460 / 575 / 3 / 50 / 100% rating 29 / 21 / 17 (fan on)
  • Page 11 INSTALLATION WELDING PROCESS PROCESS OUTPUT RANGE (AMPERES) OCV (U GMAW (CV) 40-500 GTAW (CC) 10-500 SMAW (CC) 15-500 FCAW-GS (CV) 40-500 FCAW-SS (CV) 40-500 PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH WEIGHT DEPTH 125lbs (56.6kg)* 26.66in (677mm) K2882-1 18.80in (478mm) 14.14in (359mm) TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE...
  • Page 12 INSTALLATION SAFETY PRECAUTIONS CAUTION WARNING surfaces. Where there is a combustible surface directly under stationary or fixed electrical equip- ELECTRIC SHOCK can kill. ment, that surface shall be covered with a steel plate at least .060” (1.6mm) thick, which shall ONLY QUALIFIED PERSONNEL...

  • Page 13: Input Connection

    INSTALLATION INPUT FUSE AND SUPPLY WIRE WARNING CONSIDERATIONS ELECTRIC SHOCK can kill. Refer to Technical Specification in this Installation ONLY A QUALIFIED ELECTRICIAN Section for recommended fuse, wire sizes and type of SHOULD CONNECT THE INPUT the copper wires. Fuse the input circuit with the rec- LEADS TO THE FLEXTEC™...

  • Page 14: Cable Connections

    INSTALLATION CABLE CONNECTIONS See FIGURE A.2 for locating 6-pin and 14-pin con- nectors on the front of the FLEXTEC™ 450. 6-PIN REMOTE CONTROL CONNECTOR Function Wiring 6-pin remote 77 Remote potentiometer, 5K control con- 76 Remote potentiometer, wiper nector for 75 Remote potentiometer, common remote or Trigger, common...

  • Page 15: Recommended Electrode And Work Cable Sizes For Arc Welding

    INSTALLATION RECOMMENDED ELECTRODE AND • Route all cables directly to the work and wire feeder, avoid excessive lengths and do not coil WORK CABLE SIZES FOR ARC WELDING excess cable. Route the electrode and work cables in close proximity to one another to minimize the loop General Guidelines area and therefore the inductance of the weld circuit.
  • Page 16 NOTES FLEXTEC™ 450...
  • Page 17 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions .

  • Page 18: Safety Precautions

    OPERATION SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR Read this entire section of operating instructions before operating the machine. IN THIS MANUAL WARNING INPUT POWER ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several seconds...

  • Page 19: Operation

    OPERATION GRAPHIC SYMBOLS THAT PRODUCT DESCRIPTION APPEAR ON THIS MACHINE OR The Flextec™ 450 is a multi-process CC/CV DC invert- IN THIS MANUAL er and is rated for 450 amps, 38 volts at a 60% duty cycle. The Flextec is intended for both factory and field operation.

  • Page 20: Recommended Processes And Equipment

    OPERATION RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Flextec™ 450 is designed for CC-SMAW, CC- GTAW (lift tig), CV-GMAW, CV-FCAW-SS and CV- FCAW-GS welding processes. CAG (arc gouging) is also supported. PROCESS LIMITATIONS The Flextec™ 450 is suitable only for the processes listed.

  • Page 21: Case Front Control Descriptions

    14. 6-pin remote circular connector toggles through the 4 available weld modes for the 15. Positive and negative welding output studs Flextec 450 - CC-SMAW; CC-GTAW; CV; CV- Innershield. 7. Hot Start Toggle Switch: Enables hot start function. 8. Output Control Local/Remote Toggle Switch: FIGURE B.1...

  • Page 22: Power-Up Sequence

    (Adjustment is indicated by the meters.) responsibility of the builder/user. Many variables When in Remote Mode, this control sets the maximum beyond the control of The Lincoln Electric welding current of the remote device. For example, full Company affect the results obtained in applying depression of a foot or hand amptrol results in the pre- these programs.

  • Page 23: Basic Modes Of Operation

    OPERATION Amperage Display Meter Arc Control - The Arc Control regulates the Arc Force to adjust the short circuit current. The minimum setting • Prior to STICK or TIG operation (current flow), the (-10) will produce a "soft" arc and will produce minimal meter displays preset current value.
  • Page 24 OPERATION GTAW Output Control Dial • When the Local/Remote is set to Local, this dial sets the welding amperage. This weld mode is a constant current (CC) mode fea- • When the Local/Remote is set to Remote, this dial turing continuous control from 10 – 500 amps. It is sets the maximum welding amperage.
  • Page 25 OPERATION Output Control Local/Remote – When the control is Output Control Local/Remote – When the control is set to local (no remote potentiometer/control plugged set to local (no remote potentiometer/control plugged into the 6-pin or 14-pin connectors), the output is con- into the 6-pin or 14-pin connectors), the output is con- trolled through the Output Control Dial on the front of trolled through the Output Control Dial on the front of...
  • Page 26 NOTES B-10 B-10 FLEXTEC™ 450...
  • Page 27 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Options / Accessories .

