Lincoln Electric FLEXTEC 500P Service Manual
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Lincoln Electric FLEXTEC 500P Service Manual

Lincoln Electric FLEXTEC 500P Service Manual

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FLEXTEC
500P
®
For use with machines having Code Numbers:
12246
SERVICE MANUAL
SVM265
| Issue D ate Nov-15
© Lincoln Global, Inc. All Rights Reserved.

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Summary of Contents for Lincoln Electric FLEXTEC 500P

  • Page 1 FLEXTEC 500P ® For use with machines having Code Numbers: 12246 SERVICE MANUAL SVM265 | Issue D ate Nov-15 © Lincoln Global, Inc. All Rights Reserved.
  • Page 2 Service and repair should be performed by only exhaust at the arc, or both, to keep Lincoln Electric Factory Trained Personnel. Unauthorized the fumes and gases from your breathing zone and the general area. repairs performed on this equipment may result in danger...

  • Page 3: Section A: Warnings

    American Welding Society, P.O. Box 351040, Miami, Florida 33135 MAGNETIC FIELDS MAY or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 BE DANGEROUS St. Clair Avenue, Cleveland, Ohio 44117-1199.

  • Page 4: Electric Shock Can Kill

    FLEXTEC® 500P SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover electrically “hot” when the welder is on. Do plates to protect your eyes from sparks and the rays of the arc not touch these “hot”...
  • Page 5 FLEXTEC® 500P SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. and properly operating regulators designed for If this is not possible, cover them to prevent the gas and pressure used.

  • Page 6: Electromagnetic Compatability (Emc)

    Electromagnetic Compatibility (EMC) Product Standard for Arc Welding equipment, in metallic conduit or equivalent. Shielding should be Equipment. It is for use with other Lincoln Electric equipment. It is electrically continuous throughout its length. The shielding should be designed for industrial and professional use.
  • Page 7 FLEXTEC® 500P SAFETY Ventilation As a rule of thumb, for many mild steel electrode, if the air is visibly clear and you are comfortable, then the ventilation is generally There are many methods which can be selected by the user to adequate for your work.
  • Page 8 TLV and PEL values are as of April 2006. Always check Material Know Act of 1986 and of 40CFR 370 and 372. Safety Data Sheet (MSDS) with product or on the Lincoln Electric website at http://www.lincolnelectric.com (b) The PEL for chromium (VI) is .005 milligrams per cubic meter as an 8 hour time weighted average.
  • Page 9 FLEXTEC™ 500P NOTES viii...
  • Page 10 FLEXTEC™ 500P TABLE OF CONTENTS MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety ....................................ii-viii Installation, Operation, Accessories, Maintenance ................See Instruction Manual Theory of Operation ..............................Section E Troubleshooting and Repair ............................Section F Electrical Diagrams ..............................Section G...

  • Page 11: Theory Of Operation Section

    FLEXTEC® 500P THEORY OF OPERATION TABLE OF CONTENTS - THEORY OF OPERATION SECTION - Theory Of Operation ......................Section E Input Section ..............E-2 Switch Board And Main Transformer .

  • Page 12: Input Section

    FLEXTEC® 500P THEORY OF OPERATION Figure E.2 - Input section TO FAN FAN ENA LE LINE INPUT MAIN OUTPUT OUTPUT CURRENT SWITCH RECTIFIER TRANSFORMER RECTIFIER CHOKE TRANSDUCER FREQUENCY = 20kHz ELECTRODE TERMINAL SWITCH OARD WORK OOST OOST TERMINAL RELAY RECTIFIER RECONNECT CURRENT FEED ACK CAN COMMUNICATION...

  • Page 13: Switch Board And Main Transformer

    FLEXTEC® 500P THEORY OF OPERATION Figure E.3 - Switch board and main transformer TO FAN FAN ENA LE LINE INPUT MAIN OUTPUT OUTPUT CURRENT SWITCH RECTIFIER TRANSFORMER RECTIFIER CHOKE TRANSDUCER FREQUENCY = 20kHz ELECTRODE TERMINAL SWITCH OARD WORK OOST OOST TERMINAL RELAY RECTIFIER...

