Lincoln Electric OPTIMARC AC/DC 350-TP Service Manual
Lincoln Electric OPTIMARC AC/DC 350-TP Service Manual

Lincoln Electric OPTIMARC AC/DC 350-TP Service Manual

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SVM7010
Rev 01
2021.09
®
OPTIMARC
AC/DC 350-TP
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built with
safety in mind. However, your overall
safety can be increased by proper
installation and thoughtful operation
on you part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READING
THIS MENUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act and
be careful.
SERVICE MANUAL
Copyright © The Shanghai Lincoln Electric Company
World's Leader in Welding and Cutting
THE SHANGHAI LINCOLN ELECTRIC COMPANY
No. 195, Lane 5008, Hu Tai Rd. Baoshan, Shanghai, PRC 201907
www.lincolnelectric.com.cn

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Summary of Contents for Lincoln Electric OPTIMARC AC/DC 350-TP

  • Page 1 THROUGHOUT. And, most importantly, think before you act and be careful. SERVICE MANUAL Copyright © The Shanghai Lincoln Electric Company World’s Leader in Welding and Cutting THE SHANGHAI LINCOLN ELECTRIC COMPANY No. 195, Lane 5008, Hu Tai Rd. Baoshan, Shanghai, PRC 201907...
  • Page 2: Electric And Magnetic Fields

    SAFETY WARNING ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. ELECTRIC AND ELECTRIC SHOCK MAGNETIC FIELDS...
  • Page 3: Welding Sparks

    SAFETY FUMES AND GASES WELDING SPARKS CAN BE can cause fire or DANGEROUS. explosion. 6.a Remove fire hazards from the welding area. If this 4.a Welding may produce fumes and gases is not possible, cover them to prevent the welding hazardous to health.
  • Page 4: Table Of Contents

    CONTENTS Safety ....................i-ii Installation ……………………………..………..………………….…..…... Section A Operation ……………………..……………………..…………..……..…..Section B Maintenance ……………..…………………….…..………….…….…………… Section C ………..………...………………….….……………………… Section D Theory of Operation Troubleshooting and Repair ………………………………....………………. Section E Electrical Diagrams …………………………..……..……………...…………… Section F OPTIMARC® AC/DC 350-TP...
  • Page 5 INSTALLATION Technical Specifications ……………….………….………………………………..…...…. A-2 Safety Precautions ………………………………………………...…...…..……………… A-3 Input and Grounding Connections ………………………………………...…………………… A-3 Output Connection …………………………………...….……...…..…………………… A-3 OPTIMARC® AC/DC 350-TP...
  • Page 6 For any maintenance or repair operation it is recommended to contact the nearest technical service center or directly consult the machine division of the Shanghai Lincoln Electric. Maintenance or repairs performed by unauthorized service center or personnel will void the manufacturer’s warranty.
  • Page 7: Installation

    INSTALLATION Open the input box on the rear of the case. Use a three- SAFETY PRECAUTIONS phase supply line, the three live wires should go through Read the entire installation section before the three holes of the input wire holder and be securely starting installation.
  • Page 8: Operation

    OPERATION Graphic Symbols Index ..…………………………………………………………….…………. B-2 ……………………………………………………………………………. B-5 Safety Precautions Front Panel Function ..……………………………………………………………….…………. B-5 Rear Panel Function ………………………………………………………..….……………… B-6 Fan Work Status ……………………...…………………………………..….……………… B-6 ..………………..……………………………………….…………. B-6 User Interface Operation List of Parameters and Factory Configuration ……………………………………………….. B-11 OPTIMARC® AC/DC 350-TP...
  • Page 9: Graphic Symbols Index

    OPERATION Graphic Symbols Index HIGH FREQUENCY TIG TOUGH START TIG SPOT TIG AC-SQUARE WAVE AC-SINE WAVE AC-TRIANGLE WAVE 2-STEP 2-STEP REPEAT 4-STEP 4-STEP REPEAT PULSE PULSE OFF LOW FREQUENCY PULSE SETTING HIGH FREQUENCY MEMORY SAVE PROCEDURE RECALL PROCEDURE FACTORY SETTING OPTIMARC®...
  • Page 10 OPERATION WATER-COOLING MMA WELDING SWITCH REMOTE CONTROL BRIGHTNESS CONNECTION NORMAL CONNECTION FAULTY WATER-COOLING SCREEN LOCKED PROTECTION OUTPUT IGBT TOP TUBE OUTPUT IGBT DOWN PROTECTION TUBE PROTECTION OVER/LOW VOLTAGE OVER CURRENT PROTECTION PROTECTION THERMAL PROTECTION RELAY PROTECTION OPTIMARC® AC/DC 350-TP...
  • Page 11 OPERATION MMA-DC MMA-SQUARE WAVE MMA-TRIANGLE MMA-SINE WAVE WAVE TIG-DC TIG-DC PULSE TIG-SQUARE WAVE TIG-SINE WAVE TIG-TRIANGLE WAVE TIG-SPOT ARC FORCE LANGUAGE OPTIMARC® AC/DC 350-TP...
  • Page 12: Safety Precautions