  • Page 28: Accessories

    ACCESSORIES OPTIONS / ACCESSORIES Foot Amptrol® General Options Provides 25 ft. (7.6 m) of remote current control for TIG welding. K2149-1 Work Lead Package. (6-pin plug connection). Order K870 Hand Amptrol® - Provides 25 ft. K1842-10 10ft. Weld Power Cable (Lug to Lug). (7.6 m) of remote current control for TIG welding.
  • Page 29 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .

  • Page 30: Visual Inspection

    MAINTENANCE SAFETY PRECAUTIONS PERIODIC MAINTENANCE Thermal Protection WARNING Thermostats protect the machine from excessive oper- ELECTRIC SHOCK can kill. ating temperatures. Excessive temperatures may be • Only Qualified personnel should caused by a lack of cooling air or operating the perform this maintenance.
  • Page 31 MAINTENANCE FIGURE D.1 - MAJOR COMPONENT LOCATIONS 1. Case Front Assembly 2. Divider Panel Assembly 3. Base and Center Assembly 4. Case Back Assembly & Fan 5. Wraparound FLEXTEC™ 450...
  • Page 32 NOTES FLEXTEC™ 450...
  • Page 33 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .

  • Page 34: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 BLOCK LOGIC DIAGRAM (CODE 11754) OUTPUT RECTIFIER HEATSINK ASSEMBLY SWITCH BOARD MAIN INPUT TRANSFORMER RECTIFIER INPUT TERMINAL BLOCK COIL 1 OUTPUT RECTIFIER SWITCH OUTPUT RECTIFIER COIL 2 OUTPUT CHOKE ELECTRODE INPUT BOARD frequency = 20kHz RECONNECT 2 AMP FUSE TERMINAL...

  • Page 35: General Description

    INSIDE VIEW S2 REMOTE CONNECTOR GENERAL DESCRIPTION The Flextec 450 is a multi-process CC / CV DC invert- There is also a simple user interface which makes er and is rated for 450 Amps, 38 Volts at a 60% duty setup quick and easy.
  • Page 36 When the correct three-phase input voltage is applied When the correct three-phase input voltage is applied to the Flextec 450, via the input line switch, this AC to the Flextec 450, via the input line switch, this AC voltage is applied to the input rectifier and the auxiliary voltage is applied to the input rectifier and the auxiliary transformers.

  • Page 37: Switch Board And Main Trans- Former

    THEORY OF OPERATION FIGURE E.5 - SWITCH BOARD AND MAIN TRANSFORMER OUTPUT RECTIFIER HEATSINK ASSEMBLY SWITCH BOARD MAIN INPUT TRANSFORMER RECTIFIER INPUT TERMINAL BLOCK COIL 1 OUTPUT RECTIFIER SWITCH OUTPUT RECTIFIER COIL 2 OUTPUT CHOKE ELECTRODE INPUT BOARD frequency = 20kHz RECONNECT 2 AMP FUSE TERMINAL...

  • Page 38: Output Section

    THEORY OF OPERATION FIGURE E.6 - OUTPUT SECTION OUTPUT RECTIFIER HEATSINK ASSEMBLY SWITCH BOARD MAIN INPUT TRANSFORMER RECTIFIER INPUT TERMINAL BLOCK COIL 1 OUTPUT RECTIFIER SWITCH OUTPUT RECTIFIER COIL 2 OUTPUT CHOKE ELECTRODE INPUT BOARD frequency = 20kHz RECONNECT 2 AMP FUSE TERMINAL 30 OHM BLOCK...
  • Page 39 THEORY OF OPERATION FIGURE E.7 - CONTROL BOARD, USER INTERFACE CONTROLS AND DISPLAY BOARD OUTPUT RECTIFIER HEATSINK ASSEMBLY SWITCH BOARD MAIN INPUT TRANSFORMER RECTIFIER INPUT TERMINAL BLOCK COIL 1 SWITCH OUTPUT RECTIFIER OUTPUT RECTIFIER COIL 2 OUTPUT CHOKE ELECTRODE INPUT BOARD frequency = 20kHz RECONNECT 2 AMP FUSE...

  • Page 40: Thermal Protection

    PROTECTIVE CIRCUITS Protective circuits are designed into the Flextec 450 to sense trouble and shut down the machine before dam- age occurs to the machine's internal components. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion FLEXTEC™...

