Page 1: Service Manual
RETURN TO MAIN INDEX SVM151-A September, 2002 Multi-Weld 350 Arc Converter For use with machines having Code Numbers: 10645 10736 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be in- creased by proper installation .
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.
Page 6: Table Of Contents
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN INDEX 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...P361 Series MULTI-WELD 350...
Page 7 Section A-1 - INSTALLATION SECTION - Installation...Section A Technical Specifications ...A-2 Safety Precautions ...A-3 Quick-Connect “Pig-Tails” ...A-3 Attachment and Arrangement of “Pig-Tails” ...A-3 Work Connection...A-4 Case Grounding ...A-4 Inter-Connection of Converters ...A-4 Power Source Setup ...A-6 TABLE OF CONTENTS MULTI-WELD 350 Section A-1...
Page 8: Installation
TECHNICAL SPECIFICATIONS - MULTI-WELD 350 (K1735-1) ELECTRICAL SPECIFICATIONS Output Rating @ 50°C (122°F) Input Rating @ 50°C (122°F) Max. Input Range Max. O.C.V. Output Preset Range Height 11.6 in. 295 mm Operating Temperature Range -40 to +122°F -20 to +50°C INSTALLATION Amps (DC+) 30-350...
Page 9: Safety Precautions
Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves.
Page 10: Work Connection
WARNING Be sure to follow the safety practice to use the female connector on the cable which would normally be electrically "hot" (supply lead) if disconnected when the system is energized, and the male on the normally “cold” (load lead) side. If practical, shut off power before connecting or disconnecting terminals.
Page 11 FIGURE A.2 – INTER-CONNECTING CONVERTERS FIXED PARALLEL OPERATION TO POWER SOURCE DAISY CHAIN OPERATION TO POWER SOURCE SEPARABLE PARALLEL OPERATION TO POWER SOURCE INSTALLATION ELECT. ELECT. WORK ELECT. TO ELECT. TO WORK TO WORK ELECT. TO ELECT. TO WORK PARALLEL JUMPER ELECT.
Page 12: Power Source Setup
Use CC (Constant Current) mode for maximum supply voltage. c. Set panel output control to maximum for maxi- mum current capacity. d. Activate output with the “output terminals on” switch, or jumper (2-4 on Lincoln Electric termi- nal strips). MULTI-WELD 350...
Page 13 Section B-1 - OPERATION SECTION - Operation...Section B Safety Instructions...B-2 Product Description...B-3 Recommended Equipment and Processes...B-4 Multi-System Power Source ...B-4 Distribution Box...B-4 “Pig-Tail” Leads and Connectors ...B-4 Remote Output Control Options ...B-5 CV Mode Wire Welding ...B-5 CC Mode Stick Welding and Gouging...B-5 Front Panel Controls ...B-6 Recessed Panel Controls...B-7 Paralleled Converters...B-8...
Page 14: Operation
OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS Observe additional Safety Guidelines detailed in the beginning of this manual. OPERATION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing.
Page 15: Operation
PRODUCT DESCRIPTION The Multi-Weld 350 Arc Converter (K1735-1) is part of a Multi-Weld system, ideally suited for construction site welding. It uses a single DC power source as the only input supply and provides independent, full-range The Multi-Weld 350 is a DC to DC Converter that con- verts higher voltage/lower current input power to lower voltage/higher current output power with over 90% effi- ciency.
Page 16: Recommended Equipment And Processes
60 volts, may be used. It is recommended that this power source have lower output inductance (choke) such as the Lincoln Electric DC-1000, DC-655 or DC- 600 set for maximum output in CC mode. The power source output VA capacity should be 10% greater than...
Page 17: Remote Output Control Options
REMOTE OUTPUT CONTROL OPTIONS The Multi-Weld 350 is provided with a 6-pin remote receptacle to permit use with the 25 ft.(7.6 m) K857 or 100 ft. (30.4 m) K857-1 Remote Output Control options. The remote receptacle can also be used with the LN-25 equipped with the K444-1 Remote Control option.
