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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
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT
WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
RETURN TO MAIN MENU
MULTI-SOURCE
For use with machines having Code Numbers:
SERVICE MANUAL
• World's Leader in Welding and Cutting Products •
10668
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Copyright © 2001 Lincoln Global Inc.
SVM155-A
July, 2001
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Summary of Contents for Lincoln Electric MULTI-SOURCE SVM155-A
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Page 1: Service Manual
MULTI-SOURCE For use with machines having Code Numbers: 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 your part. -
Page 2: Safety
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. -
Page 3: Electric Shock Can Kill
ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. - Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
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Page 6: Table Of Contents
RETURN TO MAIN MENU MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety...i-iv Installation ...Section A Operation...Section B Accessories...Section C Maintenance ...Section D Theory of Operation ...Section E Troubleshooting and Repair...Section F Electrical Diagrams ...Section G Parts Manual...P-367 SERIES MULTI-SOURCE... - Page 7 Section A-1 - INSTALLATION SECTION - Installation ...Section A Technical Specifications ...A-2 Safety Precautions...A-3 Select Proper Location ...A-3 Stacking...A-3 Tilting ...A-3 Electrical Input Connections...A-3 Fuse and Wire Sizes ...A-4 Input and Grounding Connections ...A-4 Reconnect Procedure ...A-4 Output Connections...A-5 Paralleling ...A-5 Multi-Source Output Limitations...A-5 Distribution Box ...A-5 “Pig Tail”...
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Page 8: Installation
TECHNICAL SPECIFICATIONS - Multi-Source K1752-1 Standard Voltage/Frequency 380/415/50 400/60 440/50 460/60 550/50 575/60 Duty Cycle 100% Duty Cycle @ 50°C (122°F) CURRENT RANGE 0-650 A RECOMMENDED INPUT WIRE AND FUSE SIZES TYPE 75°C INPUT HERTZ INPUT VOLTAGE AMPERE RATING CONDUIT AWG(IEC-MM SIZES (122°F) Ambient... -
Page 9: Safety Precautions
Dirt, dust or any foreign mate- rial that can be drawn into the welder should be kept at a minimum. Failure to observe these precautions can result in excessive operating temperatures and nui- sance shut-downs. -
Page 10: Fuse And Wire Sizes
FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the Technical Specifications page of this manual for the machine being used. They are also called inverse time or ther- mal/magnetic circuit breakers. -
Page 11: Output Connections
OUTPUT CONNECTIONS The Multi-Source has two parallel connected output studs for positive and negative connections. Each one is rated to carry the full output current. For its maximum rated current at 100% duty cycle a minimum size of 4/0 AWG welding cable is recommended. Connection of Electrode and Work Leads to Output terminals. - Page 12 NOTES MULTI-SOURCE...
- Page 13 Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION - Operation...Section B Safety Instructions ...B-2 General Description ...B-3 Recommended Equipment/Processes ...B-3 Design Features and Advantages...B-3 Recommended Equipment/Connections ...B-4 Controls and Settings ...B-4 MULTI-SOURCE...
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Page 14: Operation
Read and understand this entire section before operating your machine. SAFETY INSTRUCTIONS ------------------------------------------------------------------------ ------------------------------------------------------------------------ ------------------------------------------------------------ Only qualified personnel should operate this equipment. See additional warning information at the front of this operators manual. ----------------------------------------------------------- OPERATION WARNING ELECTRIC SHOCK can kill. •... -
Page 15: General Description
GENERAL DESCRIPTION The Multi-Source is designed to supply power to the Multi-Weld welders. It has a wide range three phase AC input and can be operated on 50 or 60 Hz. The Multi-Source output peak voltage regulates against wide changes in output loading and input line voltage variations to supply a consistently stable voltage high enough to allow the Multi-Welds to provide good man- ual electrode capability. -
Page 16: Recommended Equipment/Connections
RECOMMENDED EQUIPMENT/CONNECTIONS The Multi-weld 350 (K1735-1) is the recommended means by which to control the MULTI-SOURCE power supply. Connections between the MULTI-SOURCE and the Multi-weld may be easily made using Twist-Mate male and female connectors and the K1736-1 Distribution box. For 1/0 Cable For 3/0 Cable The Multi-weld 350 has multi-process capability and may be used in manual and semi-automatic processes. - Page 17 Section C-1 Section C-1 TABLE OF CONTENTS - ACCESSORIES - Accessories...Section C Factory Installed Options/Accessories...C-2 Field Installed Options/Accessories ...C-2 MULTI-SOURCE...