  • Page 41: Pulse Width Modulation

    THEORY OF OPERATION FIGURE E.8 - TYPICAL IGBT OUTPUTS 1 μsec 1 μsec 48 μsec 50 μsec MINIMUM OUTPUT 24 μsec 2 μsec 24 μsec 50 μsec MAXIMUM OUTPUT PULSE WIDTH MODULATION MAXIMUM OUTPUT By holding the gate signal on for 24 microseconds The term Pulse Width Modulation is used to describe each, and allowing only two microseconds of dwell time how much time is devoted to conduction in the positive...

  • Page 42: Insulated Gate Bipolar Transistor (Igbt) Operation

    THEORY OF OPERATION E-10 E-10 FIGURE E.9 - IGBT POSITIVE VOLTAGE APPLIED GATE GATE SOURCE SOURCE BODY REGION BODY REGION DRAIN DRIFT REGION DRAIN DRIFT REGION BUFFER LAYER BUFFER LAYER INJECTING LAYER INJECTING LAYER DRAIN DRAIN A. PASSIVE B. ACTIVE INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION...
  • Page 43 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 44: Troubleshooting And Repair

    HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 45: Pc Board Troubleshooting Procedures

    Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.

  • Page 46: Using The Status Led To Troubleshoot System Problems

    TROUBLESHOOTING AND REPAIR Observe all Safety Guidelines detailed throughout this manual USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS Errors are displayed on the user interface. In addition, there are status lights on the control pc board and the switch pc board that contain error sequences.
  • Page 47 TROUBLESHOOTING AND REPAIR Observe all Safety Guidelines detailed throughout this manual Error Code# Possible Solution Description 1. Damaged auxiliary transformer or intermittent “A” lead Switchboard Undervoltage Lock Out - connection. Verify 42 VAC output at 14 pin connector Switchboard auxiliary supply voltage to determine the source of the problem.
  • Page 48 See the Wiring Diagram. CAUTION 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. FLEXTEC™ 450...
  • Page 49 Wiring Diagram. CAUTION 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. FLEXTEC™ 450...
  • Page 50 See the Wiring Diagram. CAUTION 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. FLEXTEC™ 450...
  • Page 51 CAUTION 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. FLEXTEC™ 450...
  • Page 52 NOTES F-10 F-10 FLEXTEC™ 450...

  • Page 53: Test Description

    INPUT PANEL TERMINAL BLOCK TEST 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 54 TROUBLESHOOTING AND REPAIR F-12 F-12 INPUT PANEL TERMINAL BLOCK TEST (continued) FIGURE F.1 – INPUT POWER TERMINAL BLOCK LOCATION PROCEDURE 1. Remove input power. 2. Perform Case Cover Removal Procedure. 3. Perform the DC Link Capacitor Discharge Procedure. 4. Locate the Input Power Terminal Block. See Figure F.1.
  • Page 55 DC LINK CAPACITOR 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 56: Electric Shock Can Kill

    DC LINK CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.2 – SWITCH BOARD LEADS 207 & 209 B207 B209 G6568-1 S28443-2 FLEXTEC 450 PROCEDURE WARNING ELECTRIC SHOCK can kill. 4. Carefully discharge the link capacitors using a 25 watt or more, 25 to 1000 ohm resistor con- •...

  • Page 57: Input Rectifier Test

    INPUT RECTIFIER TEST 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 58 TROUBLESHOOTING AND REPAIR F-16 F-16 INPUT RECTIFIER TEST (continued) FIGURE F.3 – INPUT RECTIFIER LOCATION INPUT RECTIFIER PROCEDURE 1. Remove input power to the machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the DC Linc Capacitor Discharge Procedure. 4.

  • Page 59: Terminal Schematic

    TROUBLESHOOTING AND REPAIR F-17 F-17 INPUT RECTIFIER TEST (continued) TABLE F.1 – INPUT RECTIFIER TEST POINTS + Probe (RED) - Probe RESULT (BLACK) Terminal A D (+) Terminal 0.3V - 1.0V Terminal B D (+) Terminal 0.3V - 1.0V 0.3V - 1.0V Terminal C D (+) Terminal F (-) Terminal...
  • Page 60 NOTES F-18 F-18 FLEXTEC™ 450...

  • Page 61: Fan And F.a.n. Circuit Test

    FAN AND F.A.N. CIRCUIT TEST 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 62 #22 and #23 together. 5. Carefully apply the correct input power (three- phase). 6. When the Flextec 450 is turned on, the fan should start, and run as long as power is on. If this test results in the fan running properly, all...
  • Page 63 TROUBLESHOOTING AND REPAIR F-21 F-21 FAN AND F.A.N. CIRCUIT TEST (continued) FIGURE F.5 – THERMOSTAT #2 (OUTPUT RECTIFIER HEATSINK) 8. If the above test results in a running fan remove the jumper wire between leads #22 and #24 and plug J26 back into the switch board. Remove one of the two quick connect leads on thermo- stat # 2.
  • Page 64 NOTES F-22 F-22 FLEXTEC™ 450...

