SVM155-A View Safety Info July, 2001 TM MULTI-SOURCE For use with machines having Code Numbers: 10668 View Safety Info 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.
Return to Master TOC i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
Return to Master TOC Return to Master TOC ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 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. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
Return to Master TOC iii 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. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. 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 suivantes: 7.
v v RETURN TO MAIN MENU MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety.................................................................................................................................................i-iv Installation .............................................................................................................................Section A Operation..............................................................................................................................
Return to Master TOC Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Installation ......................................................................................................................Section A Technical Specifications .............................................................................................................A-2 Safety Precautions......................................................................................................................
Return to Master TOC Return to Section TOC A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - Multi-Source K1752-1 INPUT - THREE PHASE ONLY Standard Voltage/Frequency Input Current at Rated Output 100% Duty Cycle 380/415/50 400/60 440/50 460/60 550/50 575/60 99A 98A 79A 83A 66A 69A RATED OUTPUT Amps 533 Duty Cycle 100% Duty Cycle @ 50°C (122°F) Return to Master TOC Return to Section TOC 60 Hz-40 kW Volts at Rated Amperes 75 50 Hz-36 kW Amps 475 Volts at Rated Amperes 75.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-3 INSTALLATION Read entire Installation Section before installing the MULTI-SOURCE. SAFETY PRECAUTIONS Return to Master TOC Return to Section TOC the two holes in the base rails on the second machine with the two pins on top at the front of the bottom machine. Note: The machines must be stacked with the Case Front of each machine flush with each other. See Figure A.1. below. WARNING ELECTRIC SHOCK can kill.
Return to Master TOC Return to Section TOC A-4 A-4 INSTALLATION 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 thermal/magnetic circuit breakers. DO NOT use fuses or circuit breakers with a lower amp rating than recommended.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-5 INSTALLATION OUTPUT CONNECTIONS MULTI-SOURCE OUTPUT LIMITATIONS 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC A-6 NOTES MULTI-SOURCE A-6
Return to Master TOC Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION Operation...............................................................................................................................Section B Safety Instructions ......................................................................................................................B-2 General Description ....................................................................................................................
Return to Master TOC Return to Section TOC B-2 OPERATION Read and understand this entire section before operating your machine. SAFETY INSTRUCTIONS Return to Master TOC 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. • Keep your head out of fumes.
Return to Master TOC Return to Section TOC B-3 OPERATION 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 manual electrode capability.
Return to Master TOC Return to Section TOC B-4 B-4 OPERATION 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.
Section C-1 TABLE OF CONTENTS - ACCESSORIES Accessories...........................................................................................................................Section C Factory Installed Options/Accessories.......................................................................................C-2 Field Installed Options/Accessories ...........................................................................................
Return to Master TOC Return to Section TOC C-2 C-2 ACCESSORIES FACTORY INSTALLED OPTIONS / ACCESSORIES FIELD INSTALLED ACCESSORIES OPTIONS There are no factory installed options. 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 MultiWelds. K449 LN-25, Across the arc wire feeder. K1788-1 Roll Cage, Protect power source, facilitate moving, store cable.
D-1 TABLE OF CONTENTS -MAINTENANCEMaintenance .........................................................................................................................Section D Safety Precautions......................................................................................................................D-2 Routine and Periodic Maintenance ............................................................................................D-2 Major Component Locations .......................................
Return to Master TOC Return to Section TOC D-2 MAINTENANCE SAFETY PRECAUTIONS Perform Periodically: WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this maintenance. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment. Return to Master TOC Return to Section TOC • Do not touch electrically charged hot parts. ROUTINE AND PERIODIC MAINTENANCE Clean the inside of the machine with low pressure air stream.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC D-3 D-3 MAINTENANCE FIGURE D.1 – MAJOR COMPONENT LOCATION 1. 2. 3. 4. 5. 6. 7.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC D-4 NOTES MULTI-SOURCE D-4
Return to Master TOC Section E-1 Section E-1 TABLE OF CONTENTS -THEORY OF OPERATIONTheory of Operation Section ...............................................................................................Section E General Description ..............................................................................................................E-2 Input Voltage, Filter, Contactor and Control Transformer ....................................................