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Page 18: Section C
FACTORY INSTALLED OPTIONS / ACCESSORIES There are no factory installed options. ACCESSORIES FIELD INSTALLED ACCESSORIES K1735-1 Multi-Weld 350, Multi-process controller. K857, K857-1 Remote control, Control multi-weld remotely (25 or 100 ft.) K1736-1 Distribution box, Connects up to 10 Multi- Welds. K449 LN-25, Across the arc wire feeder. - Page 19 TABLE OF CONTENTS -MAINTENANCE- Maintenance ...Section D Safety Precautions...D-2 Routine and Periodic Maintenance ...D-2 Major Component Locations ...D-3 MULTI-SOURCE...
- Page 20 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified should perform this mainte- nance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically charged hot parts. ROUTINE AND PERIODIC MAINTE- NANCE 1.
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Page 21: Major Component Locations
MAINTENANCE FIGURE D.1 – MAJOR COMPONENT LOCATION 1. Case Front Assembly 2. Case back Assembly 3. Fan 4. Base 5. Sides 6. Roof 7. Rectifier Assembly M AL W ER W AR NI NG MULTI-SOURCE... - Page 22 NOTES MULTI-SOURCE...
- Page 23 Section E-1 -THEORY OF OPERATION- Theory of Operation Section ...Section E General Description ...E-2 Input Voltage, Filter, Contactor and Control Transformer ...E-2 Main Transformer, Control Board, Cooling Fan Motor, Digital Meter & LED’s ...E-3 SCR Bridge, Resistor Bank, Firing Board, & Output Capacitor/Resistor ...E-4 Protection Devices &...
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Page 24: Section E
THEORY OF OPERATION FIGURE E.2 – INPUT VOLTAGE CIRCUIT SURGE NOISE FILTER INPUT CONTACTOR CONTROL TRANSFORMER THERMOSTAT SWITCH CONTROL RECTIFIER GENERAL DESCRIPTION The Multi-Source is designed to supply power to the Multi-Weld Arc Converter welders. The Multi-Source is an SCR controlled constant voltage (CV) DC power supply that can operate with a wide range of three phase input voltages. -
Page 25: Troubleshooting And Repair
TROUBLESHOOTING & REPAIR FIGURE E.3 – MAIN TRANSFORMER, CONTROL BOARD, COOLING FAN MOTOR, & LEDs SURGE NOISE FILTER INPUT CONTACTOR CONTROL TRANSFORMER THERMOSTAT SWITCH CONTROL RECTIFIER MAIN TRANSFORMER, CONTROL BOARD, COOLING FAN MOTOR, DIGITAL METER AND INDICATOR LIGHTS (LEDs) The main transformer changes the high voltage, low current input power to a lower voltage, higher current output. -
Page 26: Scr Bridge, Resistor Bank, Firing Board, & Output Capacitor/Resistor
TROUBLESHOOTING & REPAIR FIGURE E.4 – SCR BRIDGE, RESISTOR BANK, FIRING BOARD, & OUTPUT CAPACITOR/RESISTOR SURGE NOISE FILTER INPUT CONTACTOR CONTROL TRANSFORMER THERMOSTAT SWITCH CONTROL RECTIFIER SCR BRIDGE, RESISTOR BANK, FIRING BOARD, CAPACITOR/RESISTOR The neutrals of the main transformer secondary wind- ings are connected together and the six starts are con- nected to the six SCR assemblies to form a six phase output. - Page 27 TROUBLESHOOTING & REPAIR PROTECTION DEVICES AND CIR- CUITS Several thermostats protect the Multi-Source from over temperature and /or excessive loading. High transformer watts could cause the main transformer to over heat so the cooling fan is activated if a thermo- stat, located on the front of the main transformer iron, should open.
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Page 28: Scr Operation
TROUBLESHOOTING & REPAIR SCR OPERATION A silicon controlled rectifier (SCR) is a three terminal device used to control rather large currents to a load. An SCR acts very much like a switch. When a gate signal is applied to the SCR it is turned ON and there is current flow from anode to cathode. - Page 29 Section F-1 -TROUBLESHOOTING & REPAIR SECTION- Troubleshooting & Repair Section...Section F How to Use Troubleshooting Guide...F-2 PC Board Troubleshooting Procedures and Replacement...F-3 Troubleshooting Guide ...F-4 Test Procedures ...F-9 Control Transformer (T2) Test ...F-9 Input Contactor Test ...F-13 Main Transformer (T1) Voltage Test ...F-17 Static SCR Test...F-21 Active SCR Test ...F-25 Control Board Test...F-31...
