Page 1: Service Manual
INVERTEC V350-PRO For use with machine code numbers 10651, 10669 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 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. 3.b.
Page 4: Safety
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 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 How to Use Troubleshooting Guide...F-2 Troubleshooting Guide ...F-4 Test Procedures ...F-15 Replacement Procedures ...F-51 Electrical Diagrams ...Section G Parts Manual ...P-369 Series RETURN TO MAIN INDEX...
Page 7 SectionA-1 - INSTALLATION SECTION - Installation Technical Specifications ...A-2 Input Grounding Connections ...A-3 Power Cord Connection ...A-3 Single Phase Input ...A-3 Three Phase Input ...A-3 Parallel Operation ...A-3 Quick Disconnect Plugs ...A-3 TABLE OF CONTENTS V350-PRO Section A-1...
Page 8: Technical Specifications
TECHNICAL SPECIFICATIONS - INPUT AC VOLTAGE & DC OUTPUT Product Ordering Input AC Name Information Voltage Amps/Volts/Duty Cycle K1728-1 200-230 / 200-230/ Factory 380-415/ 460-480/ Invertec V350- K1728-2 3 Phase Construction 60/50 Hz 60/50 Hz 208-230/ K1728-3 415/ “CE” 460-480/ 1 Phase * Overall Length Including Handle, 27.8”...
Page 9: Installation
INSTALLATION WARNING ELECTRIC SHOCK can kill. • TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH BEFORE ATTEMPTING TO CONNECT OR DIS- CONNECT INPUT POWER LINES, OUTPUT CABLES, OR CONTROL CABLES. • Only qualified personnel should perform this installation. • Connect the green lead of the power cord to ground per U.S.
Page 10 COPPER TUBE 5. Tighten set screw to collapse copper tube. Screw must apply pressure against welding cable. The top of the set screw will be well below the surface of the brass plug after tightening. 6. Slide rubber boot over brass plug. The rubber boot must be positioned to completely cover all electrical surfaces after the plug is locked into the receptacle.
Page 11 Section B-1 - OPERATION SECTION - Operation...Section B Operating Instructions ...B-2 Product Description ...B-2 Duty Cycle ...B-2 Operational Features and Controls ...B-2 Upper Control Panel ...B-2 Amps Meter...B-2 Volt Meter ...B-2 Output Control...B-2 Weld Terminals ...B-2 Thermal...B-3 Control Remote ...B-3 Hidden Middle Control Panel ...B-3 Weld Mode Select ...B-3 CC-Stick Soft...B-3...
Page 12: Operating Instructions
OPERATING INSTRUCTIONS 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. ------------------------------------------------------------------------ FUMES AND GASES can be dangerous. •...
Page 13: Thermal
For both the Construction and Factory versions, these trigger modes can be over-ridden (switched) with the WELD TERMINALS push button. When changed, the unit will power up in the configuration it was in when it was last powered down. 5. THERMAL •...
Page 14: Tig Gtaw
• The Arc Control regulates the relative Slope of the process. Slope dynamically controls the force the arc has to penetrate an open root. At the minimum setting, Arc Control is very soft and is similar to the Stick Soft mode. At the maximum setting, the slope is reduced, the OCV is reduced, and the operator has full control off the arc force required to pene- trate an open root joint.
Page 15: Tig Mode
76 (wiper) to lead 77 would produce the current that has been set by the Invertec V350-Pro’s front panel Output Control.) • Remotes of this type offered by Lincoln Electric are the K857, K812 and K870. Voltage Control •...
Page 16: Auxiliary Power
Auxiliary Power • 115VAC, 42VAC and 24VAC power is available from the two 14-pin amphenols on the rear of the unit. (K1728-2 Construction model of the Invertec V350-Pro does not have the amphenols) These supplies are intended to supply power for auxiliary equipment like wire feeders and the TIG Module.