    OPERATION The machine’s welding output will be available after a SAFETY PRECAUTIONS thermal protection shutdown. WARNING OPERATIONAL FEATURES AND ELECTRIC SHOCK can kill.  CONTROLS Do not touch electrically live parts or electrode with skin or wet clothing. FRONT PANEL (SEE FIGURE B.1) ...
  • Page 13: Fan Work Status

    OPERATION control voltage is 0-10V, the range of output signal 10. AMPHENOL SOCKET reflecting the welding current is 0-10V. This socket is used for remote control box connection. Note: This remote control cannot use simultaneously Refer to the following connection form for specific with the remote control box described in Section 10 above.
  • Page 14 OPERATION FIGURE RECALLED FAULTS REMOTE FUNCTION LOCK PROCEDURE SETTING IDENTIFICATION SCREEN NUMBER CONFIGURATION STATUS WELDING STATUS WELDING CURRENT & VOLTAGE WELDING WAVEFORM CURRENT WELDING PARAMETER PARAMETERS SETTING WELDING OUTPUT CRATER PULSE SETTINGS MEMORY MODES WAVEFORMS MODES Click the selector button (item 3 in FIGURE B.1), menu bar on the bottom will be selected with a black square box.
  • Page 15 OPERATION Save procedure. Enter the memory menu, PULSE select the save function by rotating the The setup procedures are same as above. Pulse only can selector button, then rotate the adjusting be enabled in DC TIG modes. It contains three choices as button to choose the target procedure follows: number.
  • Page 16 OPERATION RECALLED PROCEDURE NUMBER Display the recalled procedure number. It will disappear TIG-AC Sine Wave once the welding parameter is changed. When you choose the factory setting, it will display number 11. FAULT IDENTIFICATION Display the fault identification, when the faults occur more TIG AC Triangle Wave than one kind, they will be displayed in turn.
  • Page 17 OPERATION B-10 B-10 2-Step Trigger Sequence 4-Step Trigger Sequence With the 2-step trigger mode and a TIG welding mode With the 4-step trigger mode and a TIG welding mode selected, the following welding sequence will occur. selected, the following welding sequence will occur. Press and hold the TIG torch trigger.
  • Page 18 OPERATION B-11 B-11 AC BALANCE AND AC OFFSET AC balance and AC offset are enabled in TIG mode when output wave is AC square, but you can only change one parameter at the same time. The following picture indicates the output waveform when the AC balance and AC offset are set to 30% at 100A/100Hz Square wave.
  • Page 19: List Of Parameters And Factory Configuration

    OPERATION B-12 B-12 LIST OF PARAMETERS AND FACTORY CONFIGURATION PROGRAM: Min Step Factory Mode Parameter Name Selectable Value Range Setting Rate Pre-flow time 0.1~15S 0.1S 0.5S Initial current 10~200% (Percentage of the welding current) Upslope 0.1~15S 0.1S 0.5S 150A Welding Current 4~350A Downslope 0.1~15S...
  • Page 20: Maintenance

    MAINTENANCE Safety Precautions …………………………….………………………………………………. C-2 Periodic Maintenance …………………………….……………………………………………. C-2 Thermal Protection …………………………………………………………………………..C-2 Layout of Main Components ………………………………………………………………..C-3 OPTIMARC® AC/DC 350-TP...
  • Page 21: Periodic Maintenance