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Page 30: How To Use Troubleshooting Guide
TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. -
Page 31: Pc Board Troubleshooting Procedures And Replacement
• If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete. • If you return a PC Board to The Lincoln Electric Company for credit, it must be in the static-shield- ing bag. This will prevent further damage and allow proper failure analysis. -
Page 32: Troubleshooting Guide
The white power light is ON. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353. - Page 33 36,000 watts on 50HZ. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353.
- Page 34 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353. detailed in the beginning of this manual.
- Page 35 100. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353.
- Page 36 OFF position. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1- 800-833-9353.
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Page 37: Control Transformer (T2) Test
CONTROL TRANSFORMER (T2) VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the 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 F-10 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE TEST FIGURE F.1. CONTROL TRANSFORMER LOCATION & LEADS TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Remove the Top and Right case side. 3. Locate the Control Transformer (T2) on the left side of the input box (facing the back of the machine).
- Page 39 F-11 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE TEST 6. Carefully apply primary power and test for the correct secondary voltages. See Table F.1. Primary H1 & H2 Voltage 575 VAC 460 VAC 380 VAC Approximate Secondary Resistance (X1-X3) Approximate Primary Resistance (H1-H2) X2-X3 Thermostat NOTE: If the correct main AC input power to...
- Page 40 F-12 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE TEST NOTE: If the secondary voltage is not pre- sent at terminal #X3 but is present at terminal #X2 the internal thermostat is faulty. See Figure F.2. FIGURE F.2. Thermostat Secondary Thermostat 7.
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Page 41: Input Contactor Test
INPUT CONTACTOR TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the 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 F-14 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (Continued) FIGURE F.3. INPUT CONTACTOR CONNECTIONS CONTACTOR COIL 1. Disconnect the main input supply power to the machine. 2. With the 3/8” nut driver, remove the case top and the left case side. 3.
- Page 43 F-15 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (Continued) FIGURE F.4. INPUT CONTACTOR TEST CONNECTIONS Test Points Test Points Test Points TEST FOR CONTACT CONTINUITY 1. Disconnect the main input supply power to the machine. 2. Remove the two leads connected to the input contactor coil, #240 and #241.
- Page 44 F-16 F-16 NOTES MULTI-SOURCE...
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Page 45: Main Transformer (T1) Voltage Test
MAIN TRANSFORMER (T1) VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the 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 F-18 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.5. Input Contactor, Reconnect Panel, and Primary Leads to Main Transformer Reconnect Panel Assembly Input Contactor TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Using a 3/8” nutdriver, remove roof and sides of case cover.
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Page 47: Lift Bail
F-19 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.6. Main Secondary Lead Test Points Phase Angle Winding Test Points 7. Test for 120 VAC between leads #250 to #251. See Figure F.6. See Wiring Diagram. If the 120 VAC is not present, check for loose or faulty wiring. - Page 48 F-20 F-20 NOTES MULTI-SOURCE...
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Page 49: Static Scr Test
F-21 TROUBLESHOOTING & REPAIR Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the 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 F-22 TROUBLESHOOTING & REPAIR STATIC SCR TEST 1. Remove main supply power to the machine. 2. Remove the roof and case sides. FIGURE F.7. FIRING BOARD LED & PLUG LOCATIONS FIRING BOARD (Continued) 3. Lower the front control panel. 4. Remove Plug J4 from the firing board. See Figure F.7.
- Page 51 F-23 TROUBLESHOOTING & REPAIR STATIC SCR TEST FIGURE F.8. Shunt and Lead Connections 4. Using the 9/16” wrench, remove the two positive output leads connecting the out- put bridge to the shunt. See Figure F.8. This will partially electrically isolate the SCR Bridge for testing purposes.
- Page 52 F-24 TROUBLESHOOTING & REPAIR STATIC SCR TEST FIGURE F.9. SCR HEAT SINK TEST POINTS Anode Cathode 7. Repeat previous step(s) testing SCR 2, SCR 3, SCR 4, SCR 5, and SCR 6. To further check the SCRs’ functions use an SCR tester and proceed to Active SCR Test.
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Page 53: Active Scr Test
ACTIVE SCR TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the 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 F-26 TROUBLESHOOTING & REPAIR 1. Remove main supply power to the Multi- Source. 2. Remove the roof and case sides. FIGURE F.10. FIRING BOARD LED & PLUG LOCATIONS FIRING BOARD ACTIVE SCR TEST (Continued) 3. Lower the front control panel and remove Plug J4 from the Firing Board.