Page 17 - ACCESSORIES SECTION - Accessories...Section C Connection of Lincoln Electric Wire Feeders...C-2 Thru C-9 V350-PRO/LN-25 with Optional 6 Pin K441-1 Remote...C-2 V350-PRO/LN-25 with Optional 6 Pin K857 Remote ...C-3 LN-25 with K431 Remote Option...C-4 V350-PRO/LN-25 with K867 Adapter ...C-5 V350-PRO/LN-7 with K480 Control Cable ...C-6 V350-PRO/LN-7 with K867 Adapter ...C-7...
Page 18: Accessories
CONNECTION OF LINCOLN ELEC- TRIC WIRE FEEDERS CONNECTION OF THE LN-25 TO THE V350-PRO “ACROSS THE ARC” WITH OPTIONAL 6 PIN K441-1 REMOTE CON- TROL. 1. Remove input power to the V350-PRO. 2. Connect the electrode cable to the output terminal of polarity required by the electrode.
Page 19 CONNECTION OF THE LN-25 TO THE V350-PRO “ACROSS THE ARC” WITH OPTIONAL 6 PIN K857 REMOTE CON- TROL. 1. Remove input power to the V350-PRO. 2. Connect the electrode cable to the output terminal of polarity required by the electrode. Connect the work lead to the other terminal.
Page 20 CONNECTION OF THE LN-25 WITH K431 REMOTE OPTION TO THE V350-PRO. NOTE: AN LN-25 CAN ONLY BE USED WITH A FAC- TORY OR “CE” VERSION OF THE V350-PRO. 1. Remove input power to the V350-PRO. 2. Connect the electrode cable to the output terminal of polarity required by the electrode.
Page 21 CONNECTION OF THE K867 ADAPTER WITH LN-25 OPTION/V350-PRO. 1. Insulate each unused lead individually. 2. Remove 6 pin plug from K432 cable in order to connect K867 adapter. 3. Label each lead (A thru F) as they are removed from the 6 pin plug. 4.
Page 22 CONNECTION OF THE LN-7 TO THE V350- PRO USING K480 CONTROL CABLE (SEE FIGURE C.5) NOTE: AN LN-7 CAN ONLY BE USED WITH A FAC- TORY OR “CE” VERSION OF THE V350-PRO. IF YOUR LN-7 COMES EQUIPPED WITH A K291 OR K404 INPUT CABLE, REFER TO THE CONNECTION OF THE LN-7 USING K867 UNIVERSAL ADAPTER.
Page 23 CONNECTION OF THE K867 ADAPTER FOR USE WITH THE K291 OR K404 INPUT CABLES AND LN-7. 1. Insulate each unused lead individually. 2. Splice leads and insulate. Figure C.6 Connection of LN-7 to V350-PRO using K867 adapter. E L E C T R O D E C A B L E E L E C T R O D E C A B L E T O L N - 7 T O L N - 7...
Page 24 CONNECTION OF THE LN-742 TO THE V350-PRO (SEE FIGURE C.7) NOTE: AN LN-7 CAN ONLY BE USED WITH A FAC- TORY OR “CE” VERSION OF THE V350-PRO. 1. Remove input power to the V350-PRO. 2. Connect the electrode cable from the LN-742 to the “+”...
Page 25 CONNECTION OF THE LN-10 TO THE V350- PRO USING THE K1505 CONTROL CABLE. NOTE: AN LN-10 CAN ONLY BE USED WITH A FAC- TORY OR “CE” VERSION OF THE V350-PRO. 1. Remove input power to the V350-PRO. 2. Connect the K1505 control cable from the LN-10 to the Invertec 24/42VAC 14 pin amphenol con- necter on the rear of the V350-PRO.
Page 26 C-10 Cobramatic Connection Instructions A Cobramatic can only be used with a Factory or "CE" version of the V350 1. Turn the Invertec power switch "off" 2. Connect the control cable from the Cobramatic to the 24/42 VAC 14-pin wire feeder amphenol on the rear of the Invertec.