  • Page 65: T1 Transformer Test

    T1 TRANSFORMER TEST 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 66 FIGURE F.6 – TRANSFORMER LOCATIONS T2 TRANSFORMER T1 TRANSFORMER PROCEDURE 1. Remove the input power to the Flextec 450 8. If the primary voltages are correct and the sec- machine. ondary voltages are low or not present the T1 Transformer may be faulty.
  • Page 67 TROUBLESHOOTING AND REPAIR F-25 F-25 T1 TRANSFORMER TEST (continued) FIGURE F.7 – RECONNECT TERMINAL BLOCK LOCATION RECONNECT TERMINAL BLOCK TABLE F.2 – TRANSFORMER T1 TEST POINTS Description Test Points Expected Readings Conditions/Comments Primary Voltage H11 to H12 380VAC Correct Input Power Applied Primary Voltage H11 to H13 460VAC...
  • Page 68 NOTES F-26 F-26 FLEXTEC™ 450...

  • Page 69: T2 Transformer Test

    T2 TRANSFORMER TEST 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 70 T1 transformer be properly connected. Make cer-tain the lead “A” is connected to the correct position in the reconnect terminal block to match the three phase input power being applied to the Flextec 450 machine. See Figure F.9. FLEXTEC™ 450...
  • Page 71 TROUBLESHOOTING AND REPAIR F-29 F-29 T2 TRANSFORMER TEST (continued) FIGURE F.9 – T2 TRANSFORMER TEST RECONNE CT TERMINAL BLOCK ~380V ~36.6V ~460V ~42V ~575V A UXILIARY TRANSFOR MERS ~115V ~230V ~460V FIGURE F.10 – T2 TRANSFORMER CONNECTIONS CONNECTORS FAN CAPACITOR FLEXTEC™...
  • Page 72 NOTES F-30 F-30 FLEXTEC™ 450...

  • Page 73: Switch Board Test

    SWITCH BOARD TEST 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 74: Switch Board

    SWITCH BOARD TEST (continued) FIGURE F.11 – SWITCH BOARD LOCATION SWITCH BOARD PROCEDURE 1. Disconnect the input power to the Flextec 450 6. Check the switch board voltages per Table F.5. machine. See Figure F.12 for test point locations. 2. Perform the Case Cover Removal Procedure 7.
  • Page 75 F-33 SWITCH BOARD TEST (continued) FIGURE F.12 – SWITCH BOARD PRIMARY SIDE #207 #209 #207 #209 CAN COMMUNICATION LED 2 G6568-1 S28443-2 FLEXTEC 450 LED 3 PIN 1 CURRENT CALIBRATION SHUNT INPUT FAN CONTROL VOLTAGE VOLTAGE FEEDBACK CALIBRATION SECONDARY INPUT VOLTAGE...
  • Page 76 SWITCH BOARD TEST (continued) TABLE F.3 – SWITCH BOARD LEDs DESCRIPTION INDICATES LIGHT CONDITIONS LED 1 +5.0VDC Supply Power applied to (Green) Flextec 450 LED 2 Power applied to Communication is Flextec 450 Powered (Green) LED 3 Status LED Power applied to Indicator...
  • Page 77 TROUBLESHOOTING AND REPAIR F-35 F-35 SWITCH BOARD TEST (continued) TABLE F.4 – SWITCH BOARD RESISTANCE MEASUREMENTS DESCRIPTION METER TEST POINTS EXPECTED READINGS CONDITIONS AND POLARITY Checking for short B209(+) to B201(-) Greater Than 100,000 Machine “off” no circuit on the “High Ohms input power applied Side”...
  • Page 78 NOTES F-36 F-36 FLEXTEC™ 450...

  • Page 79: Output Rectifier Test

    OUTPUT RECTIFIER TEST 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 80: Electric Shock Can Kill

    TROUBLESHOOTING AND REPAIR F-38 F-38 OUTPUT RECTIFIER TEST (continued) FIGURE F.13 – OUTPUT RECTIFIER CONNECTIONS BOLTED CONNECTION BOLTED CONNECTION (X1) (LEAD TO CHOKE) SPIKE BLOCKERS THERMOSTAT BOLTED CONNECTION (X3) WARNING 5. Measure the rectifiers per chart below with your ELECTRIC SHOCK can kill. meter set for diode checking.

  • Page 81: Choke Test

    CHOKE TEST 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 82: Chassis Ground

    TROUBLESHOOTING AND REPAIR F-40 F-40 CHOKE TEST (continued) FIGURE F.14 – CHOKE CHOKE ASSEMBLY CHASSIS GROUND PROCEDURE 6. Choke Coil Grounded: Reduced inductance. 1. Remove the Input Power. Alternate weld current path. Electrically isolate 2. Perform the Case Cover Removal Procedure. the choke coil by disconnecting both choke 3.