- Page 55 F-27 F-27 TROUBLESHOOTING & REPAIR ACTIVE SCR TEST (Continued) 4. Using a 9/16” wrench, remove the two positive output leads connecting the out- put bridge to the shunt. See Figure F.11. This will partially electrically isolate the SCR bridge for testing purposes. See the Wiring Diagram.
- Page 56 F-28 TROUBLESHOOTING & REPAIR FIGURE F.12. SCR Heat Sink Test Points Anode Cathode 5. Remove the red insulating paint from heat sink test points. See Figure F.12. 6. Perform test procedure as follows. Refer to Figure F.13. Repeat test for all six SCRs.
- Page 57 F-29 TROUBLESHOOTING & REPAIR 6 VOLT LANTERN BATTERY To test SCRs construct the circuit outlined above. Resistor values are plus or minus ten percent. The voltmeter scale should be low, approximately 0-5 or 0-10 volts DC. 7. To test SCRs, construct the circuit outlined in Figure F.13.
- Page 58 F-30 F-30 NOTES MULTI-SOURCE...
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Page 59: Control Board Test
CONTROL BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the 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 F-32 TROUBLESHOOTING & REPAIR CONTROL BOARD TEST (Continued) Firing Board FIGURE F.14. CONTROL BOARD LOCATION TEST PROCEDURE FOR NORMAL CON- TROL BOARD OPERATION 1. Remove main supply power to the Multi- Source. 2. Remove screws, loosen and lower the front panel to access and inspect the con- trol board located in the right side of the control box.
- Page 61 F-33 TROUBLESHOOTING & REPAIR CONTROL BOARD TEST (Continued) 10. LED 6 indicates that the fan motor driver circuit has been activated and the fan motor should be running. LED 6 and the fan motor will be on for about 5 minutes after LED 4 goes off.
- Page 62 F-34 F-34 NOTES MULTI-SOURCE...
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Page 63: Firing Board Test
FIRING BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the 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 F-36 TROUBLESHOOTING & REPAIR FIRING BOARD TEST (Continued) FIGURE F.16. FIRING BOARD LOCATION Firing Board TEST PROCEDURE FOR NORMAL FIRING BOARD OPERATION 1. Disconnect main AC input power to the machine. 2. Remove screws, loosen and lower the front panel to access the firing board on the left side of control box while facing the machine.
- Page 65 F-37 TROUBLESHOOTING & REPAIR FIRING BOARD TEST (Continued) TABLE F.2. - LED 7, 8 and 9 Check List LED 7 is ON LED 7 is OFF or is DIM- MER than other LEDs LED 8 is ON LED 8 is OFF or is DIM- MER than other LEDs LED 9 is ON LED 9 is OFF or is DIM-...
- Page 66 F-38 TROUBLESHOOTING & REPAIR FIRING BOARD TEST (Continued) FIGURE F.17. FIRING BOARD PLUG & PIN LOCATIONS FIRING BOARD Jumper Plug #288 #285 #286 #283 #284 MULTI-SOURCE F-38 #231 #215 #340 #287...
- Page 67 MULTI-SOURCE METER ACCURACY CHECK WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the 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 68 F-40 TROUBLESHOOTING & REPAIR MULTI-SOURCE METER ACCURACY CHECK (Continued) METER ACCURACY CHECK 1. With power off, connect a resistive load and the meter grade shunt to the output terminals. Use either a resistive grid, multisource welders or a combination of both. 2.
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Page 69: Normal Open Circuit Voltage Waveform - No Load
F-41 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM - NO LOAD 50 volts This is the typical DC open circuit volt- age waveform generated from a properly operating machine. Note that each ver- tical division represents 50 volts and that each horizontal division represents 2 mil- liseconds in time. - Page 70 F-42 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM ONE OUTPUT SCR NOT FUNCTIONING - NO LOAD 50 volts This is NOT the typical DC output volt- age waveform. One output SCR is not functioning. Note the “gap” in the wave- form.
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Page 71: Typical Scr Gate Voltage Waveform - No Load
F-43 TROUBLESHOOTING & REPAIR TYPICAL SCR GATE VOLTAGE WAVEFORM - NO LOAD 1 volt This is the typical SCR gate pulse volt- age waveform. The machine was in an open circuit condition (no load) and operating properly. Note that each verti- cal division represents 1 volt and that each horizontal division represents 2 mil- liseconds in time. - Page 72 F-44 F-44 NOTES MULTI-SOURCE...