Return to Master TOC Return to Section TOC E-2 THEORY OF OPERATION FIGURE E.
Return to Master TOC Return to Section TOC E-3 FIGURE E.
Return to Master TOC Return to Section TOC E-4 FIGURE E.
Return to Master TOC Return to Section TOC E-5 TROUBLESHOOTING & REPAIR PROTECTION DEVICES AND CIRCUITS 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 thermostat, located on the front of the main transformer iron, should open.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC E-6 TROUBLESHOOTING & REPAIR FIGURE E.5 SCR OPERATION Return to Master TOC Return to Master TOC Return to Section TOC SCR OPERATION Return to Section TOC E-6 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.
Section F-1 TABLE OF CONTENTS -TROUBLESHOOTING & REPAIR SECTIONTroubleshooting & Repair Section.......................................................................................Section F How to Use Troubleshooting Guide............................................................................................F-2 PC Board Troubleshooting Procedures and Replacement.........................................................F-3 Troubleshooting Guide .........................................................
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-2 TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-3 TROUBLESHOOTING & REPAIR PC BOARD TROUBLESHOOTING PROCEDURES AND REPLACEMENT WARNING ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.
Return to Master TOC Return to Section TOC F-4 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE OUTPUT PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Contact the Lincoln Electric Service Dept. 1-800-833-9353 (WELD) Return to Master TOC RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is evident.
Return to Master TOC Return to Section TOC F-5 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE OUTPUT PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Check the welding cables for loose or faulty connections. 2. Make certain the Multi-Weld(s) are connected and operating properly. 3. Check (at the output terminals of the Multi-Source) for approximately 75-80VDC open circuit voltage. If this voltage is present, the problem is most likely external to the MultiSource machine.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-6 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE OUTPUT PROBLEMS (SYMPTOMS) F-6 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS The Multi-Source has only momentary output after the input contactor activates.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-7 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE OUTPUT PROBLEMS (SYMPTOMS) F-7 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS The amber thermal light is lit.
Return to Master TOC Return to Section TOC F-8 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTIONS PROBLEMS 1. Remove all external loading to the Multi-Source and then carefully remove the input power. 1. The ON/OFF power switch may be faulty. See the Wiring Diagram. 2. The input contactor may be stuck closed. Perform the Input Contactor Test.
Return to Master TOC Return to Section TOC F-9 TROUBLESHOOTING & REPAIR 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.
Return to Master TOC Return to Section TOC F-10 CONTROL TRANSFORMER (T2) VOLTAGE TEST FIGURE F.1. CONTROL TRANSFORMER LOCATION & LEADS Control Transformer (T2) X1 H1 H2 X3 Return to Master TOC Return to Section TOC F-10 TROUBLESHOOTING & REPAIR TEST PROCEDURE Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 1. Disconnect main AC input power to the machine. 2. Remove the Top and Right case side. 4. Locate the Control Transformer primary leads H1 & H2.
Return to Master TOC Return to Section TOC 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. NOTE: If the correct main AC input power to the Control Transformer is present, and the secondary voltages are not correct, the Control Transformer may be faulty. Replace.
F-12 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE TEST Return to Master TOC Return to Section TOC F-12 FIGURE F.2. Thermostat Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Secondary X1 X3 X2 Thermostat NOTE: If the secondary voltage is not present at terminal #X3 but is present at terminal #X2 the internal thermostat is faulty. See Figure F.2. 7. Replace any leads previously removed. 8.
Return to Master TOC Return to Section TOC F-13 TROUBLESHOOTING & REPAIR 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-14 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (Continued) FIGURE F.3. INPUT CONTACTOR CONNECTIONS 240 241 CONTACTOR COIL 1. Disconnect the main input supply power to the machine. Return to Master TOC Return to Section TOC 2. With the 3/8” nut driver, remove the case top and the left case side. 3. Locate the two leads connected to the input contactor coil, #240 and #241. See Figure F.3 for location.