  • Page 83: Control Board Test

    CONTROL BOARD TEST 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 84 TROUBLESHOOTING AND REPAIR F-42 F-42 CONTROL BOARD TEST (continued) FIGURE F.15 – CONTROL PC BOARD PIN 1 PIN 8 PIN 6 PIN 1 PIN 16 PIN 1 J1 0 PIN 8 PIN 12 PIN 4 PIN 10 L ED 1 PIN 8 PIN 1 PIN 1...
  • Page 85 TROUBLESHOOTING AND REPAIR F-43 F-43 CONTROL BOARD TEST (continued) TABLE F.6 – CONTROL BOARD VOLTAGE TESTS DESCRIPTION TEST POINTS EXPECTED CONDITIONS/COMMENT READINGS Input Power from J8 Pin 5 (#82)+ 50VDC Correct three-phase input D1 Rectifier power applied to machine J8 Pin 2 (#83)- 15VDC to J8 Pin 1 (#225)+ 15VDC...
  • Page 86 TROUBLESHOOTING AND REPAIR F-44 F-44 CONTROL BOARD TEST (continued) TABLE F.7 – CONTROL PC BOARD FUNCTIONS & ERROR CODES G6617 CONTROL P.C. BOARD LED# COLOR FUNCTION GREEN STATUS “OK” STATUS “ERROR” (CHECK CODE FOR SPECIFIC ERROR) ERROR CODE # INDICATION 31 Primary Overcurrent Error Excessive primary current present.

  • Page 87: Error Logs

    TROUBLESHOOTING AND REPAIR F-45 F-45 CONTROL BOARD TEST (continued) FUNCTIONS Receives input voltage from 36 Volt auxiliary trans- former, T1. Reads the user selected weld settings from the front panel knobs and switches. Used to put machine into test modes. Communicates the user settings to the switch- board.
  • Page 88 NOTES F-46 F-46 FLEXTEC™ 450...

  • Page 89: Display Board Test

    DISPLAY BOARD TEST 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 90: Front View

    TROUBLESHOOTING AND REPAIR F-48 F-48 DISPLAY BOARD TEST (continued) FIGURE F.16 – DISPLAY BOARD FRONT VIEW PIN 7 J 10 PIN 8 L ED 1 PROCEDURE 1. Remove the input power. 7. If the 15VDC is present at the control board but not at the display board check the continuity of 2.

  • Page 91: Thermostat Test - Thermal Protection

    THERMOSTAT TEST - THERMAL PROTECTION 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 92 TROUBLESHOOTING AND REPAIR F-50 F-50 THERMOSTAT TEST - THERMAL PROTECTION (continued) FIGURE F.17 – THERMOSTAT CIRCUIT OUTPUT RECTIFIER TRANSFORMER THERMOSTAT THERMOSTAT (BOLTED CONNECTION) (CONNECTED W/EPOXY) #IT/STAT PIN 1 Thermostat PIN 4 LED 6 WARNING ELECTRIC SHOCK can kill. • Disconnect input power before servicing.
  • Page 93 TROUBLESHOOTING AND REPAIR F-51 F-51 THERMOSTAT TEST - THERMAL PROTECTION (continued) FIGURE F.18 – THERMOSTAT #2 THERMOSTAT #2 (OUTPUT RECT. HEATSINK) THERMOSTAT #1 (MAIN TRANSFORMER) FLEXTEC™ 450...
  • Page 94 NOTES F-52 F-52 FLEXTEC™ 450...

  • Page 95: Case Cover Removal And Replacement

    CASE COVER REMOVAL AND REPLACEMENT 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 96 TROUBLESHOOTING AND REPAIR F-54 F-54 CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.19 – CASE COVER SCREW LOCATIONS CASE COVER SCREWS CASE COVER SCREWS PROCEDURE WARNING 5. Access to the main switchboard is made by ELECTRIC SHOCK can kill. removing the top and right side panels.

  • Page 97: Input Board Removal And Replacement

    INPUT BOARD REMOVAL AND REPLACEMENT 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 98: Input Board

    INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.20 – INPUT BOARD LOCATION INPUT BOARD PROCEDURE 1. Disconnect the input power to the Flextec 450 7. Using the 3/8 inch wrench, remove the two nuts machine. securing the Input Board to the two mounting studs.

  • Page 99: Replacement Procedure

    TROUBLESHOOTING AND REPAIR F-57 F-57 INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Place the new Input Board onto the mounting studs. Secure the Input Board using the two nuts previously removed. 2. Replace Plug J60 onto the Input Board. 3.
  • Page 100 NOTES F-58 F-58 FLEXTEC™ 450...