Page 18: Front Panel Controls
FIGURE B.2 – FRONT PANEL CONTROLS FRONT PANEL CONTROLS The numbered items of Figure B.2 match the num- bered items described below: These few instruments and controls are basic to the operation and monitoring of the Converter. They are intuitively laid out so that the panel left side is weld cur- rent related, and the right side is weld voltage related: (1) Input Power/ Mode Switch has three positions: Center is OFF, which shuts off input power to the...
Page 19: Recessed Panel Controls
Average AMPS for about 7 seconds after welding stops in CC and CV modes only. • The 5 second memory display is indicated by the display’s left-most decimal point blinking, and is interrupted if arc is restarted. Accuracy of Actual AMPS is within 3%, and typical- ly within 10 amps of Preset.
Page 20: Paralleled Converters
Disconnecting the Remote plug from this recepta- cle automatically transfers output control back to the panel Output Control (item (2) above). Remote output On/Off switching can also be done through this Remote Control receptacle by per- forming the following wiring changes: 1.
Page 21: Transporting
TRANSPORTING The Converter may be carried by one or two persons using the front and rear top and bottom handles. It can also be set vertically on a two wheel cart, or horizon- tally on a wagon, to move it longer distances. STORAGE The Multi-Weld 350 may be set on a floor, or shelf, hor- izontally on its skid, or vertically standing on its rear top...
Page 22 B-10 B-10 NOTES MULTI-WELD 350...
Page 23 Section C-1 - ACCESSORIES SECTION - Accessories ...Section C Options/Accessories ...C-2 Field Installed Options ...C-2 Semiautomatic Welding Accessories ...C-2 Connection of Lincoln Electric Wire Feeders...C-2 Connection of the LN-25 ...C-3 TABLE OF CONTENTS MULTI-WELD 350 Section C-1...
Page 24: Accessories
OPTIONS/ACCESSORIES The following options/accessories are available for your Multi-Weld 350 from your local Lincoln Distributor. FIELD INSTALLED OPTIONS K1736-1 DISTRIBUTION BOX - Makes connecting up to 10 Multi-Weld 350s quick and easy. Contains cop- per bus bar for connecting multiple “pig-tails.” Four “pig-tails”...
Page 25: Connection Of The
CONNECTION OF THE LN-25 TO THE MULTI-WELD 350 “ACROSS THE ARC” (SEE FIGURE C.1.) 1. Shut the welder off. 2. Connect the electrode cable from the LN-25 to the “+” terminal of the welder. NOTE: Welding cable must be sized for current and duty cycle of application.
Page 26 NOTES MULTI-WELD 350...
Page 27 Section D-1 - MAINTENANCE SECTION - Maintenance ...Section D Safety Precautions...D-2 Maintenance...D-2 Digital Meter Calibration...D-2 Service ...D-3 TABLE OF CONTENTS MULTI-WELD 350 Section D-1...
Page 28: Maintenance
SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. Have qualified personnel do the maintenance work. Always use the greatest care when working near mov- ing parts.
Page 29 SERVICE The Multi-Weld 350 was designed for easy service using quick-to-replace components and assembly modules that can be simply swapped out at the job site to minimize down time. More prolonged troubleshoot- ing and repair of the module may be done later on the service bench.
Page 30 NOTES MULTI-WELD 350...
Page 31 Section E-1 - THEORY OF OPERATION SECTION - General Description ...E-2 Input Power Source, Contactor and DC Buss Power Supply Board ...E-2 Power Modules and Feedback ...E-3 Analog Control Power Supply Board and Weld Control Board ...E-4 Mode Selector and Output Controls...E-5 Protection Features...E-6 Insulated Gate Bipolar Transistor (IGBT) Operation...E-7 Pulse Width Modulation ...E-8...
Page 32: General Description
POWER SUPPLY BOARD The Multi-Weld 350 receives DC input power from an 80 VDC buss Multi-Source (recommended), although other external DC sources such as the Lincoln Electric DC-1000, DC-655, or DC-600 can be used if they pro- duce 50 VDC or above.