  • Page 14: Output Section

    FLEXTEC® 500P THEORY OF OPERATION Figure E.4 - Output section TO FAN FAN ENA LE LINE INPUT MAIN OUTPUT OUTPUT CURRENT SWITCH RECTIFIER TRANSFORMER RECTIFIER CHOKE TRANSDUCER FREQUENCY = 20kHz ELECTRODE TERMINAL SWITCH OARD WORK OOST OOST TERMINAL RELAY RECTIFIER RECONNECT CURRENT FEED ACK CAN COMMUNICATION...
  • Page 15 FLEXTEC® 500P THEORY OF OPERATION Figure E.5 - User interface board and user controls TO FAN FAN ENA LE LINE INPUT MAIN OUTPUT OUTPUT CURRENT SWITCH RECTIFIER TRANSFORMER RECTIFIER CHOKE TRANSDUCER FREQUENCY = 20kHz ELECTRODE TERMINAL SWITCH OARD WORK OOST OOST TERMINAL RELAY...

  • Page 16: Thermal Protection

    THEORY OF OPERATION THERMAL PROTECTION PROTECTIVE CIRCUITS Protective circuits are designed into the FLEXTEC 500P to sense trouble and shut down the machine before damage occurs to the Three normally closed (NC) thermostats protect the FLEXTEC 500P machine’s internal components.

  • Page 17: Pulse Width Modulation

    FLEXTEC® 500P THEORY OF OPERATION Figure E.6 - Typical IGBT outputs MINIMUM OUTPUT MAXIMUM OUTPUT PULSE WIDTH MODULATION MAXIMUM OUTPUT By holding the gate signal on for 24 microseconds each and allowing only two microseconds of dwell time (off time) during the The term Pulse Width Modulation is used to describe how much time 50-microsecond cycle, the output is maximized.

  • Page 18: Insulated Gate Bipolar Transistor (Igbt) Operation

    FLEXTEC® 500P THEORY OF OPERATION Figure E.7 - Insulated gate bipolar transistor (IGBT) operation 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.

  • Page 19: Table Of Contents

    FLEXTEC® 500P TROUBLESHOOTING AND REPAIR TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR SECTION - Troubleshooting and Repair ....................Section F How to Use Troubleshooting Guide ..........F-3 PC Board Troubleshooting Procedures .
  • Page 20 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR SECTION - Troubleshooting and Repair ....................Section F Input Rectifier Removal And Replacement Procedure .......F-81 Auxiliary Transformer (T1) Removal And Replacement Procedure .

  • Page 21: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 22: Troubleshooting And Repair

    FLEXTEC® 500P TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURES 4. Test the machine to determine if the failure symptom has been WARNING corrected by the replacement PC board. NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

  • Page 23: Troubleshooting Guide

    6. Perform the Main Transformer Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 24 3. Perform the Switch board Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 25: Vrd™ Operation

    ** It is normal for the lights to alternate during OCV preset adjustment, depending on preset voltage test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 26: Error Codes

    If any of these conditions persist contact an authorized Lincoln Field Service Shop. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 27: Case Cover Removal And Replacement Procedure

    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.
  • Page 28 ROOF MOUNTING SCREWS (2) REMOVAL PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Using a 3/8” nutdriver, remove the eight screws (two on top and three on each side) securing the roof to the machine. See Figure F.1 and Figures F.2 and F.3.
  • Page 29 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.2 – Left side mounting screw locations ROOF MOUNTING SCREWS (THREE ON EACH SIDE) LEFT CASE SIDE MOUNTING SCREWS (3) CORNER CAP MOUNTING SCREWS (TWO ON EACH SIDE) Figure F.3 –...
  • Page 30 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position the left case side onto the machine. 2. Using a 3/8” nutdriver, attach the three screws securing the left case side to the machine. 3.

  • Page 31: Capacitor Discharge Procedure

    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 32 LED4 B204 PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Locate the two large bolted connections labeled “207” and “209” on the switch board. See Figure F.4. See Wiring Diagram.

  • Page 33: 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 34 Figure F.5 – Input rectifier location INPUT RECTIFIER TOP VIEW PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Locate the input rectifier. See Figure F.5.
  • Page 35 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR INPUT RECTIFIER TEST (continued) Figure F.6 – Input rectifier detail – – INPUT RECTIFIER SCHEMATIC Table F.1 – Forward voltage drop tests TEST POINT (POSITIVE) TEST POINT (NEGATIVE) EXPECTED RESULTS TERMINAL A POSITIVE TERMINAL .03V - 1.0V TERMINAL B POSITIVE TERMINAL .03V - 1.0V...
  • Page 36 FLEXTEC™ 500P NOTES F-18...