Return to Master TOC Return to Section TOC F-15 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (Continued) FIGURE F.4. INPUT CONTACTOR TEST CONNECTIONS Return to Master TOC Return to Section TOC Test Points T3 W T2 V T1 U Test Points Test Points TOP VIEW Return to Master TOC Return to Section TOC TEST FOR CONTACT CONTINUITY Figure F.4. If the resistance is high, the input contactor is faulty. Replace the input contactor. 1. Disconnect the main input supply power to the machine. 2.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-16 NOTES MULTI-SOURCE F-16
Return to Master TOC Return to Section TOC F-17 TROUBLESHOOTING & REPAIR 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-18 F-18 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.5. Input Contactor, Reconnect Panel, and Primary Leads to Main Transformer Locations Reconnect Panel Assembly Input Contactor T3 W T2 V T1 U TOP VIEW Return to Master TOC Return to Section TOC INPUT CONTACTOR TEST PROCEDURE the input contactor (1CR). Diagram. See Figure F.5. 1.
TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) Return to Master TOC Return to Section TOC F-19 FIGURE F.6. Main Secondary Lead Test Points Transformer Secondary Leads Return to Master TOC Return to Section TOC Lift Bail #250 Return to Master TOC Return to Section TOC Transformer Assembly Phase Angle Winding Test Points Return to Master TOC #251 7. Test for 120 VAC between leads #250 to #251. See Figure F.6. See Wiring Diagram. a. b.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-20 NOTES MULTI-SOURCE F-20
Return to Master TOC Return to Section TOC F-21 TROUBLESHOOTING & REPAIR STATIC 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.
Return to Master TOC Return to Section TOC F-22 F-22 TROUBLESHOOTING & REPAIR STATIC SCR TEST (Continued) 1. Remove main supply power to the machine. 2. Remove the roof and case sides. 3. Lower the front control panel. 4. Remove Plug J4 from the firing board. See Figure F.7. FIGURE F.7.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-23 TROUBLESHOOTING & REPAIR STATIC SCR TEST (Continued) FIGURE F.8. Shunt and Lead Connections Leads 4. Using the 9/16” wrench, remove the two positive output leads connecting the output bridge to the shunt. See Figure F.8. This will partially electrically isolate the SCR Bridge for testing purposes. See Wiring Diagram. a. 5.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-24 TROUBLESHOOTING & REPAIR STATIC SCR TEST (Continued) FIGURE F.9. SCR HEAT SINK TEST POINTS Remove Red Paint Anode Cathode 7. Repeat previous step(s) testing SCR 2, SCR 3, SCR 4, SCR 5, and SCR 6. 9. Reconnect any secondary leads removed from the SCRs.
Return to Master TOC Return to Section TOC F-25 TROUBLESHOOTING & REPAIR 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.
Return to Master TOC Return to Section TOC F-26 F-26 TROUBLESHOOTING & REPAIR ACTIVE SCR TEST (Continued) 1. Remove main supply power to the MultiSource. 2. Remove the roof and case sides. 3. Lower the front control panel and remove Plug J4 from the Firing Board. See Figure F.10. FIGURE F.10.