Page 33: Power Modules And Feedback
THEORY OF OPERATION FIGURE E.3 – POWER MODULES AND FEEDBACK MULTI-WELD 350 BLOCK LOGIC DIAGRAM INPUT DIODES INPUT CONTACTOR CAPACITORS ON/OFF MODE SWITCH (1/2) POWER SOURCE (EXTERNAL) POWER SUPPLY BOARD POWER MODULES AND FEED- BACK The external DC source voltage is applied to parallel capacitors incorporated within each of the two Power (Chopper) Modules.
Page 34: Analog Control Power Supply Board And Weld Control Board
THEORY OF OPERATION FIGURE E-4 – ANALOG CONTROL POWER SUPPLY BOARD AND WELD CONTROL BOARD MULTI-WELD 350 BLOCK LOGIC DIAGRAM INPUT DIODES INPUT CONTACTOR INPUT CAPACITORS ON/OFF MODE SWITCH (1/2) POWER SOURCE (EXTERNAL) POWER SUPPLY BOARD ANALOG CONTROL POWER SUPPLY BOARD AND WELD CONTROL BOARD The Analog Control Power Supply Board, which is pow- ered by 40 VDC delivered from the DC Buss Power...
Page 35: Mode Selector And Output Controls
THEORY OF OPERATION FIGURE E.5 – MODE SELECTOR AND OUTPUT CONTROLS MULTI-WELD 350 BLOCK LOGIC DIAGRAM INPUT DIODES INPUT CONTACTOR INPUT CAPACITORS ON/OFF MODE SWITCH (1/2) POWER SOURCE (EXTERNAL) POWER SUPPLY BOARD MODE SELECTOR AND OUTPUT CONTROLS In CC mode, machine output is at open circuit voltage. The OUTPUT control presets amps in the 30 to 350 A range and then adjusts actual welding current to match the preset when welding.
Page 36: Protection Features
THEORY OF OPERATION PROTECTION FEATURES The Multi-Weld 350 design features electronic protec- tion systems to help assure reliable operation even under adverse conditions. These systems include: FAN AS NEEDED (F.A.N.) The cooling fan will turn on when the arc starts and remain on for about a minute after the arc is out to cool down the power components.
Page 37: Insulated Gate Bipolar Transistor (Igbt) Operation
THEORY OF OPERATION SOURCE DRAIN A. PASSIVE INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION An IGBT is a type of transistor. IGBTs are semicon- ductors well suited for high frequency switching and high current applications. Drawing A shows an IGBT in a passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow.
Page 38: Theory Of Operation
THEORY OF OPERATION FIGURE E.7 – TYPICAL IGBT OUTPUTS PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the cycle. Changing the pulse width is known as MODU- LATION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine.
Page 39: Chopper Technology Fundamentals
THEORY OF OPERATION CHOPPER TECHNOLOGY FUNDAMENTALS The new era of welding machines such as the Multi- Weld 350 employ a technology whereby a DC source is turned on and off (chopped up) at high speed, then smoothed through an inductor to control an arc. EXTERNAL DC SOURCE In this system, current from a DC source such as the...
Page 40 E-10 E-10 NOTES MULTI-WELD 350...
Page 41 Section F-1 - TROUBLESHOOTING & REPAIR SECTION - Troubleshooting & Repair Section...Section F How to Use Troubleshooting Guide ...F-2 PC Board Troubleshooting Procedures ...F-3 Troubleshooting Guide ...F-4 - F-12 Test Procedures ...F-13 Case Cover Assembly Removal and Replacement Procedure ...F-13 Power Module Capacitor Discharge Procedure ...F-15 Input Contactor Coil Resistance and Supply Voltage Test ...F-17 Analog Control Power Supply PC Board Test ...F-20...
Page 42: 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 43: Pc Board Troubleshooting Procedures
• 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-shielding bag. This will prevent further damage and allow prop- er failure analysis.
Page 44: Troubleshooting Guide
Selector switch is turned on. 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 1-800-833-9353. POSSIBLE AREAS OF...
Page 45 The fan operates normally. 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 1-800-833-9353. detailed in the beginning of this manual.
Page 46 Thermal light is off. 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 1-800-833-9353. POSSIBLE AREAS OF...
Page 47 The preset range is not correct. 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 1-800-833-9353.