  • Page 37: T1 Transformer Thermostat Test

    T1 TRANSFORMER THERMOSTAT 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 38 TOP VIEW T1 TRANSFORMER THERMOSTAT PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Locate T1 transformer thermostat. See Figure F.7. See Wiring Diagram.
  • Page 39 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR T1 TRANSFORMER THERMOSTAT TEST (continued) Figure F.8 – T1 transformer thermostat lead locations LEAD 229 LEAD 230 F-21...
  • Page 40 FLEXTEC™ 500P NOTES F-22...

  • Page 41: 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 42 #22 together. See Figure F.10. See Wiring Diagram. 14. Perform the Case Cover Replacement Procedure. 6. Carefully apply the correct input power to the Flextec 500P. 7. When the machine is turned on, the fan should start and run as long as the power is on.
  • Page 43 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR FAN AND F.A.N. CIRCUIT TEST (continued) Figure F.10 – Plug J26 lead locations LEAD #24 LEAD #22 Figure F.11 – Thermostat #2 location THERMOSTAT #2 F-25...
  • Page 44 FLEXTEC™ 500P NOTES F-26...

  • Page 45: Auxiliary Transformer (T1) Test

    AUXILIARY TRANSFORMER (T1) 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 46 3. Perform the Capacitor Discharge Procedure. 4. Locate the auxiliary transformer (T1). See Figure F.12. 5. Carefully apply the correct input power to the Flextec 500P and turn ON the machine. 6. Using a digital volt/ohmmeter, test for the correct primary voltages at the reconnect terminal block.
  • Page 47 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER (T1) TEST (continued) Figure F.13 – Reconnect panel and lead location RECONNECT PANEL Figure F.14 – D3 and D4 rectifier leads and location X14 (X4) X15 (X5) D4 RECTIFIER D3 RECTIFIER X13 (X3) X16 (X6) DIVIDER PANEL F-29...
  • Page 48 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER (T1) TEST (continued) Table F.2 – Primary and secondary voltage tests DESCRIPTION TEST POINT TEST POINT EXPECTED READING PRIMARY VOLTAGE 115 VAC PRIMARY VOLTAGE 380 VAC PRIMARY VOLTAGE 460 VAC PRIMARY VOLTAGE 575 VAC SECONDARY VOLTAGE X13 (X3) X14 (X4)

  • Page 49: 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 50 7. Carefully apply the correct input power to the Flextec 500P and turn ON the machine. 8. Check the LEDs per Table F.4. See Figure F.16 for LED locations.
  • Page 51 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST (continued) Figure F.16 – Switch board LED and plug locations B209 B207 B209 B207 LED 2 LED2 LED 1 LED1 LED3 R207 LED5 B201 R249 B201 LED4 B204 LED 3 LED 4 LED 5 B204 221A...
  • Page 52 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST (continued) Table F.3 – Switch board resistance tests DESCRIPTION TEST POINT TEST POINT EXPECTED READING CONDITION Checking for short circuit B209 (+) B201 (–) GREATER THAN 100,000 MACHINE “OFF” NO on the “High Side” IGBTs OHMS INPUT POWER APPLIED Checking for short circuit...
  • Page 53 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR SWITCH BOARD TEST (continued) Table F.5 – Switch board voltage tests DESCRIPTION TEST POINT TEST POINT EXPECTED READING CONDITION (POS) (NEG) FAN SUPPLY VOLTAGE PLUG J26 PIN 1 PLUG J26 PIN 2 115 VAC FAN NOT ACTIVATED. IF 115VAC IS NOT PRESENT, PERFORM THE AUXILIARY FROM AUXILIARY (LEAD #24)
  • Page 54 FLEXTEC™ 500P NOTES F-36...