Page 27 Section D-1 Section D-1 TABLE OF CONTENTS -MAINTENANCE- Maintenance ...Section D Input Filter Capacitor Discharge Procedure ...D-2 Routine Maintenance...D-2 Periodic Maintenance ...D-3 Thermal Protection ...D-3 Major Component Locations ...D-4 V350-PRO...
Page 28: Input Filter Capacitor Discharge Procedure
WARNING Have qualified personnel do the maintenance work. Always use the greatest care when working near moving parts. Do not put your hands near the cooling blower fan. If a problem cannot be corrected by following the instructions, take the machine to the nearest Lincoln Field Service Shop.
Page 29: Overload Protection
MAINTENANCE OVERLOAD PROTECTION The machine is electrically protected from producing high output currents. Should the output current exceed 430A, an electronic protection circuit will reduce the current to approximately 100A. The machine will con- tinue to produce this low current until the protection cir- cuit is reset.
Page 30 FIGURE D.2 – MAJOR COMPONENT LOCATIONS 1. Center Panel 2. Base Assembly 3. Control Box Assembly 4. Case Back 5. Case Front 6. Case Wraparound L IN W AR MAINTENANCE V350-PRO...
Page 31 Section E-1 -THEORY OF OPERATION SECTION- Theory of Operation ...Section E General Description ...E-2 Input Line Voltage, Auxiliary Transformer and Precharge...E-2 Switch Board and Main Transformer ...E-3 Power board, Control Board, and SPI Communications...E-4 Output Rectifier and Choke ...E-5 Thermal Protection ...E-6 Protection Circuits ...E-6 Over current Protection ...E-6 Under/Over Voltage Protection ...E-6...
Page 32: Theory Of Operation
THEORY OF OPERATION FIGURE E.2 – INPUT VOLTAGE AND PRECHARGE Input Input switch Rectifier & 100A Breaker Reconnect Switch 115VAC Fan Supply Auxiliary Transformer 115VAC, 42VAC 24VAC Power Board 28VAC 40VDC 14 Pin Amphenol 6 Pin Remote Control & Trigger Amphenol GENERAL DESCRIPTION The Invertec V350-Pro is an inverter based welding...
Page 33 THEORY OF OPERATION FIGURE E.3 – SWITCH BOARD & MAIN TRANSFORMER Input Input switch Rectifier & 100A Breaker Reconnect Switch 115VAC Fan Supply Auxiliary Transformer 115VAC, 42VAC 24VAC Power Board 28VAC 40VDC 14 Pin Amphenol 6 Pin Remote Control & Trigger Amphenol SWITCH BOARD &...
Page 34: Control Board
THEORY OF OPERATION FIGURE E.4 – POWER BOARD, CONTROL BOARD AND SERIAL PERIPHERAL INTERFACE (SPI) COMMUNICATIONS Input Input switch Rectifier & 100A Breaker Reconnect Switch 115VAC Fan Supply Auxiliary Transformer 115VAC, 42VAC 24VAC Power Board 28VAC 40VDC 14 Pin Amphenol 6 Pin Remote Control &...
Page 35: Output Rectifier And Choke
THEORY OF OPERATION FIGURE E.5 – OUTPUT RECTIFIER AND CHOKE Input Input switch Rectifier & 100A Breaker Reconnect Switch 115VAC Fan Supply Auxiliary Transformer 115VAC, 42VAC 24VAC Power Board 28VAC 40VDC 14 Pin Amphenol 6 Pin Remote Control & Trigger Amphenol OUTPUT RECTIFIER AND CHOKE The output rectifier receives the AC output from the...
Page 36: Protective Circuits
THEORY OF OPERATION THERMAL PROTECTION Two normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are con- nected to the control board. One of the thermostats is located on the heat sink of the switch board and the other is located on the output choke.
Page 37 THEORY OF OPERATION INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION An IGBT is a type of transistor. IGBT are semiconduc- tors well suited for high frequency switching and high current applications. Example A in Figure E.8 shows an IGBT in passive mode.