Page 48 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 1-800-833-9353. POSSIBLE AREAS OF...
Page 49 The fan does not run when welding. 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 1-800-833-9353.
Page 50 No control of welding output. 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 1-800-833-9353. POSSIBLE AREAS OF...
Page 51 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 1-800-833-9353. detailed in the beginning of this manual.
Page 52 When stick welding the electrode “stubs”. 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 1-800-833-9353. POSSIBLE AREAS OF...
Page 53: Case Cover Assembly Removal And Replacement Procedure
AND REPLACEMENT PROCEDURE 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 54 F-14 TROUBLESHOOTING & REPAIR CASE COVER ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) CASE COVER FRONT SCREW HOLE (13) REMOVAL PROCEDURE 1. Set the CC/CV power switch to OFF. 2. Remove input power to the machine. WARNING ELECTRIC SHOCK can kill. Disconnect input power before removing the case cover and performing tests or making repairs to the machine.
Page 55: Power Module Capacitor Discharge Procedure
TROUBLESHOOTING & REPAIR POWER MODULE CAPACITOR DISCHARGE PROCEDURE 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 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 F-16 TROUBLESHOOTING & REPAIR POWER MODULE CAPACITOR DISCHARGE PROCEDURE (CONTINUED) FIGURE F.2 – POWER MODULE CAPACITOR TERMINAL DISCHARGE L T S L I N PROCEDURE 1. Set the CC/CV power switch to OFF. 2. Remove input power to the machine. WARNING ELECTRIC SHOCK can kill.
Page 57: Input Contactor Coil Resistance And Supply Voltage Test
TROUBLESHOOTING & REPAIR INPUT CONTACTOR COIL RESISTANCE AND SUPPLY VOLTAGE TEST 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 58 F-18 TROUBLESHOOTING & REPAIR INPUT CONTACTOR COIL RESISTANCE AND SUPPLY VOLTAGE TEST (CONTINUED) FIGURE F.3 – INPUT CONTACTOR DETAILS LEADS #303A #330 COIL TEST PROCEDURE 1. Set the CC/CV power switch to OFF. 2. Remove input power to the machine. WARNING ELECTRIC SHOCK can kill.
Page 59 F-19 TROUBLESHOOTING & REPAIR INPUT CONTACTOR COIL RESISTANCE AND SUPPLY VOLTAGE TEST (CONTINUED) WARNING ELECTRIC SHOCK can kill. With the input power ON, there are high volt- ages inside the machine. Do not reach into the machine or touch any internal part of the machine while power is on.
Page 60: Analog Control Power Supply Pc Board Test
TROUBLESHOOTING & REPAIR ANALOG CONTROL POWER SUPPLY PC BOARD TEST 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 61 F-21 TROUBLESHOOTING & REPAIR ANALOG CONTROL POWER SUPPLY PC BOARD TEST (CONTINUED) FIGURE F.4 – ANALOG CONTROL POWER SUPPLY PC BOARD L I N TEST PROCEDURE 1. Set the CC/CV power switch to OFF. 2. Remove input power to the machine. WARNING ELECTRIC SHOCK can kill.
Page 62 F-22 TROUBLESHOOTING & REPAIR ANALOG CONTROL POWER SUPPLY PC BOARD TEST (CONTINUED) 9. If all the voltages are correct, the Analog Control Power Supply PC Board is operat- ing properly. 10. If any of the output voltages are not correct and the input voltage is correct, the Analog Control Power Supply PC Board may be faulty.
Page 63: Dc Buss Power Supply Pc Board Test
TROUBLESHOOTING & REPAIR DC BUSS POWER SUPPLY PC BOARD TEST 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 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 F-24 TROUBLESHOOTING & REPAIR DC BUSS POWER SUPPLY PC BOARD TEST(CONTINUED) FIGURE F.5 – DC BUSS POWER SUPPLY PC BOARD L I N L T S TEST PROCEDURE 1. Set the CC/CV power switch to OFF. 2. Remove input power to the machine. WARNING ELECTRIC SHOCK can kill.