  • Page 55: Output Rectifier (D2) Assembly Test

    OUTPUT RECTIFIER (D2) ASSEMBLY 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 56 Figure F.17 – Output rectifier assembly location OUTPUT RECTIFIER (D2) ASSEMBLY PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Locate the output rectifier (D2). See Figure F.17.
  • Page 57 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER (D2) ASSEMBLY TEST (continued) Figure F.18 – Output rectifier leads and test points BOOST RECTIFIER Figure F.19 – Output rectifier leads and test points – BOOST RECTIFIER BOOST RECTIFIER SCHEMATIC Table F.6 – Output rectifier forward voltage drop tests TEST POINT (POS) TEST POINT (NEG) EXPECTED READING...
  • Page 58 FLEXTEC™ 500P NOTES F-40...

  • Page 59: 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 60 PROCEDURE 10. Connect any previously removed leads. See Wiring Diagram. 11. Perform the Case Cover Replacement Procedure. 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure.
  • Page 61 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR CHOKE TEST (continued) Figure F.21 – Choke detail TOP CHOKE LEAD FROM OUTPUT RECTIFIER CHOKE ASSEMBLY BOTTOM CHOKE LEAD TO POSITIVE OUTPUT TERMINAL F-43...
  • Page 62 FLEXTEC™ 500P NOTES F-44...

  • Page 63: User Interface Board Test

    USER INTERFACE 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 64 Table F.7 with all plugs in board. See Figure F.23. See Wiring Diagram. 6. Carefully apply the correct input power to the Flextec 500P and turn ON the machine. 7. Observe and make sure the status LEDs on the front and rear of the user interface board are indicating a properly functioning user interface board.

  • Page 65: Display Side

    FLEXTEC® 500P TROUBLESHOOTING AND REPAIR USER INTERFACE BOARD TEST (continued) Figure F.23 – User interface board LED and plug locations LED 1 LED 2 LED 3 DISPLAY SIDE LED2 LED3 LED1 DISP1 DISP2 SWITCH LED 4 REAR SIDE LED4 1 2 3 4 5 6 7 8 Analog 14 pin and 12 Hot Start, Arc Control, Mode, Weld Terminals,...
  • Page 66 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR USER INTERFACE BOARD TEST (continued) Table F.7 – User interface board resistance tests TEST POINT TEST POINT EXPECTED READING PLUG J1 PIN 1 PLUG J1 PIN 6 0 - 10 K OHMS DEPENDANT ON ARC CONTROL POT POSITION.
  • Page 67 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR USER INTERFACE BOARD TEST (continued) Table F.9 – User interface board voltage tests DESCRIPTION TEST POINT TEST POINT EXPECTED READING CONDITION (POS) (NEG) INPUT FROM D4 PLUG J4 PIN 4 PLUG J4 PIN 3 APPROX 40 VDC MACHINE ON.
  • Page 68 FLEXTEC™ 500P NOTES F-50...

  • Page 69: Weld Output Thermostat Circuit Test

    WELD OUTPUT THERMOSTAT 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 70 10. If thermostat #2 is faulty, perform the Thermostat #2 Removal And Replacement Procedure. 1. Remove the input power to the Flextec 500P machine. 11. Connect any previously removed plugs and leads. See Wiring 2. Perform the Case Cover Removal Procedure.
  • Page 71 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR WELD OUTPUT THERMOSTAT CIRCUIT TEST (continued) Figure F.26 – Plug J20 pin and lead locations LEAD 224 LEAD 225 Figure F.27 – Thermostat #2 location THERMOSTAT #2 F-53...
  • Page 72 FLEXTEC™ 500P NOTES F-54...

  • Page 73: Current Transducer (Lem) Test

    CURRENT TRANSDUCER (LEM) 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 5. Locate plug J29 on the switch board. See Figure F.29. See Wiring Diagram. 6. Carefully apply the correct input power to the Flextec 500P and turn the machine ON. 7. Using a digital volt/ohmmeter, carefully check for the DC supply voltages to the current transducer per Table F.10.
  • Page 75 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER (LEM) TEST (continued) Figure F.29 – Plug J29 pin and lead locations B209 B207 LED2 LED1 LED3 R207 LED5 R249 B201 LED4 B204 Table F.10 – DC supply voltages from switch board DESCRIPTION TEST POINT (POS) TEST POINT (NEG) EXPECTED READING...
  • Page 76 FLEXTEC™ 500P NOTES F-58...