Page 38: Pulse Width Modulation
THEORY OF OPERATION FIGURE E.9 — TYPICAL IGBT OUTPUTS. PULSE WIDTH MODULATION The term Pulse Width Modulation is used to describe how much time is devoted to conduction in the posi- tive and negative portions of the cycle. Changing the pulse width is known as modulation.
Page 39 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 Input Filter Capacitor Discharge Procedure ...F-15 Main Switch Board Test ...F-17 Input Rectifier Test ...F-21 Power Board Test...F-25 Output Diode Modules Test ...F-29...
Page 40: Troubleshooting And Repair
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 41 • 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 proper failure analysis.
Page 42: Troubleshooting Guide
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(WELD). POSSIBLE AREAS OF...
Page 43 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(WELD). detailed in the beginning of this manual.
Page 44 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(WELD). POSSIBLE AREAS OF...
Page 45 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(WELD). POSSIBLE AREAS OF...
Page 46 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(WELD). POSSIBLE AREAS OF...
Page 47 TROUBLESHOOTING & REPAIR DESCRIPTION/ FAULT CODES DEFINITION Main transformer primary over current Capacitor bank “A” (lower) is under voltage NOTE: If more than one fault message is being displayed, perform all the checks for the faults before replacing the printed circuit board CORRECTIVE SERVICE FACILITY ACTION...
Page 48 F-10 TROUBLESHOOTING & REPAIR DESCRIPTION/ FAULT CODES DEFINITION Capacitor bank "B"(upper) is under voltage. Capacitor bank "A"(lower) is over voltage. NOTE: If more than one fault message is being displayed, perform all the checks for the faults before replacing the printed circuit board CORRECTIVE SERVICE FACILITY ACTION...
Page 49 F-11 TROUBLESHOOTING & REPAIR DESCRIPTION/ FAULT CODES DEFINITION Capacitor bank "B"(lower) is over voltage. The soft start function failed. NOTE: If more than one fault message is being displayed, perform all the checks for the faults before replacing the printed circuit board CORRECTIVE ACTION Make sure the reconnect...
Page 50 F-12 TROUBLESHOOTING & REPAIR DESCRIPTION/ FAULT CODES DEFINITION Electrical "glitch" on the primary over current fault detector circuit. Capacitor banks "A" (lower) and "B"(upper) are not balanced. The machine has detected a fault in the central processing unit (CPU). NOTE: If more than one fault message is being displayed, perform all the checks for the faults before replacing the printed circuit board CORRECTIVE...
Page 51 F-13 TROUBLESHOOTING & REPAIR DESCRIPTION/ FAULT CODES DEFINITION Electrical "glitch" on the V/F signals from the main switch board to the control board. The selected weld mode “bad node” “####” does not exist in the weld table that is presently loaded in the machine.
Page 52 F-14 F-14 NOTES V350-PRO...
Page 53: Input Filter Capacitor Discharge Procedure
TROUBLESHOOTING & REPAIR INPUT FILTER 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 54 F-16 TROUBLESHOOTING & REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued) WARNING ELECTRIC SHOCK • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. •...
Page 55: Main Switch Board Test
TROUBLESHOOTING & REPAIR MAIN SWITCH 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 56 F-18 TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD TEST (continued) FIGURE F.2 MAIN SWITCH BOARD LEAD LOCATIONS TEST PROCEDURE 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver, remove the case wraparound. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section.
Page 57 F-19 TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD TEST (continued) 6. If any test fails replace the switch board. See Main Switch Board Removal and Replacement. 7. If the switch board resistance tests are OK, check connections on plugs J20, J21, J22 and all asso- ciated wiring.
Page 58 F-20 F-20 NOTES V350-PRO...
Page 59: Input Rectifier Test
F-21 TROUBLESHOOTING & REPAIR 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 60 F-22 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (CONTINUED) TEST PROCEDURE 1. Remove input power to the V350-PRO machine. 2. Using a 5/16” nut driver, remove the case wraparound cover. 3. Perform Capacitor Procedure detailed earlier in this section. 4. Locate the input rectifier and associated leads.