Page 65 F-25 TROUBLESHOOTING & REPAIR DC BUSS POWER SUPPLY PC BOARD TEST(CONTINUED) 8. Check the DC Buss Power Supply PC Board input and output voltages according to Table F.2. See Figure F.5 and the Wiring Diagram. 9. If all the voltages are correct, the DC Buss Power Supply PC Board is operating prop- erly.
Page 66: Chopper Pc Board Input Voltages And Resistance Tests
TROUBLESHOOTING & REPAIR CHOPPER PC BOARD INPUT VOLTAGES AND RESISTANCE TEST 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 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 67 F-27 TROUBLESHOOTING & REPAIR CHOPPER PC BOARD INPUT VOLTAGES AND RESISTANCE TEST (CONTINUED) FIGURE F.6 – POWER MODULE ASSEMBLY DETAILS CLAMP BRACKET IGBT HEAT SINK P45/45A L IN TEST PROCEDURE 1. Set the CC/CV power switch to OFF. 2. Remove input power to the machine. WARNING ELECTRIC SHOCK can kill.
Page 68 F-28 TROUBLESHOOTING & REPAIR CHOPPER PC BOARD INPUT VOLTAGES AND RESISTANCE TEST (CONTINUED) Test Procedure for the Left Side Power Module 1. Locate the Power Module Capacitor termi- nals. Using the 7/16" wrench, disconnect leads #X1, #X4, #401, #401A and the cop- per straps.
Page 69: Normal Open Circuit Voltage Waveform (Cc Mode)
F-29 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CC MODE – INPUT VOLTAGE APPLIED 75 VDC 0 volts 5µs This is the typical CC open circuit out- put voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division rep- resents 5 µs in time.
Page 70: Normal Open Circuit Voltage Waveform Cv Mode - Output Control At Maximum
F-30 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CV MODE – OUTPUT CONTROL AT MAXIMUM 0 volts 5µs This is the typical CV output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 µs in time.
Page 71 F-31 TROUBLESHOOTING & REPAIR NORMAL WELD VOLTAGE WAVEFORM MACHINE LOADED TO 350 AMPS AT 34 VOLTS – CC-STICK MODE 50µs This is the typical CC output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 50 volts and that each horizontal division represents 50µs in time.
Page 72 F-32 TROUBLESHOOTING & REPAIR NORMAL WELD VOLTAGE WAVEFORM MACHINE LOADED TO 350 AMPS AT 34 VOLTS – CV MODE 50µs This is the typical CV output voltage generated from a properly operating machine. Note that each vertical divi- sion represents 50 volts and that each horizontal division represents 50µs in time.
Page 73 F-33 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CV MODE – OUTPUT CONTROL AT MINIMUM 0 volts This is the typical CV open circuit out- put voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division rep- resents 1 millisecond in time.
Page 74: Case Front Assembly Removal And Replacement
TROUBLESHOOTING & REPAIR CASE FRONT ASSEMBLY REMOVAL AND REPLACEMENT 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 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 75 F-35 TROUBLESHOOTING & REPAIR CASE FRONT ASSEMBLY REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.7 – CASE FRONT ASSEMBLY REMOVAL PLUG ASSEMBLIES L IN L T S REMOVAL PROCEDURE 1. Set the CC/CV power switch to OFF. 2. Remove input power to the machine. WARNING ELECTRIC SHOCK can kill.
Page 76 WELD CONTROL OR PERIPHERAL PC BOARD REMOVAL AND REPLACEMENT 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 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 77 F-37 TROUBLESHOOTING & REPAIR WELD CONTROL OR PERIPHERAL PC BOARD REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.8 – CASE FRONT ASSEMBLY DETAILS REMOVAL PROCEDURE Refer to Figure F.8. 1. Set the CC/CV power switch to OFF. 2. Remove input power to the machine. WARNING ELECTRIC SHOCK can kill.
Page 78 F-38 TROUBLESHOOTING & REPAIR WELD CONTROL OR PERIPHERAL PC BOARD REMOVAL AND REPLACEMENT (CONTINUED) 7. Carefully label and remove the 12 molex plugs from the Weld Control PC board. Press and hold the keeper on each plug as you remove it. Also remove plug P31 from the Peripheral PC Board as shown in Figure F.8.