  • Page 77: Dc Bus Board Test

    DC BUS 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 78: Divider Panel Assembly

    3. Perform the Capacitor Discharge Procedure. 4. Locate the DC bus board. See Figure F.30. 5. Carefully apply the correct input power to the Flextec 500P and turn the machine ON. 6. Locate the red LED on the DC bus board. See Figure F.31.
  • Page 79 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR DC BUS BOARD TEST (continued) Figure F.31 – DC bus board LED and plug locations J47 RED Table F.12 – DC bus board voltage tests DESCRIPTION TEST POINT TEST POINT EXPECTED READING INPUT FROM DC RECTIFIER PLUG J46 PIN 1 (+) PLUG J46 PIN 3 (+) 65 VDC...
  • Page 80 FLEXTEC™ 500P NOTES F-62...

  • Page 81: D3 And D4 Rectifier Test

    D3 AND D4 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 82 D3 RECTIFIER HORIZONTAL DIVIDER PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Locate the D3 and D4 rectifiers. See Figure F.32. See Wiring Diagram.
  • Page 83 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR D3 AND D4 RECTIFIER TEST (continued) Figure F.33 – D3 and D4 rectifier lead locations and test points X14 (X4) X15 (X5) – RECTIFIER X13 (X3) X16 (X6) SCHEMATIC D4 RECTIFIER D3 RECTIFIER Table F.13 – D3 and D4 rectifier test points TEST POINT (POS) TEST POINT (NEG) EXPECTED READING...
  • Page 84 FLEXTEC™ 500P NOTES F-66...

  • Page 85: Boost Relay Test

    BOOST RELAY 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 86 PROCEDURE 12. If faulty, perform the Boost Relay Removal And Replacement Procedure. 1. Remove the input power to the Flextec 500P machine. 13. Connect all previously removed leads. 2. Perform the Case Cover Removal Procedure. 14. Perform the Case Cover Replacement Procedure.
  • Page 87 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR BOOST RELAY TEST (continued) Figure F.35 – Boost relay terminal and lead locations BOOST RELAY F-69...
  • Page 88 FLEXTEC™ 500P NOTES F-70...

  • Page 89: Main Transformer Test

    MAIN 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 90 MAIN RELAY TRANSFORMER PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Locate the main transformer. See Figure F.36. 5. Label and disconnect, leads 40 and 20 from the boost relay. See Figure F.37.
  • Page 91 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST (continued) Figure F.37 – Boost relay lead location BOOST RELAY Figure F.38 – Switch board terminal locations B209 B207 LED2 LED1 LED3 R207 LED5 R249 B201 LED4 B204 B201 B204 F-73...
  • Page 92 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST (continued) Table F.14 – Main transformer resistance tests DESCRIPTION TEST POINT TEST POINT EXPECTED READING BOOST WINDING AND LEAD #40 LEAD #20 VERY LOW RESISTANCE REACTOR (DISCONNECTED FROM THE BOOST (DISCONNECTED FROM THE BOOST (LESS THAN ONE OHM) RELAY) RELAY)

  • Page 93: Special Testing Modes

    SPECIAL TESTING MODES 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 94 TESTING 13. The 12 pin remote connector controls voltage set (10.0 to 45.0 1. Remove the input power to the Flextec 500P machine. volts) when Local / Remote switch is in the Remote position. 2. Perform the Case Cover Removal Procedure.
  • Page 95 TESTING 13. The 12 pin remote connector controls current set (10 to 500 1. Remove the input power to the Flextec 500P machine. amps) when Local / Remote switch is in the Remote position. 2. Perform the Case Cover Removal Procedure.
  • Page 96 13. The displays will show “---” “---”. ERROR LOG READING PROCEDURE 14. The weld terminal switch will be used to step through the test 1. Remove the input power to the Flextec 500P machine. steps and the error log. 2. Perform the Case Cover Removal Procedure.
  • Page 97 21. At this point, all software has been verified. PROCEDURE 22. Carefully remove the input power from the machine. 1. Remove the input power to the Flextec 500P machine. 23. Place the #8 dip switch in the OFF position. 2. Perform the Case Cover Removal Procedure.
  • Page 98 FLEXTEC™ 500P NOTES F-80...