Return to Master TOC Return to Section TOC F-27 TROUBLESHOOTING & REPAIR ACTIVE SCR TEST (Continued) 4. Using a 9/16” wrench, remove the two positive output leads connecting the output bridge to the shunt. See Figure F.11. This will partially electrically isolate the SCR bridge for testing purposes. See the Wiring Diagram. FIGURE F.11.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-28 TROUBLESHOOTING & REPAIR ACTIVE SCR TEST (Continued) FIGURE F.12. SCR Heat Sink Test Points Remove Red Paint Anode Cathode 5. Remove the red insulating paint from heat sink test points. See Figure F.12. NOTE: Do not disassemble the heat sinks. 6. Perform test procedure as follows. Refer to Figure F.13.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-29 ACTIVE SCR TEST (Continued) FIGURE F.13. SCR Test Setup SW1 R2 Return to Master TOC Return to Section TOC V 6 VOLT LANTERN BATTERY R1 A SCR UNDER TEST Return to Master TOC BATTERY TEST Return to Section TOC Check the battery by shorting leads (A) and (C) and then close switch SW1. Replace battery if voltage is less than 4.5 volts. A.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-30 NOTES MULTI-SOURCE F-30
Return to Master TOC Return to Section TOC F-31 TROUBLESHOOTING & REPAIR 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.
Return to Master TOC Return to Section TOC F-32 TROUBLESHOOTING & REPAIR CONTROL BOARD TEST (Continued) J2 J5 J6 J7 J1 J8 J3 J4 Control Board Return to Master TOC Return to Section TOC Firing Board FIGURE F.14. CONTROL BOARD LOCATION TEST PROCEDURE FOR NORMAL CONTROL BOARD OPERATION 1. Remove main supply power to the MultiSource. 2. Remove screws, loosen and lower the front panel to access and inspect the control board located in the right side of the control box. See Figure F.14. 3.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC 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. See Figure F.15. 11.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-34 NOTES MULTI-SOURCE F-34
Return to Master TOC Return to Section TOC F-35 TROUBLESHOOTING & REPAIR 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.
Return to Master TOC Return to Section TOC F-36 TROUBLESHOOTING & REPAIR FIRING BOARD TEST (Continued) FIGURE F.16. FIRING BOARD LOCATION J2 J5 J6 Return to Master TOC Return to Section TOC J7 J8 J3 J4 TEST PROCEDURE FOR NORMAL FIRING BOARD OPERATION Return to Master TOC 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. See Figure F.16. Return to Section TOC 3.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-37 TROUBLESHOOTING & REPAIR FIRING BOARD TEST (Continued) TABLE F.2. - LED 7, 8 and 9 Check List IF THEN LED 7 is ON AC power is being supplied to the Firing Board from leads #283 and #284 connected, through the resistor bank, to the phase angle winding in the Main Transformer. See Figure F.17.
Return to Master TOC Return to Section TOC F-38 FIRING BOARD TEST (Continued) FIGURE F.17.
Return to Master TOC Return to Section TOC F-39 TROUBLESHOOTING & REPAIR 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.
Return to Master TOC Return to Section TOC F-40 TROUBLESHOOTING & REPAIR MULTI-SOURCE METER ACCURACY CHECK (Continued) METER ACCURACY CHECK PROCEDURE TO RECALIBRATE METER IS OUT OF RANGE 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. Turn machine on. Return to Master TOC Return to Section TOC 3.
Return to Master TOC NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM - NO LOAD 0 volts 2 ms Return to Master TOC This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 2 milliseconds in time. Note: Scope probes connected at machine output terminals: (+) probe to positive terminal, (-) probe to negative terminal.
Return to Master TOC ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM ONE OUTPUT SCR NOT FUNCTIONING - NO LOAD 0 volts 2 ms Return to Master TOC Return to Master TOC Return to Section TOC 50 volts Return to Section TOC F-42 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC Return to Section TOC F-42 This is NOT the typical DC output voltage waveform. One output SCR is not functioning. Note the “gap” in the waveform.