Page 61 F-23 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (CONTINUED) TEST POINT TERMINALS + PROBE 207A 207A 207A 9. If the input rectifier does not meet the acceptable readings outlined in Table F.2 the component may be faulty. Replace Note: Before replacing the input rectifier, check the input power switch and per- form the Main Switch Board Test.
Page 62 F-24 F-24 NOTES V350-PRO...
Page 63: Power Board Test
F-25 TROUBLESHOOTING & REPAIR 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-26 TROUBLESHOOTING & REPAIR POWER BOARD TEST (CONTINUED) TEST PROCEDURE 1. Remove input power to the V350-PRO machine. 2. Using a 5/16” nut driver, remove the case wraparound cover. 3. Perform Capacitor Procedure detailed earlier in this section. 4. Locate the power board and plugs J41, J42 and J43.
Page 65 F-27 TROUBLESHOOTING & REPAIR POWER BOARD TEST (CONTINUED) Table F.3 Power Board Voltage Checks CHECK POINT TEST LOCATION DESCRIPTION POWER PC CHECK 40VDC BOARD SUPPLY FROM CONNECTOR RECT. BRIDGE PLUG J41 TO POWER BD. POWER PC CHECK +15VDC BOARD SUPPLY FROM CONNECTOR POWER PC PLUG J42...
Page 66 F-28 F-28 NOTES V350-PRO...
Page 67: Output Diode Modules Test
TROUBLESHOOTING & REPAIR OUTPUT DIODE MODULES 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 68 F-30 TROUBLESHOOTING & REPAIR OUTPUT DIODE MODULES TEST (continued) NEGATIVE OUTPUT TERMINAL TEST PROCEDURE 1. Remove input power to the V350-PRO. 2. Locate the output terminals on the front panel of the machine. See Figure F.5. 3. Remove any output cables and load from the output terminals.
Page 69 F-31 TROUBLESHOOTING & REPAIR OUTPUT DIODE MODULES TEST (continued) 5. If 200 ohms is measured then the output diodes are not “shorted”. NOTE: There is a 200 ohm resistor across the welding output terminals. 6. If less than 200 ohms is measured, one or more diodes or the snubber board may be faulty.
Page 70 F-32 F-32 TROUBLESHOOTING & REPAIR OUTPUT DIODE MODULES TEST (continued) Figure F.7 Snubber and Output Diode Locations Output Diode Modules Snubber Board LEFT SIDE V350-PRO...
Page 71: Auxiliary Transformer Test
TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER 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 72 F-34 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST (continued) Auxiliary Transformer Secondary Lead Plugs P52 and P56 TEST PROCEDURE 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver, remove the case wraparound cover. 3. Perform the Input Capacitor Discharge Procedure detailed earlier in this section.
Page 73 F-35 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER NO.1 TEST (continued) LEAD IDENTIFICATION 31 TO 532 42 TO 541 24 TO 541 54 TO 41A 7. Carefully apply the correct input voltage to the V350-PRO and check for the correct sec- ondary voltages per table F.4. Make sure the reconnect jumper lead and switch are config- ured correctly for the input voltage being applied.
Page 74 F-36 F-36 NOTES V350-PRO...
Page 75: Current Transducer Test
TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER 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 76 F-38 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST (continued) FIGURE F.10 Metal Plate Removal & Plug J8 Location Metal Plate L IN R EM O TE O FF TEST PROCEDURE 1. Remove input power to the V350-PRO. 2. Using the 5/16” nut driver, remove the case wraparound cover.
Page 77 F-39 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST (continued) OUTPUT LOAD CURRENT 9. Check the feedback voltage from the current transducer using a resistive load bank and with the V350-PRO in mode 200. Mode 200 is a constant current test mode. This mode can be accessed from the front panel of the V350 by pressing and holding the Mode Select but- ton while turning the machine on.
Page 78 F-40 F-40 NOTES V350-PRO...