  • Page 99: Input Rectifier Removal And Replacement Procedure

    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 100 Figure F.42 – Input rectifier lead locations – REMOVAL PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Using a 5/16” nutdriver, remove the five screws, lockwashers and washers securing the leads to the input rectifier.
  • Page 101 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE Figure F.43 – Input rectifier mounting screw locations INPUT RECTIFIER MOUNTING SCREWS (2) – TOP VIEW REPLACEMENT PROCEDURE 1. Apply a coating of Dow Corning 340 heat sink compound (Lincoln part #T12837) to the rear of the new input rectifier.
  • Page 102 FLEXTEC™ 500P NOTES F-84...

  • Page 103: Auxiliary Transformer (T1) Removal And Replacement Procedure

    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 104 LEADS H1 THRU H6 REMOVAL PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Label and disconnect leads H1, H2, H3, H4, H5 and H6 from their connection points.
  • Page 105 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER (T1) REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.45 – Auxiliary transformer (T1) secondary lead connection points X14 (X4) X15 (X5) X13 (X3) X16 (X6) D4 RECTIFIER D3 RECTIFIER Figure F.46 – Auxiliary transformer (T1) mounting screws TOP VIEW MOUNTING SCREWS (4)
  • Page 106 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR AUXILIARY TRANSFORMER (T1) REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position the new auxiliary transformer (T1) into the machine. 2. Using a phillips screwdriver, attach the four screws and washers securing the auxiliary transformer (T1) to the machine. 3.

  • Page 107: T1 Transformer Thermostat Removal And Replacement Procedure

    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 108 T1 THERMOSTAT TRANSFORMER (T1) REMOVAL PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Label and disconnect leads #229 and #230 from the T1 transformer.
  • Page 109 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR T1 TRANSFORMER THERMOSTAT REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Clean any remaining adhesive from the auxiliary transformer (T1) mating surface before installing new thermostat. 2. Apply a coating of E2614 epoxy adhesive to the mating surfaces of the thermostat and the transformer.
  • Page 110 FLEXTEC™ 500P NOTES F-92...

  • Page 111: Fan Removal And Replacement Procedure

    FAN 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 112 13. Using a 3/8” nutdriver, loosen the bolt securing the ground lug to the divider panel. See Figure F.51. See Wiring Diagram. Only 1. Remove the input power to the Flextec 500P machine. loosen the bolt enough to allow for the removal of the fan.
  • Page 113 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR FAN REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.49 – Switch board plug J26 location SWITCH BOARD Figure F.50 – Fan mounting screw locations FAN MOUNTING SCREWS (4) F-95...
  • Page 114 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR FAN REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.51 – Ground lug mounting screw location GROUND LUG MOUNTING BOLT Figure F.52 – Fan terminal and lead locations 24 23 GROUND FAN TERMINALS F-96...
  • Page 115 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR FAN REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.53 – Fan taping detail FAN TAPE REPLACEMENT PROCEDURE 13. Using a 3/8” nutdriver, attach the screw and washer securing each rear corner cap. 1. Using the tape (supplied with fan), cover the three holes on the 14.
  • Page 116 FLEXTEC® 500P NOTES F-98...

  • Page 117: Switch Board Removal And Replacement Procedure

    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 118 B204 B204 REMOVAL PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Label and disconnect plugs J23, J22, J28, J26, J21, J29, J30 and J20 from the switch board.
  • Page 119 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR SWITCH BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.55 – Switch board mounting screw locations SWITCH BOARD MOUNTING SCREWS (2) – TOP VIEW Figure F.56 – Heat sink mounting bracket screw locations MOUNTING SCREWS (2) F-101...
  • Page 120 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR SWITCH BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.57 – Heat sink mounting screw locations B209 B207 LED2 LED1 LED3 R207 LED5 R249 B201 LED4 B204 SWITCH BOARD MOUNTING BOLTS (2) REPLACEMENT PROCEDURE 1. Using a 7/16” nutdriver, attach the two bolts, lockwashers and washers securing the switch board and heat sink assembly to the mounting brace.

  • Page 121: Output Rectifier Removal And Replacement Procedure

    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 122 HEAVY POSITIVE OUTPUT LEAD REMOVAL PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Using a 7/16” nutdriver, remove the bolt and associated washers securing the X1 and X3 leads to the output rectifier.
  • Page 123 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.59 – Thermostat #2 and boost rectifier lead connection points LEAD #224 BOOST RED LEAD RECTIFIER Figure F.60 – Output rectifier mounting screw locations MOUNTING SCREWS MOUNTING SCREWS F-105...
  • Page 124 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Apply a thin coating of Penetrox heat sink compound (Lincoln part #T12837-1) to the mating surfaces of the heavy positive output lead and the output rectifier heatsink. 2.