  • Page 101: Control Board Removal And Replacement

    CONTROL BOARD REMOVAL AND REPLACEMENT 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 102 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.21 – CONTROL BOARD LOCATION CONTROL BOARD PROCEDURE 1. Disconnect the input power to the Flextec 450 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the DC Link Capacitor Discharge Procedure.
  • Page 103 TROUBLESHOOTING AND REPAIR F-61 F-61 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.22 – CONTROL BOARD PLUG LOCATIONS J1 0 L ED 1 REPLACEMENT PROCEDURE 1. Mount the new Control Board using the two screws previously removed. 2. Connect the seven molex type plugs previously removed.
  • Page 104 NOTES F-62 F-62 FLEXTEC™ 450...

  • Page 105: Display Board Removal And Replacement

    DISPLAY BOARD REMOVAL AND REPLACEMENT 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 106 REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.23 – DISPLAY BOARD LOCATION DISPLAY BOARD CASE FRONT ASSEMBLY PROCEDURE 1. Disconnect the input power to the Flextec 450 machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the DC Link Capacitor Discharge Procedure.
  • Page 107 TROUBLESHOOTING AND REPAIR F-65 F-65 DISPLAY BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.24 – DISPLAY BOARD PIN 7 J 10 PIN 8 L ED 1 REPLACEMENT PROCEDURE 1. Carefully connect J10 into the new Display Board. 2. Align the Display Board with the three mounting pins and slide the Display Board into place.
  • Page 108 NOTES F-66 F-66 FLEXTEC™ 450...

  • Page 109: Switch Board Removal And Replacement

    SWITCH BOARD REMOVAL AND REPLACEMENT 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 110 • Do not touch electrically hot parts. • Only Qualified personnel should perform this maintenance. 1. Remove input power to the Flextec 450 machine. 2. Perform Case Cover Removal Procedure. 3. Perform the DC Link Capacitor Discharge Procedure. 4. Locate the Switch Board. See Figure F.25.
  • Page 111 TORX MOUNTING SCREWS #207 #209 TORX MOUNTING SCREWS G6568-1 S28443-2 FLEXTEC 450 POWER LEAD POWER LEAD #201 #204 5. Disconnect the four plugs (J20, J21, J22, J26) 8. Carefully and gently remove the Switch Board from the switch board. See Figure F.26.
  • Page 112 FIGURE F.27 – MODULE BAR GREASE REMOVAL AND APPLICATION POINTS COPPER BARS REPLACEMENT PROCEDURE 1. Lay the Flextec 450 on its side so that the heatsink is in a horizontal position. This simpli- fies the mounting of the replacement switch board.
  • Page 113 See Figure F.29. movement of the switch board after contact and help ensure the thermal compound interface. See Figure F.28. FIGURE F.29 – SWITCH PC BOARD BOLTED CONNECTIONS G6568-1 S28443-2 FLEXTEC 450 3 SCREWS 3 SCREWS (LEFT MODULE) (LEFT MODULE) FLEXTEC™ 450...
  • Page 114 TORX MOUNTING SCREWS #207 #209 TORX MOUNTING SCREWS G6568-1 S28443-2 FLEXTEC 450 POWER LEAD POWER LEAD #201 #204 6. Attach power leads #207 and #209 to the switch 8. Plug in the 4 molex connectors from the wiring board. Torque the connection to 40-48 in-lbs.

  • Page 115: Output Rectifier Removal And Replacement

    OUTPUT RECTIFIER REMOVAL AND REPLACEMENT 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 116 TROUBLESHOOTING AND REPAIR F-74 F-74 OUTPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.31 – OUTPUT RECTIFIER BOLT LOCATIONS OUTPUT RECTIFIER ASSEMBLY REMOVAL PROCEDURE 5. Using the 1/2” wrench, remove the bolt, lock WARNING washer and flat washers securing the choke ELECTRIC SHOCK can kill.
  • Page 117 TROUBLESHOOTING AND REPAIR F-75 F-75 OUTPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.32 – OUTPUT RECTIFIER BOLT LOCATIONS BOLTED CONNECTION BOLTED CONNECTION (X1) (CHOKE LEAD #220 ) SPIKE BLOCKERS THERMOSTAT BOLTED CONNECTION (X3) FIGURE F.33 – OUTPUT RECTIFIER PLASTIC MOUNTING BRACKETS PLASTIC MOUNTING OUTPUT HEATSINK BRACKETS...
  • Page 118 TROUBLESHOOTING AND REPAIR F-76 F-76 OUTPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position the new Output Rectifier assembly into place. 2. Using the two bolts and washers previously removed assembly the bottom two plastic mounting brackets onto the machine base. 3.
  • Page 119 TROUBLESHOOTING AND REPAIR F-77 F-77 Retest a machine: If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. If you repair or replace any electrical components. INPUT IDLE AMPS AND WATTS Input Volts/Hertz Maximum Idle Amps Maximum Idle KW...
  • Page 120 TROUBLESHOOTING AND REPAIR F-78 F-78 TEST AFTER REPAIR FLEXTEC – CONSTANT CURRENT GRID LOAD TESTING Dip Switch #4 in the ON position; All other Dip Switch positions OFF. Switches and potentiometers: Weld Terminals On/Remote Switch – REMOTE Position Process Selection Switch – GTAW Position Local / Remote Switch –...
  • Page 121 NOTES F-79 F-79 FLEXTEC™ 450...
  • Page 122 NOTES F-80 F-80 FLEXTEC™ 450...
  • Page 123 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (Code 11626) (G6890) .