Page 79: Fan Control And Motor Test
TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR 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 80 F-42 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST (continued) TEST PROCEDURE 1. Remove the input power to the V350-PRO machine. 2. Using the 5/16” nut driver, remove the case wraparound cover. 5. Carefully apply the correct input power to the machine.
Page 81 F-43 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST (continued) 7. If the 115VAC is low or not present perform The Auxiliary Transformer Test. Also check plug J22 and associated leads for loose or faulty connections. See the Wiring Diagram. 8.
Page 82 F-44 F-44 NOTES V350-PRO...
Page 83: Spi Cable Resistance And Voltage Test
TROUBLESHOOTING AND REPAIR SPI CABLE RESISTANCE AND 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 84 F-46 TROUBLESHOOTING AND REPAIR SPI CABLE RESISTANCE AND VOLTAGE TEST (continued) TEST PROCEDURE 1. Remove the input power to the V350-PRO. 2. Using the 5/16” nut driver, remove the case wraparound cover. 3. Perform the Capacitor Discharge Procedure. 4. Using a 5/16” nut driver, remove the control box top.
Page 85: Voltage And Current Calibration Procedure
TROUBLESHOOTING AND REPAIR VOLTAGE AND CURRENT CALIBRATION 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 86 F-48 TROUBLESHOOTING AND REPAIR VOLTAGE AND CURRENT CALIBRATION PROCEDURE (continued) CALIBRATION CHECK The calibration of the V350-PRO can be checked using a resistive load bank with the V350-PRO in mode 200. Mode 200 is a constant current test mode. 1. Press and hold in the Mode Select button. 2.
Page 87 F-49 TROUBLESHOOTING AND REPAIR VOLTAGE AND CURRENT CALIBRATION PROCEDURE (continued) CURRENT CALIBRATION PROCEDURE 1. Connect the resistive load band (approxi- mately .087 ohms) and test ammeter to the welding output terminals. 2. Press and hold in the Mode Select button. 3.
Page 88 F-50 F-50 NOTES V350-PRO...
Page 89: Control Board Removal And Replacement
TROUBLESHOOTING & REPAIR CONTROL 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 90 F-52 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.16 - CONTROL BOARD LOCATION Control Board L IN PROCEDURE 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver remove the case wrap- around cover. 3.
Page 91 F-53 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.18. - METAL PLATE LOCATION 5/16" Screws Metal Plate L IN O FF CAUTION Observe static precautions detailed in PC Board Troubleshooting Procedures at the beginning of this section. 8.
Page 92 F-54 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) 11.. Beginning at the right side of the machine remove plugs J10A and J10B. Note: Be sure to label each plugs position upon removal. See Figure F.19. 12. Working your way across the top of the board from right to left, label and remove plugs #J9, #J8, #J7, #J6, and #J5.
Page 93 F-55 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) 14. Using a 3/8” nut driver remove the four mounting nuts from the four corners of the control board. See Figure F.20. 15. Remove the control board. Note: Gentle prying from behind the board using a flathead screw- driver may be required.
Page 94 F-56 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) 17. Replace the four 3/8” mounting nuts at the cor- ners of the board. 18. Replace plugs #J3, #J4, #J5, #J6, #J7, #J8, #J9, #J10B, and #J10A previously removed. 19. Using a 5/16” nut driver, replace the metal plate on the top of the machine that holds the case front assembly to the center panel.
Page 95: Display Board Removal And Replacement
TROUBLESHOOTING & REPAIR DISPLAY 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 96 F-58 TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.21 – DISPLAY BOARD LOCATION Display Board L I N PROCEDURE 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver remove the case wraparound cover. Status Board Mode Board 3.
Page 97 F-59 TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.22 – CASE FRONT SCREW LOCATION Welder Output Terminal Screws 5. Using a 5/16” nut driver remove the four screws from the top and bottom of the front of the machine.
Page 98 F-60 TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL & REPLACEMENT (continued) 10. Remove plug #J37 from the display board. 11. Remove plug #J3 originating from the control board located directly across from the display board. 12. Remove the display board. Note: Gentle prying from behind the board may be required.