  • Page 125: Choke Removal And Replacement Procedure

    CHOKE 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 126 HEAVY POSITIVE SCREWS (4) OUTPUT LEAD REMOVAL PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Perform the Current Transducer Removal Procedure. 5. Perform the Switch Board Removal Procedure.
  • Page 127 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR CHOKE REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position the new choke into the machine. 2. Using a 3/8” nutdriver, attach the four screws and washers securing the choke to the base assembly. 3.
  • Page 128 FLEXTEC® 500P NOTES F-110...

  • Page 129: Troubleshooting And Repair

    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 130 LED5 Power, REMOVAL PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Label and disconnect plugs J1, J2, J3 and J4 from the rear of the user interface board.
  • Page 131 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.63 – User interface mounting screw locations MOUNTING SCREWS LED4 1 2 3 4 5 6 7 8 Analog 14 pin and 12 Hot Start, Arc Control, Mode, Weld Terminals, Pin Remote Signals Output Control Pots...
  • Page 132 FLEXTEC® 500P NOTES F-114...

  • Page 133: Thermostat #2 Removal And Replacement Procedure

    THERMOSTAT #2 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.
  • Page 134 Figure F.64 – Thermostat #2 lead locations THERMOSTAT #2 REMOVAL PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Label and disconnect lead #224 and the red lead from thermostat #2.
  • Page 135 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR THERMOSTAT #2 REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.65 – Thermostat #2 mounting screw locations MOUNTING SCREWS (2) REPLACEMENT PROCEDURE 1. Clean the mating surface of output rectifier heatsink before replacing thermostat #2. 2. Apply a coating of Penetrox heat sink compound (Lincoln part #T12837-1) to the rear of thermostat #2.
  • Page 136 FLEXTEC® 500P NOTES F-118...

  • Page 137: Current Transducer Removal And Replacement Procedure

    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 138 12. Using a 1/4” nutdriver, remove the screw securing the current transducer to the LEM support. See Figure F.70. 1. Remove the input power to the Flextec 500P machine. 13. The current transducer can now be removed and replaced. 2. Perform the Case Cover Removal Procedure.

  • Page 139: Top View

    FLEXTEC® 500P TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.67 – LEM support mounting screw locations LEM SUPPORT MOUNTING SCREWS (2) TOP VIEW Figure F.68 – Front panel mounting screw locations FRONT PANEL MOUNTING SCREWS (2) FRONT CORNER CAP MOUNTING SCREWS (2) F-121...

  • Page 140: Mounting Screw

    FLEXTEC® 500P TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.69 – Lead #221 connection point LEAD #221 Figure F.70 – Current transducer mounting screw location MOUNTING SCREW CURRENT TRANSDUCER LEM SUPPORT F-122...
  • Page 141 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Using a 1/4” nutdriver, attach the screw securing the current transducer to the LEM support. Make sure the arrow on the LEM is pointing towards the front of the machine. 2.
  • Page 142 FLEXTEC® 500P NOTES F-124...

  • Page 143: Dc Bus Board Removal And Replacement Procedure

    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 144 (continued) Figure F.71 – DC bus board plugs REMOVAL PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Label and disconnect plugs J46 and J47 from the DC bus board.

  • Page 145: Mounting Nuts

    FLEXTEC® 500P TROUBLESHOOTING AND REPAIR DC BUS BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.72 – DC bus board mounting nut locations DIVIDER PANEL ASSEMBLY MOUNTING NUTS (4) MOUNTING POSTS (4) DC BUS BOARD REPLACEMENT PROCEDURE 1. Carefully position the DC bus board onto the mounting posts of the divider panel assembly.
  • Page 146 FLEXTEC® 500P NOTES F-128...