Page 79: Amps/Volts Digital Meter And Potentiometer Removal And Replacement
AMPS/VOLTS DIGITAL METER AND POTENTIOMETER REMOVAL AND REPLACEMENT 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 80 F-40 TROUBLESHOOTING & REPAIR AMPS/VOLTS DIGITAL METER AND POTENTIOMETER REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.9 – DIGITAL METER AND POTENTIOMETER DETAILS LENS BEZEL SPACER SEAL KNOB DIGITAL METER REMOVAL PROCEDURE Refer to Figure F.9. 1. Set the CC/CV power switch to OFF. 2.
Page 81 F-41 TROUBLESHOOTING & REPAIR AMPS/VOLTS DIGITAL METER AND POTENTIOMETER REMOVAL AND REPLACEMENT (CONTINUED) 7. Carefully remove the Amps or Volts Digital Meter molex plug from the Weld Control PC Board. Press and hold the keeper on the plug as you remove it. 8.
Page 82: Input Contactor Removal And Replacement
TROUBLESHOOTING & REPAIR INPUT CONTACTOR REMOVAL AND REPLACEMENT 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 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 83 F-43 TROUBLESHOOTING & REPAIR INPUT CONTACTOR REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.10 – INPUT CONTACTOR ASSEMBLY DETAILS LEADS #X1A #XBP5 INPUT CONTACTOR LEADS #303A #330 BASE BOLTS (2) REMOVAL PROCEDURE Refer to Figure F.10. 1. Set the CC/CV power switch to OFF. 2.
Page 84 F-44 TROUBLESHOOTING & REPAIR INPUT CONTACTOR REMOVAL AND REPLACEMENT (CONTINUED) 7. Using the 17 mm wrench, remove the nuts from the input contactor terminal closest to the machine front. Label the leads and note their placement: bottom nut (not removed), lead #X1A, Lead #X1, lead #BP5.
Page 85: Input Diode Removal And Replacement
TROUBLESHOOTING & REPAIR INPUT DIODE REMOVAL AND REPLACEMENT 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 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 F-46 TROUBLESHOOTING & REPAIR INPUT DIODE REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.11 – INPUT DIODE ASSEMBLY DETAILS HEAT SINK MYLAR THERMOSTAT (LEADS #306 &#307) CHOKE ATTACHMENT POINT REMOVAL PROCEDURE Refer to Figure F.11. 1. Set the CC/CV power switch to OFF. 2.
Page 87 F-47 TROUBLESHOOTING & REPAIR INPUT DIODE REMOVAL AND REPLACEMENT (CONTINUED) 10. Disconnect thermostat leads #306 and #307. 11. Carefully remove the input diode assembly. 12. Using the 1 ⁄ " wrench, loosen the appropri- ate diode and remove the diode that is to be replaced.
Page 88: Fan Motor Assembly Removal And Replacement
TROUBLESHOOTING & REPAIR FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT 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 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 89 F-49 TROUBLESHOOTING & REPAIR FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT(CONTINUED) FIGURE F.12 – FAN MOTOR ASSEMBLY DETAILS REMOVAL PROCEDURE Refer to Figure F.12. 1. Set the CC/CV power switch to OFF. 2. Remove input power to the machine. MOTOR LEADS #303A #330 MOTOR...
Page 90 F-50 TROUBLESHOOTING & REPAIR FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT(CONTINUED) 3. Perform the Input Diode Removal proce- dure. 4. Disconnect the red motor lead from leads #303 and #303A and the blue motor lead from lead #300 at their in-line connectors. Cut any necessary cable ties.
Page 91: Power Capacitor Removal And Replacement
TROUBLESHOOTING & REPAIR POWER CAPACITOR REMOVAL AND REPLACEMENT 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 92 F-52 TROUBLESHOOTING & REPAIR POWER CAPACITOR REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.13 – POWER CAPACITOR MOUNTING DETAILS CLAMP BRACKET ANALOG CONTROL SUPPLY PC BOARD (4 SCREWS) PROCEDURE Refer to Figure F.13. 1. Set the CC/CV power switch to OFF. 2. Remove input power to the machine. WARNING ELECTRIC SHOCK can kill.