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Page 73: Input Contactor Cleaning And/Or Replacement
INPUT CONTACTOR CLEANING AND/OR REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the 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 F-46 TROUBLESHOOTING & REPAIR INPUT CONTACTOR CLEANING AND/OR REPLACEMENT (Continued) FIGURE F.19. INPUT CONTACTOR (top view) REMOVAL PROCEDURE 1. Disconnect input power to the machine. 2. Remove case sides and roof using a 3/8” nut driver. 3. Label leads T1, T2, T3, U, V, W and their respective terminals.
- Page 75 F-47 F-47 TROUBLESHOOTING & REPAIR INPUT CONTACTOR CLEANING AND/OR REPLACEMENT (Continued) FIGURE F.21. INPUT CONTACTOR CLEANING/INSPECTION CONTACTOR COIL MULTI-SOURCE...
- Page 76 F-48 F-48 NOTES MULTI-SOURCE...
- Page 77 CONTROL BOARD REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the 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 F-50 TROUBLESHOOTING & REPAIR CONTROL BOARD REPLACEMENT PROCEDURE (Continued) FIGURE F.22. FRONT PANEL W/OUT COVER Firing Board REMOVAL PROCEDURE 1. Disconnect input power to the machine. 2. Using a 3/8” nut driver, remove screws and lower the front control panel to access the control board on the right side of control box while facing the machine.
- Page 79 FIRING BOARD REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
- Page 80 F-52 TROUBLESHOOTING & REPAIR FIRING BOARD REPLACEMENT PROCEDURE (Procedure) FIGURE F.24. FRONT PANEL W/OUT COVER Firing Board REMOVAL PROCEDURE 1. Disconnect input power to the machine. 2. Using a 3/8” nut driver, remove screws and lower the front control panel to access the firing board on the left side of control box while facing the machine.
- Page 81 SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the 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 F-54 TROUBLESHOOTING & REPAIR SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE Bridge Assembly Mount REMOVAL PROCEDURE 1. Disconnect input power to the machine. 2. Using a 3/8” nut driver, remove the case sides and roof. 3. Locate, label, and remove leads #301 and #264 from the thermostat.
- Page 83 F-55 TROUBLESHOOTING & REPAIR SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE FIGURE F.27. Bolt, Lead, and Shunt Locations Copper Leads Positive Output Leads #251 6. Using a 9/16” nut driver, remove the two positive output leads connecting the out- put bridge to the shunt.
- Page 84 13. Clear all leads and carefully maneuver SCR bridge out of the right side of the machine. NOTE: Upon reassembly, apply a thin layer of Lincoln Electric T12837 (Dow Corning 340) heat sink compound to all bolted electrical connections on the alu- minum heat sinks.
- Page 85 F-57 TROUBLESHOOTING & REPAIR SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE FIGURE F.29. Individual Heatsink Removal Bridge Assembly REMOVAL OF INDIVIDUAL SCR HEAT SINK ASSEMBLIES 1. Using a 9/16” nut driver, remove the nuts and respective washers securing the posi- tive buss bar in position.
- Page 86 F-58 TROUBLESHOOTING & REPAIR SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE INSTALLATION OF SCR OUTPUT BRIDGE NOTE: Upon reassembly, apply a thin layer of Lincoln T12837 (Dow Corning #340) heat sink compound to all bolted elec- trical connections on the aluminum heat sinks, including positive buss bar.
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Page 87: Retest After Repair
F-59 TROUBLESHOOTING & REPAIR Testing is required after the removal of any mechanical part that could affect the machine’s elec- trical characteristics, or if any electrical components are repaired or replaced. Input Volts/Phase/Hertz 380/3/50 400/3/50 415/3/50 460/3/60 500/3/50 575/3/60 MAXIMUM OPEN CIRCUIT VOLTAGE PERFORM METER ACCURACY TEST RETEST AFTER REPAIR NO LOAD READINGS (FAN OFF) - Page 88 F-60 F-60 NOTES MULTI-SOURCE...
- Page 89 ELECTRICAL DIAGRAMS TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS ............SECTION G WIRING DIAGRAM .
- Page 90 WIRING DIAGRAM - 1 2 1 3 4 4 6 5 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. ELECTRICAL DIAGRAMS MULTI-SOURCE WIRING DIAGRAM...
- Page 91 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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Page 92: Electrical Diagrams
Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. - Page 93 ELECTRICAL DIAGRAMS SCHEMATIC - FIRING PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
- Page 94 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
- Page 95 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
- Page 96 Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99 Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309...