    WARNING repair and welding test. For any maintenance or repair operation, it is recommended to contact the nearest technical service THERMAL PROTECTION centre or directly consult the machine division of the Shanghai Lincoln Electric. Thermostats protect machine from excessive operating temperatures. Excessive temperatures may be...
  • Page 22 MAINTENANCE LAYOUT OF MAIN COMPONENTS FIGURE C.1 Ⅰ Case Front Assembly Ⅱ Divider Panel Assembly Ⅲ Base & Centre Assembly Ⅳ Case Back Assembly Ⅴ Wraparound Assembly Ⅴ Ⅱ Ⅳ Ⅰ Ⅲ OPTIMARC® AC/DC 350-TP...
  • Page 23 THEORY OF OPERATION Input Power, Input Rectifier & Pre-charge Board……………………………………………… D-2 D r i v e B o a r d & I n v e r t e r … … … … … … … … … … … … … … … … … … … … … … … … … … … … … D-3 S t a b i l i z i n g A r c B o a r d …...
  • Page 24: Input Power, Input Rectifier & Pre-Charge Board

    THEORY OF OPERATION INPUT POWER、INPUT RECTIFIER & PRE-CHARGE BOARD When the input line switch on, three-phase 380VAC input voltage is applied to the Input Rectifier, the rectified 540VDC is applied to the Pre-charge Board through terminals #209(+) & #207(-), and charge two electrolytic capacitors in series after passing through a 100Ω...
  • Page 25: Drive Board & Inverter

    THEORY OF OPERATION DRIVE BOARD & INVERTER DRIVE BOARD The Drive Board receives 15VDC from the Control Board through leads #231 and #232, then provides 15VDC to the Pre-charge Board through leads #236(+) and #235(-). The Pre-charge Board provides 540VDC bus voltage to the full bridge inverter, two IGBT modules are driven by the 20kHz PWM signal provided by the Drive Board to convert the bus voltage into a 540V high-frequency AC square wave, then apply to the primary of the Main Transformer.
  • Page 26: Stabilizing Arc Board

    THEORY OF OPERATION STABILIZING ARC BOARD Stabilizing Arc Board is powered by an individual auxiliary transformer, receives 220VAC come from leads #216 and #217. Leads #220D (+) and #221D (-) connect to the output terminals. Leads #222A and #223A connect to the power supply terminals of chopper IGBT. FIGURE D.3 OPTIMARC®...
  • Page 27: Aux Transformers & Fan

    THEORY OF OPERATION AUX TRANSFORMERS & FAN AUX TRANSFORMER T1 Primary of the aux transformer T1 (380VAC) is connected to input switch through leads 201D and 202D, secondary output two pairs 16VAC power supply to the Control Board. The resistance of primary coil is about 80Ω, the resistance of each pair of 16VAC secondary coil is about 0.6-0.8Ω.
  • Page 28: Theory Of Operation

    THEORY OF OPERATION CONTROL BOARD, DISPLAY BOARD, GAS VALVE & WATER VALVE Control Board The Control Board get two pairs of 16VAC power supply from T1. Functions of the Control Board: 1. Received the primary current signal, over/low voltage signal and pre-charge relay signal of Pre- charge Board that come from the Drive Board.
  • Page 29: Main Transformer, Output Rectifier, Chopper Board & Hf Board

    THEORY OF OPERATION MAIN TRANSFORMER, OUTPUT RECTIFIER, CHOPPER BOARD & HF BOARD Main Transformer The Main Transformer get 540VAC square wave from the H-bridge, then output two-way high-frequency square wave 75VAC to the Output Rectifier, another high-frequency square wave 45VAC provide power supply to the HF Board through leads #262 &...
  • Page 30: Thermostat

    THEORY OF OPERATION THERMOSTAT There are totally three thermostats installed on the machine. T1 monitors the temperature of the Chopper switch, T2 monitors the temperature of two IGBT modules in H-inverter, T3 monitors the temperature of load resistor on the Stabilizing Arc Board. All three are NO switch, any one trip will result in thermal fault, and output of the machine disabled until the temperature drops to the thermostat reset level.
  • Page 31 TROUBLESHOOTING AND REPAIR How to Use Troubleshooting Guide …………………………...….………..……………….. E-2 PC Board Troubleshooting Procedures …………………………….………..……………… E-3 Troubleshooting Guide …………………………………………….….………………………. E-4 Case Cover Removal ……..………………………….…………………..…………………… E-7 Input Rectifier Removal …….………….………………………….…..…….………………. E-9 Input Rectifier Test …….……………….………………………….…..…….………………. E-10 Aux Transformer Removal ………………………………………………..………..… E-11 Aux Transformer Test ……………………..……………………………..………..…...
  • Page 32: 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 33: Pc Board Troubleshooting Procedures