Page 99: Main Switch Board Removal And Replacement
TROUBLESHOOTING & REPAIR MAIN SWITCH 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 100 F-62 TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.23 – MAIN SWITCH BOARD LEAD LOCATIONS PROCEDURE 1. Remove the input power to the V350-PRO. 2. Using a 5/16” nut driver remove the case wrap- around cover. 3.
Page 101 F-63 TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.24 – 3/16” ALLEN BOLT LOCATION 9. Using a 3/16” allen wrench remove four allen bolts and washers as shown in Figure F.24. At this point, the board is ready for removal. Carefully remove the board from the 4 nylon mounting pins.
Page 102 F-64 F-64 NOTES V350-PRO...
Page 103: Mode Board Removal And Replacement
TROUBLESHOOTING & REPAIR 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 104 F-66 TROUBLESHOOTING & REPAIR REMOVAL AND REPLACEMENT (continued) FIGURE F.26 – MODE BOARD LOCATION S TA L IN O FF PROCEDURE 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver remove the case wraparound cover. MODE BOARD Display Board Status Board Mode Board...
Page 105 F-67 TROUBLESHOOTING & REPAIR REMOVAL AND REPLACEMENT (continued) FIGURE F.27 – CASE FRONT SCREW REMOVAL Welder Output Terminal Screws 5. Using a 5/16” nut driver remove the four screws from the top and bottom of the front of the machine. See Figure F.27. 6.
Page 106 F-68 TROUBLESHOOTING & REPAIR REMOVAL AND REPLACEMENT (continued) CONTR CONTROL SELECT SELECT WELD MODE WELD MODE CC-STICK SOFT CC-STICK CRISP TIG GTAW CV-WIRE CV-FLUX CORED 9. Remove plug #J34 from the mode board. 10. Remove plug #J31 originating from the status board located directly above the mode board.
Page 107 F-69 TROUBLESHOOTING & REPAIR REMOVAL AND REPLACEMENT (continued) 18. Replace the mode board. 19. Replace the 1/4” nuts and their washers that mount the “Hot Start” and “Arc Control” knobs. 20. Using a small screwdriver replace the two knobs previously removed. Be sure to place both potentiometers in the full counter clock- wise position and position knobs for proper calibration.
Page 108 F-70 F-70 NOTES V350-PRO...
Page 109: Status Board Removal And Replacement
TROUBLESHOOTING & REPAIR STATUS 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 110 F-72 TROUBLESHOOTING & REPAIR STATUS BOARD REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver remove the case wraparound cover. FIGURE F.30 – STATUS BOARD LOCATION L I N 3. Perform Discharge Procedure detailed earlier in this section.
Page 111 F-73 TROUBLESHOOTING & REPAIR STATUS BOARD REMOVAL AND REPLACEMENT (continued) 5. Using a 5/16” nut driver remove the four screws from the top and bottom of the front of the machine. See Figure F.31. 6. Using a phillips head screwdriver remove the six screws and their washers from around the input power switch.
Page 112 F-74 TROUBLESHOOTING & REPAIR STATUS BOARD REMOVAL AND REPLACEMENT (continued) 10. Remove plug #J311 and plug #J31 from the sta- tus board. 11. Remove plug #J37 originating from the display board located directly above the status board. 12. Remove the status board. Note: Gentle prying from behind the board will be required.
Page 113: Snubber Board Removal And Replacement
TROUBLESHOOTING & REPAIR SNUBBER 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 114 F-76 TROUBLESHOOTING & REPAIR SNUBBER BOARD REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver remove the case wrap- around cover. FIGURE F.32 – SNUBBER BOARD LOCATION Snubber Board 5. Remove small lead #B1 from the board. Figure F.33.
Page 115: Power Board Removal And Replacement
TROUBLESHOOTING & REPAIR POWER 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 116 F-78 TROUBLESHOOTING & REPAIR POWER BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.34 POWER BOARD LOCATION POWER BOARD LEFT SIDE PROCEDURE 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver remove the case wrap- around cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section.