Return to Master TOC TYPICAL SCR GATE VOLTAGE WAVEFORM - NO LOAD 0 volts 2 ms Return to Master TOC Return to Master TOC Return to Section TOC 1 volt Return to Section TOC F-43 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC Return to Section TOC F-43 This is the typical SCR gate pulse voltage waveform. The machine was in an open circuit condition (no load) and operating properly.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-44 NOTES MULTI-SOURCE F-44
Return to Master TOC Return to Section TOC F-45 TROUBLESHOOTING & REPAIR 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-46 TROUBLESHOOTING & REPAIR INPUT CONTACTOR CLEANING AND/OR REPLACEMENT (Continued) FIGURE F.19. INPUT CONTACTOR (top view) T3 W T2 V T1 U TOP VIEW 8. For contactor cleaning or inspection see Figure F.21. REMOVAL PROCEDURE 1. Disconnect input power to the machine. REPLACEMENT PROCEDURE 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-47 TROUBLESHOOTING & REPAIR INPUT CONTACTOR CLEANING AND/OR REPLACEMENT (Continued) FIGURE F.21.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-48 NOTES MULTI-SOURCE F-48
Return to Master TOC Return to Section TOC F-49 TROUBLESHOOTING & REPAIR 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.
Return to Master TOC Return to Section TOC F-50 TROUBLESHOOTING & REPAIR CONTROL BOARD REPLACEMENT PROCEDURE (Continued) FIGURE F.22. FRONT PANEL W/OUT COVER J2 J5 J6 J7 J1 J8 J3 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC J4 Control Board Firing Board REMOVAL PROCEDURE 5. Carefully remove the control board. 1. Disconnect input power to the machine. REPLACEMENT PROCEDURE 2.
Return to Master TOC Return to Section TOC F-51 TROUBLESHOOTING & REPAIR 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.
Return to Master TOC Return to Section TOC F-52 TROUBLESHOOTING & REPAIR FIRING BOARD REPLACEMENT PROCEDURE (Procedure) FIGURE F.24. FRONT PANEL W/OUT COVER J2 J5 J6 J7 J1 J8 J3 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC J4 Control Board Firing Board REMOVAL PROCEDURE REPLACEMENT PROCEDURE 1. Disconnect input power to the machine. 1. Replace the firing board. 2.
Return to Master TOC Return to Section TOC F-53 TROUBLESHOOTING & REPAIR 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-54 F-54 TROUBLESHOOTING & REPAIR SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE FIGURE F.26. Bolt and Lead Locations 9/16" Bolts #264 #301 Return to Master TOC Return to Section TOC LEFT SIDE Bridge Assembly Mount 4. Lower the control panel using a 3/8” nut driver. Return to Master TOC Return to Section TOC REMOVAL PROCEDURE 1. Disconnect input power to the machine. 2.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-55 TROUBLESHOOTING & REPAIR SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE FIGURE F.27. Bolt, Lead, and Shunt Locations Copper Leads Positive Output Leads Return to Master TOC #251 Return to Section TOC 1/2" Bolts RIGHT SIDE 6. Using a 9/16” nut driver, remove the two positive output leads connecting the output bridge to the shunt. See Figure F.27. 7.
Return to Master TOC Return to Section TOC F-56 TROUBLESHOOTING & REPAIR SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE FIGURE F.28. Mounting Bolt J2 J5 J6 Return to Master TOC Return to Section TOC J7 J1 J8 J3 J4 Control Board Firing Board Return to Master TOC Return to Section TOC Mounting Bolt 13. Clear all leads and carefully maneuver SCR bridge out of the right side of the machine.
Return to Master TOC Return to Section TOC F-57 TROUBLESHOOTING & REPAIR SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE FIGURE F.29. Individual Heatsink Removal Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Positive Buss Bar Snubber Assembly SCR Bridge Assembly Anode Heatsink Cathode Heatsink SCR Assembly Mounting Studs REMOVAL OF INDIVIDUAL SCR HEAT SINK ASSEMBLIES INSTALLATION OF INDIVIDUAL SCR HEAT SINK ASSEMBLIES 1.