    Have an electrician install and service complete. this equipment. Turn the input power If you return a PC board to The Lincoln Electric OFF at the fuse box before working Company for credit, it must be in the static- equipment.
  • Page 34 If the problem still persists, weld performance. problems, bad connections, Contact your local authorized excessive loops in cabling, etc. Lincoln Electric Field Service 2. Verify weld mode is correct for facility for technical assistance. processes. 3. The power source may require calibration.
  • Page 35 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OPERATING PROBLEMS Remote output control not 1. Verify the remote control is set to 1 functioning. The machine (enable remote control).
  • Page 36 COURSE OF ACTION WELDING PROBLEMS Major physical or electrical Contact your local authorized damage is evident when Lincoln Electric Field Service the sheet metal covers are facility for technical assistance. removed. Input breaker keeps 1. Make certain that fuses or 1.
  • Page 37: Case Cover Removal

    CASE COVER REMOVAL 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 38 TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL (continued) FIGURE E.2 – RIGHT CASE SIDE REMOVAL Self-tapping screw FIGURE E.3 – LEFT CASE SIDE REMOVAL Self-tapping screw OPTIMARC® AC/DC 350-TP...
  • Page 39: Input Rectifier Removal

    INPUT RECTIFIER REMOVAL 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 40: 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 41: Aux Transformer Removal

    AUX TRANSFORMER REMOVAL 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 42: Aux Transformer Test

    AUX 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 43 TROUBLESHOOTING AND REPAIR E-13 E-13 AUX TRANSFORMER TEST (continued) TABLE E.3 – AUX TRANSFORMER ACTIVE TEST METER PROBE (+) METER PROBE (–) METER MODE EXPECTED VALUE T1、T2 AUX TRANSFORMER 201D 202D AC VOLTAGE 380VAC AC VOLTAGE 16VAC AC VOLTAGE 16VAC AC VOLTAGE 16VAC AC VOLTAGE...
  • Page 44: Control Board Removal

    CONTROL BOARD REMOVAL 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 45: Igbt Module Removal

    IGBT MODULE REMOVAL 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 46 TROUBLESHOOTING AND REPAIR E-16 E-16 IGBT MODULE REMOVAL (continue) FIGURE E.7 - IGBT MODULE REMOVAL OPTIMARC® AC/DC 350-TP...
  • Page 47 IGBT MODULE 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 48: Igbt Module Test

    TROUBLESHOOTING AND REPAIR E-18 E-18 IGBT MODULE TEST (continue) FIGURE E.8 - IGBT MODULE ACTIVE TEST WIRING SWITCH LAMP CLOSE D1 G6 S7 OPEN CLOSE D3 G4 S5 OPEN OPTIMARC® AC/DC 350-TP...
  • Page 49 OUTPUT DIODE REMOVAL 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 50: Output Diode Test

    OUTPUT DIODE 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 51: Pre-Charge Board And Capacitors Removal

    PRE-CHARGE BOARD AND CAPACITORS REMOVAL 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 52: Chopper Board Removal

    CHOPPER BOARD REMOVAL 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 53: Drive Board Removal

    DRIVE BOARD REMOVAL 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 DRIVE 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 55: Drive Board Test

    TROUBLESHOOTING AND REPAIR E-25 E-25 DRIVE BOARD TEST (continue) Turn off the power to the machine. Disconnect leads 207 and 209 from the Pre-charge Board and insulate the terminals. Turn on the power to the machine. Using an oscilloscope, perform the drive signal waveform test per Table E.7.
  • Page 56: Stabilizing Arc Board Removal

    STABILIZING ARC BOARD REMOVAL 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 57: Hf Board Removal

    HF BOARD REMOVAL 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: Hf Board Test

    HF 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 59: Display Drive Board Removal

    DISPLAY DRIVE BOARD REMOVAL 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 60: Fan Removal

    FAN REMOVAL 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 61: Fan Test

    FAN 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: Retest After Repair

    E-32 RETEST AFTER REPAIR 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 63: Wiring Diagram

    WIRING DIAGRAM Wiring Diagram - 76251 ……………………….………………..….………..……………….. OPTIMARC® AC/DC 350-TP...
  • Page 64 WIRING DIAGRAM OPTIMARC® AC/DC 350-TP...
  • Page 65 NOTE World’s Leader in Welding and Cutting THE SHANGHAI LINCOLN ELECTRIC COMPANY No. 195, Lane 5008, Hu Tai Rd. Baoshan, Shanghai, PRC 201907 www.lincolnelectric.com.cn OPTIMARC® AC/DC 350-TP...

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