  • Page 124: Electrical Diagrams

    ELECTRICAL DIAGRAMS WIRING DIAGRAM - (CODE 11626) (G6890) FLEXTEC 450 WIRING DIAGRAM TO EARTH LEFT SIDE OF MACHINE GENERAL INFORMATION GROUND BASE CAVITY NUMBERING SEQUENCE PER THE ELECTRICAL SYMBOLS PER E1537. (VIEWED FROM COMPONENT SIDE OF P.C. BOARD) NATIONAL ELECTRIC...

  • Page 125: Wiring Diagram (Code 11754) (G6890-3

    ELECTRICAL DIAGRAMS WIRING DIAGRAM - (CODE 11754) (G6890-3) FLEXTEC 450 WIRING DIAGRAM TO EARTH LEFT SIDE OF MACHINE GENERAL INFORMATION GROUND BASE CAVITY NUMBERING SEQUENCE PER THE ELECTRICAL SYMBOLS PER E1537. (VIEWED FROM COMPONENT SIDE OF P.C. BOARD) NATIONAL ELECTRIC...

  • Page 126: Schematic - Complete Machine (Code 11626) (G6462

    MANUFACTURING TOLERANCE PER E2056 SCALE: CONTROL: CLEVELAND EQUIPMENT TYPE: FLEXTEC 450 UNLESS OTHERWISE SPECIFIED TOLERANCE: PAGE ___ OF ___ ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm) NONE ON 3 PLACE DECIMALS IS ± .002 in. ( ± 0.05 mm)
  • Page 127 Use the “WELD TERMINALS” switch to enable and disable output TROUBLESHOOTING THE FLEXTEC 450 SWITCHBOARD ERROR CODES FOR THE FLEXTEC 450 CONTROL BOARD CONSTANT CURRENT TEST MODE ERROR CODE # INDICATION...
  • Page 128 TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. VIEW OF CONNECTOR ON PC BOARD MANUFACTURING TOLERANCE PER E2056 SCALE: EQUIPMENT TYPE: FLEXTEC 450 ELECTRICAL SYMBOLS PER E1537. CONTROL: CLEVELAND UNLESS OTHERWISE SPECIFIED TOLERANCE: PAGE ___ OF ___ ON 2 PLACE DECIMALS IS ±...

  • Page 129: Schematic - Complete Machine (Code 11754) (G6462-3

    Set “HOT START” switch to “OFF” Turn on input power. GREEN +5V DC POWER SUPPLY "OK" USING THE FLEXTEC 450 CONTROL BOARD STATUS LED Use the “OUTPUT CONTROL KNOB” to adjust the setpoint to a desired value on the right display GREEN CAN POWER SUPPLY "OK"...

  • Page 130: Schematic - Complete Machine (Code 11754) (G6462-3

    ELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE (CODE 11754) (G6462-3) PG 3 ERROR CODE TROUBLESHOOTING GUIDE Primary Overcurrent Description Peak current through the transformer primary has exceeded threshold (140 amps). Verify connections to the switchboard, transformer and output rectifier assemblies Possible Solution 1 are made correctly and there are no damaged components in the machine.

  • Page 131: Schematic - Control Pc Board (G4767-2F1

    ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD (G4767-2F1) PG 1 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 CLEVELAND SCALE:...
  • Page 132 G-10 ELECTRICAL DIAGRAMS G-10 SCHEMATIC - CONTROL PC BOARD (G4767-2F1) PG 2 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 SCALE: CONTROL:...

  • Page 133: Schematic - Control Pc Board (G4767-2F1

    G-11 ELECTRICAL DIAGRAMS G-11 SCHEMATIC - CONTROL PC BOARD (G4767-2F1) PG 3 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 SCALE: EQUIPMENT TYPE:...

  • Page 134: Schematic - Control Pc Board (G4767-2F1

    G-12 ELECTRICAL DIAGRAMS G-12 SCHEMATIC - CONTROL PC BOARD (G4767-2F1) PG 4 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 CLEVELAND SCALE:...