Return to Master TOC Return to Section TOC 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 electrical connections on the aluminum heat sinks, including positive buss bar. 1. Carefully maneuver SCR bridge back into original position. Return to Master TOC Return to Section TOC 2.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-59 RETEST AFTER REPAIR Testing is required after the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced. NO LOAD READINGS (FAN OFF) Input Volts/Phase/Hertz Maximum Idle Amps Maximum Idle KW 380/3/50 15.0 2.0 400/3/50 20.0 2.25 415/3/50 25.0 2.5 460/3/60 6.5 2.0 500/3/50 17.0 2.0 575/3/60 6.5 2.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-60 NOTES MULTI-SOURCE F-60
TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTIONELECTRICAL DIAGRAMS . . . . . . . . . . . . WIRING DIAGRAM . . . . . . . . . . . . . . CONTROL PC BOARD SCHEMATIC . CONTROL PC BOARD ASSEMBLY . . FIRING PC BOARD SCHEMATIC . . . FIRING PC BOARD ASSEMBLY . . . . SNUBBER PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM - MULTI-SOURCE WIRING DIAGRAM INPUT SNUBBER ASSEMBLY H2 U S1 297 X1 240 T1 T1 H2 Return to Master TOC 3 POWER L2 L1 W 12 V 9 11 10 1 TO PRIMARY COILS U 6 3 203 205 5 J11 1 2 3 4 5 6 7 8 9 10 251 207 230 234 235 LED (G) (LEFT) 204 206 7 TO T2 8 9 208 260 FRONT TRANSFORMER IRON 261 TO T1 10 11 232 233 550-575V CONNECTION 12 H1 L1 W 12 11 10 V 9 8 7 U 6 5 4 TO PRIMARY COILS - WORK - 264 222C TO T1 TP1 L3 10 12 11 V 9 8 7 U 6 5
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC G-3 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.
D34 C61 R46 R47 D19 R67 R68 R79 R81 R84 R93 LED5 C25 C29 D16 D21 C24 R44 X3 R76 R83 R80 C8 C7 D25 D29 D26 D24 R73 R74 D27 C30 X13 D1 R42 C57 G3726-2 D33 R91 R92 R86 R94 C34 X5 C40 R99 C62 R100 Q3 Q5 C5 Q2 C32,C35,C36,C44,C49,C50 R38 1 S19400-10R0 RESISTOR,MF,1/4W,10.0,1% C51,C52,C53,C54,C55,C56 R40 1 S19400-6812 RESISTOR,MF,1/4W,68.1K,1% C57,C58,C59 R41,R42,R88 3 S19400-1502 RESISTOR,MF,1/4W,15.
Return to Master TOC ELECTRICAL DIAGRAMS SCHEMATIC - FIRING PRINTED CIRCUIT BOARD Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-5 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
PC BOARD ASSEMBLY-FIRING G 3742-1 ITEM PART NO. S16668-5 DESCRIPTION .022/50 C29,C34,C35,C37,C44 C2,C4,C10,C11,C21,C22 6 S13490-95 C7,C8,C18,C20,C24,C31,C33 7 S13490-108 .15/100 C17,C19 2 T11577-41 .022/400 C30 1 S13490-74 10/150 .33/50 C32 1 S13490-73 20/50 C38,C40,C42 3 T11577-58 .0047/3000V C39,C41,C43 3 T11577-46 .
Return to Master TOC 14312-1 Return to Master TOC M Return to Master TOC C7 TP7 C8 TP8 OUTPUT SNUBBER CAD Return to Master TOC Return to Section TOC POS NEG Return to Section TOC PC BOARD ASSEMBLY - SNUBBER M14312-1 Return to Section TOC G-7 ELECTRICAL DIAGRAMS GND Return to Section TOC G-7 Ch'ge. Sht. No. 2-19-93G THE LINCOLN ELECTRIC CO. SCALE DR NOTE: EQUIP. C.S. SUBJECT FULL DATE TRANSFORMER WELDERS TYPE CLEVELAND, OHIO U.S.A. 7-23-93C OUTPUT SNUBBER P.C. BD.
Return to Master TOC We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three column troubleshooting chart, please share this information with us. Please include the machine’s code number and how the problem was resolved. Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave.
