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...
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.
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...
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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.
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.
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...
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) ...
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.
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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.
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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.
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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.
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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.
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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.
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...
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...
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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...
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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 …...
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...
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.
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®...
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.
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.
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 &...
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.
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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 ……………………..……………………………..………..…...
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.
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.
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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.
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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).
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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.
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.
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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...
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.
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.
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.
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.
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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...
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.
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.
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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.
TROUBLESHOOTING AND REPAIR E-18 E-18 IGBT MODULE TEST (continue) FIGURE E.8 - IGBT MODULE ACTIVE TEST WIRING SWITCH LAMP CLOSE D1 G6 S7 OPEN CLOSE D3 G4 S5 OPEN OPTIMARC® AC/DC 350-TP...
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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.
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.
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.
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.
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.
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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.
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.
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.
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.
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.
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.
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.
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.
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.
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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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