  • Page 147: D3 And D4 Rectifiers Removal And Replacement Procedure

    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 148 D4 RECTIFIER D3 RECTIFIER REMOVAL PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Label and disconnect leads X15 (X5), POS, NEG and X16 (X6) from the D3 rectifier.
  • Page 149 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR D3 AND D4 RECTIFIERS REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.74 – Rectifier mounting nut and washers locations RECTIFIER MOUNTING NUT AND WASHERS D4 RECTIFIER D3 RECTIFIER DIVIDER PANEL REPLACEMENT PROCEDURE 1. Clean the mating surface on the divider panel before installing the new rectifier.
  • Page 150 FLEXTEC® 500P NOTES F-132...

  • Page 151: Boost Relay Removal And Replacement Procedure

    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 152 (continued) Figure F.75 – Boost relay lead locations REMOVAL PROCEDURE 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure. 4. Label and disconnect leads 227, 228, AC, 40, 20 and AC from the boost relay terminals.
  • Page 153 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR BOOST RELAY REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.76 – Boost relay mounting hardware RELAY SUPPORT BRACKET MOUNTING MOUNTING SCREWS (2) NUTS (2) REPLACEMENT PROCEDURE 1. Carefully position the new boost relay onto the relay support bracket.
  • Page 154 FLEXTEC® 500P NOTES F-136...

  • Page 155: Main Transformer Removal And Replacement Procedure

    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 156 13. Carefully maneuver the main transformer out of the machine. 14. The main transformer can now be removed and replaced. 1. Remove the input power to the Flextec 500P machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Capacitor Discharge Procedure.
  • Page 157 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.78 – Boost relay lead 40 and 20 locations Figure F.79 – X1, X3 and main transformer mounting screw locations MOUNTING SCREWS (4) F-139...
  • Page 158 FLEXTEC® 500P TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.80 – Switch board brace hole location LEAD #201 LEAD #204 SWITCH BOARD BRACE HOLE REPLACEMENT PROCEDURE 10. Perform the Choke Replacement Procedure. 11. Perform the Case Cover Replacement Procedure. 1.

  • Page 159: Retest After Repair Procedure

    FLEXTEC® 500P TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR PROCEDURE Testing is required after the removal of any component that could affect the machine’s electrical characteristics or if any electrical components are repaired or replaced. IDLE WATTS VOLTAGES IDLE WATTS CONDITIONS 380 / 460 / 575 150 W FAN ON...
  • Page 160 FLEXTEC™ 500P NOTES F-142...
  • Page 161 FLEXTEC™ 500P DIAGRAMS TABLE OF CONTENTS - DIAGRAMS SECTION - Diagrams ..........................Section G Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2...
  • Page 162 FLEXTEC 500 P WIRING DIAGRAM (CODE 12246) RIGHT SIDE OF MACHINE CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF P.C. BOARD) J23 ,J26, J4, J21 ,J22 J2, J8 J29, J46 RECONNECT PANEL 4A FUSE ~380V INPUT TERMINAL BLOCK SWITCH J26-1 TO EARTH GROUND PER THE NATIONAL ELECTRIC CODE ~460V J26-2...
  • Page 163 UPDATED SCHEMATIC CLOSED WHILE ENGINEERING CONTROLLED CHANGE DETAIL: OUTPUT RECTIFIER HEATSINK ASSEMBLY BOOST WELDING IN SMAW MANUFACTURER: RELAY MODE, OPEN IN OCV AND IN ALL OTHER SWITCH BOARD Located on inside left case back MODES INPUT Schematic: G8134 RECTIFIER Located right side Main Calibration trimmer locations Two isotop (SOT-227)

  • Page 164: Bus Board

    UPDATED SCHEMATIC ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: USER INTERFACE USER INTERFACE SWITCHBOARD P.C. BOARD P.C. BOARD P.C. BOARD (DISPLAY SIDE) DIP SWITCH ARCLINK CAN COMM. FROM 5-PIN AND 12-PIN AND ALPS SIGNAL AUXILIARY THERMOSTAT PRIMARY DC INPUT (550-900 VDC) LED4 ARCLINK CAN 1 2 3 4 5 6 7 8 (209 IS POSITIVE)
  • Page 165 UPDATED SCHEMATIC ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: ERROR CODE TROUBLESHOOTING GUIDE Flextec 500/500P Error Codes User Interface not Connected to Switchboard Description CAN communication between switchboard and User Interface PCB has timed out. Possible Solution 1 Check the physical wiring and connections between User Interface PCB and switchboard. Possible Solution 2 Verify power supply to switchboard.

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