Page 93 F-53 TROUBLESHOOTING & REPAIR POWER CAPACITOR REMOVAL AND REPLACEMENT (CONTINUED) 7. Using the slot head screw driver, remove the two screws and lock washers from the tunnel assembly top cover. Then remove the four screws, lock washers, and flat washers that mount the Analog Control Power Supply PC Board.
Page 94: Chopper Pc Board And Diode Module Removal And Replacement
CHOPPER PC BOARD AND DIODE MODULE REMOVAL AND REPLACEMENT 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 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 95 F-55 TROUBLESHOOTING & REPAIR CHOPPER PC BOARD REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F. 14 – CHOPPER PC BOARD AND DIODE MODULE CONNECTIONS L IN L T S REMOVAL Refer to Figure F.14. 1. Set the CC/CV power switch to OFF. 2.
Page 96 F-56 TROUBLESHOOTING & REPAIR CHOPPER PC BOARD REMOVAL AND REPLACEMENT (CONTINUED) 3. Perform the Case Cover Removal proce- dure. 4. Perform the Power Capacitor Discharge procedure. 5. Carefully turn the machine onto its side. 6. Using the 3/8" wrench, remove the four screws holding the tunnel assembly to the machine base.
Page 97 F-57 TROUBLESHOOTING & REPAIR DIODE MODULE REMOVAL AND REPLACEMENT FIGURE F.15 – DIODE MODULE MOUNTING DETAILS L T S L IN REMOVAL Refer to Figure F.15. 1. Set the CC/CV power switch to OFF. 2. Remove input power to the machine. DIODE MODULE 9/64"...
Page 98: Diode Module Removal And Replacement
F-58 TROUBLESHOOTING & REPAIR DIODE MODULE REMOVAL AND REPLACEMENT(CONTINUED) 3. Perform the Case Cover Removal proce- dure. 4. Perform the Power Capacitor Discharge procedure. 5. Carefully turn the machine onto its side. 6. Using the 3/8" wrench, remove the four screws holding the tunnel assembly to the machine base.
Page 99 F-59 TROUBLESHOOTING & REPAIR DIODE MODULE REMOVAL AND REPLACEMENT(CONTINUED) FIGURE F.16 – DIODE MODULE TIGHTENING SEQUENCE 2 TO 3 TURNS EACH SPRING WASHER PLAIN WASHER 12-18 IN-LBS. Refer to Figure F.16. 4. Place a spring washer then a flat washer over each outer mounting screw and insert them into the holes.
Page 100: Retest After Repair
F-60 TROUBLESHOOTING & REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine’s electrical characteristics. • If you repair or replace any electrical components. Input Volts 50 –...
Page 101 ELECTRICAL DIAGRAMS TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS ............SECTION G WIRING DIAGRAM .
Page 102 Enhanced Diagram ELECTRICAL DIAGRAMS WIRING DIAGRAM - MULTI-WELD 350 MULTI-WELD 350 WIRING DIAGRAM 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. MULTI-WELD 350...
Page 103 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. MULTI-WELD 350...
Page 104 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #2 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. MULTI-WELD 350...
Page 105 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #3 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. MULTI-WELD 350...
Page 106 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #4 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. MULTI-WELD 350...
Page 107 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #5 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. MULTI-WELD 350...
Page 108 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 109 ELECTRICAL DIAGRAMS SCHEMATIC - PERIPHERAL PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. MULTI-WELD 350...
Page 110 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 111 G-11 G-11 ELECTRICAL DIAGRAMS SCHEMATIC - POWER PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. MULTI-WELD 350...
Page 112 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 113 G-13 G-13 ELECTRICAL DIAGRAMS SCHEMATIC - ANALOG PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. MULTI-WELD 350...
Page 114 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 115 G-15 G-15 ELECTRICAL DIAGRAMS SCHEMATIC - BY-PASS PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. MULTI-WELD 350...
Page 116 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 117 G-17 G-17 ELECTRICAL DIAGRAMS SCHEMATIC - CHOPPER PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. MULTI-WELD 350...
Page 118 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 119 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...

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