  • Page 135: Schematic - Control Pc Board (G4767-2F1

    G-13 ELECTRICAL DIAGRAMS G-13 SCHEMATIC - CONTROL PC BOARD (G4767-2F1) PG 5 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 SCALE: CONTROL:...

  • Page 136: Schematic - Control Pc Board (G4767-2F1

    G-14 ELECTRICAL DIAGRAMS G-14 SCHEMATIC - CONTROL PC BOARD (G4767-2F1) PG 6 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 SCALE: EQUIPMENT TYPE:...

  • Page 137: Schematic - Control Pc Board (G4767-2F1

    G-15 ELECTRICAL DIAGRAMS G-15 SCHEMATIC - CONTROL PC BOARD (G4767-2F1) PG 7 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 SCALE: EQUIPMENT TYPE:...
  • Page 138 G-16 ELECTRICAL DIAGRAMS G-16 SCHEMATIC - SWITCH PC BOARD (G6567-2F0) PG 1 +2Vref1 POWER SUPPLY +3.3V_BUS THERMO1_I POWER_SUPPLY_VOLTAGE +15V Vref1 RELAY_CONTROL +1V Offset XRSn SETPOINT_P XRSn R177 33074ADT SOFT_START_CONTROL 50V+ 3.3V+_BUS 0.1W 15V+_DRIVER FAN_CONTROL_P R176 P_COM (TO SOLID STATE RELAY) V+5CAN 6 PIN 0.063W...
  • Page 139 G-17 ELECTRICAL DIAGRAMS G-17 SCHEMATIC - SWITCH PC BOARD (G6567-2F0) PG 2 DSP_PWM DSP_PWM DSP_IO COM +5V 0.1uF SLOPE_ADJUST DSP_SYNC STATUS_LED_GREEN EPWM1A EPWM1B DSP_D_CLK CC_MODE DSP_D_CLK DSP_D_CLK_P EPWM2A EPWM2B MIN_ON_TIME TEST_PT1 OUTPUT_ENABLE OUTPUT_ENABLE_P EPWM3A EPWM3B SLOPE_ADJUST FAN_CONTROL DSP_SYNC DSP_SYNC_P EPWM4A EPWM4B OCV_PWM_A STATUS_LED_RED...

  • Page 140: Schematic - Switch Pc Board (G6567-2F0

    G-18 ELECTRICAL DIAGRAMS G-18 SCHEMATIC - SWITCH PC BOARD (G6567-2F0) PG 3 DSP_PWM DSP_PWM SLOPE COMPENSATION FTP40 R204 R203 0.063W 0.063W FTP52 100K 0.063W 100K 0.063W R199 33074ADT Slope Compensation DSP_D_CLK_P SLOPE_ADJUST R197 33074ADT 4.75K FTP22 0.1W MIN_ON_TIME_P 100K FTP20 0.022uF 0.063W R200...

  • Page 141: Schematic - Switch Pc Board (G6567-2F0

    G-19 ELECTRICAL DIAGRAMS G-19 SCHEMATIC - SWITCH PC BOARD (G6567-2F0) PG 4 C112 C147 47pF C119 330pF FEEDBACK ADJUST 820pF 100V 100K SHUNT INPUT 0.063W R269 R267 R271 R270 100K R240 60mV @ 600A 0.063W 0.1W 0.063W 0.063W 2.8V = 1000 Amps +15V AGND AGND...
  • Page 142 G-20 ELECTRICAL DIAGRAMS G-20 SCHEMATIC - SWITCH PC BOARD (G6567-2F0) PG 5 15V+_DRIVER 5V+_SW_PCB FTP10 15V+_DRIVER DC BUS CAPACITORS 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K 1.5K 3.32K 0.1uF 0.063W OUTPUT_A OUTPUT_A OUT7 0.1uF...
  • Page 143 G-21 ELECTRICAL DIAGRAMS G-21 SCHEMATIC - SWITCH PC BOARD (G6567-2F0) PG 6 +15V +15V FTP18 0.55A V+5CAN FTP24 +15V_DRIVER V+5CAN 50V+ 600V 15V+_DRIVER 200V TPS76150 V+5CAN 330uH 0.125 C104 .95A 0.0033uF 630V 82uF 0.1uF 0.001F FTP28 0.1uF 10uF 10uF 43.2K LED4 200V 200V...

  • Page 144: Schematic - Input Pc Board (M22617-2D0

    G-22 ELECTRICAL DIAGRAMS G-22 SCHEMATIC - INPUT PC BOARD (M22617-2D0) +52V 35-90 Vdc Input 24VDC 33.2K 681K 33.2K 33.2K 300V 5.1V 0.5W 47.5K 47.5K 0.0033uF 33.2K 33.2K 630V 100V 0.5A 400V 300V 1A/FR 22uF 0.5A 0.5A 400V 400V 400V 47.5 47.5 431I 1A/FR...

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