Page 117 F-79 TROUBLESHOOTING & REPAIR POWER BOARD REMOVAL AND REPLACEMENT (continued) 5. Locate the three plug connections. J41, J42 and J43. See figure F.35. 6. Carefully remove the three plugs from the power board. 7. Remove the four screws and associated washers at the corners of the board using a flathead screw- driver.
Page 118 F-80 F-80 NOTES V350-PRO...
Page 119: Input Rectifier Removal And Replacement
TROUBLESHOOTING & REPAIR INPUT RECTIFIER 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 120 F-82 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4.
Page 121 F-83 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) 9. Apply a thin coat of Penetrox A-13 heatsink com- pound to the point of contact between the input rectifier and the mounting surface. 10. Secure the new input bridge into its proper posi- tion with the two 3/16”in.
Page 122 F-84 F-84 NOTES V350-PRO...
Page 123: Output Rectifier Modules Removal And Replacement
TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER MODULES REMOVAL AND 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 124 F-86 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver remove the case wrap- around cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4.
Page 125 F-87 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (continued) 8. Under the copper plate previously removed, there is an allen bolt. Remove it using a 9/64” allen wrench. 9. Using a 7/16” socket remove the mounting bolts at the top and bottom of the modules.
Page 126 F-88 F-88 NOTES V350-PRO...
Page 127: Current Transducer Removal And Replacement
TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER 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 128 F-90 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver remove the case wrap- around cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4.
Page 129 F-91 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) 7. Label and remove the four leads connected to the two wire feeder circuit breakers. Pliers may be necessary. 8. Label and remove the two leads connecting to the CB2 circuit breaker. Pliers may be necessary. 9.
Page 130 F-92 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) 14. The back of the machine may now gently be pulled away to gain access to the current trans- ducer. Note: The rear of the machine cannot be removed completely. 15.
Page 131 F-93 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) 24. Replace the current transducer. 25. Replace the two 3/8” mounting nuts previously removed. 26. Reconnect plug #J90 to the current transducer. 27. Replace any necessary cable ties previously cut. 28.
Page 132: Retest After Repair
F-94 TROUBLESHOOTING AND REPAIR Retest a machine: If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. If you repair or replace any electrical components: Input Volts 230VAC 460VAC 575VAC...
Page 133 ELECTRICAL DIAGRAMS TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS ............SECTION G WIRING DIAGRAM .
Page 134: Electrical Diagrams
ELECTRICAL DIAGRAMS WIRING DIAGRAM - INVERTEC V350-PRO 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. V350-PRO...
Page 135 ELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE 6-2-2000A ENHANCED NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. WIRING DIAGRAM V350-PRO...
Page 136 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. V350-PRO...
Page 137 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. V350-PRO...
Page 138 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. V350-PRO...
Page 139 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. V350-PRO...
Page 140 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 141 ELECTRICAL DIAGRAMS SCHEMATIC - POWER SUPPLY PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO...
Page 142 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 143 G-11 G-11 ELECTRICAL DIAGRAMS SCHEMATIC - SWITCH PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO...
Page 144 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 145 G-13 G-13 ELECTRICAL DIAGRAMS SCHEMATIC - DISPLAY PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO...
Page 146 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 147 G-15 G-15 ELECTRICAL DIAGRAMS SCHEMATIC -STATUS PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO...
Page 148 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 149 G-17 G-17 ELECTRICAL DIAGRAMS SCHEMATIC - MODE SELECT PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO...
Page 150 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 151 G-19 G-19 ELECTRICAL DIAGRAMS SCHEMATIC - REMOTE PRINTED CIRCUIT BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO...
Page 152 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 153 G-21 G-21 ELECTRICAL DIAGRAMS SCHEMATIC-SNUBBER PRINTED CIRCUIT BOARD 6-2-2000 S24761 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO...
Page 154 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 155 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...

Lincoln Electric INVERTEC V350-PRO SVM152-A Service Manual

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