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TROUBLESHOOTING AND REPAIR - Red-D

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1. 1666815 100pF a 22uF 22uF 0 1uF 0 1uF 44 vVOVVZ 20V 20V ALS v Ta 14 3 15V 4700pF WP VPP emp MMBT4401 3 R20 LEZSZSNN IRES 12 ZN RP age NOISE_GND Vo ADDR1 25 0 NOISE GND ADDRZ 24 THERMAL ui R88 ADDR3 23 ADDR4 22 4 75 C25 Lea 1 MA VV X10 ADDR 21 25 BATA 10 0K ASL 259 MS Tr ADDR7 19 33 DATA2 100pF 1659 0151 ADDRE 18 5 ADDRY 8 88 7 DDR10 7 38 DATA4 NOISE m MMBT4401 VRE DDR TT 5 40 DATAS 4 H R15 MMBT4401 ADDR12 5 44 DATAT 1 7 80746AN VADDR13 34 a DATA Q5 4 6 2 3 30 DATAS 475 PWRDN INT ADDR 32 132 DATAG ABBR t 34 10 48 DANT ilc C22 Jo ADDRIS 17 39 DATATZ 10 0K LL0LAN8 DORIS DATA A R258 mE V ICSB 26 45 DATAS x V 46 27 ADDR 1 19 AVS N MMBT4401 29 AW H0 0L 9814 10 0 R199 VW 10 0K R200 MA 10 0K R180 10 0K R181 MMA 10 0K R164 NOISE_GND V MMBT4401 3
2. STT CURRENT FLO 124 tuF Y PRIMARY CURRENT SHUTDOWN 0 3 0 9A 1 gt 56 HI MMA MMA I lt 56A LO mc33074AD 100 Nears 58 LT1016 R107 15 267K VV 10 0K 6 4 MC33074AD CURRENT LIMIT 21 7 5 URRENT NODE CONTROL DISABLE TH Jour 11 FETS AS SOON AS PRIMARY CURRENT IB GREATER THAN A REFERENCE LEVEI oLnyveorsav 08 9 AAA SV 15 5 9 CURRENT TRANSDUCER C7 Ser iN R113 R112 1 00k av 300A OUTPUT 0 0222 924 VA 1 50K CURRENT TRANSDUCER INPUT VOLTAGE 4 4 gt MSELO d BAA gt V MSEL1 in X8 VAN SELEN lout 0 99 8 47 D sTuP R78 dURRENT eri 5VA 2 INTECRATOS an pl 2 ood ak K AD8403ARU10 MSELEN 2 R129 66AV8 34 15V BATBSA Va R75 HSR Ca 1 50K 9x RE CURRENT SENSE VA 1 gt X30 gt
3. NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not available from Lincoln Electric This information is pro vided for reference only 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 Improper PC board repairs could result in damage to the LINCOLN i machine V350 PRO SVM ERROR REPORTING FORM 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 col umn 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 Cleveland Ohio 44117 1199 FAX 216 481 2309 SVM Number Page Number if necessary Your Company Your Name Please give detailed description below SD287 01 99 LINCOLN P
4. G 4 CONTROL PC BOARD SCHEMATIC 2 G 5 CONTROL PC BOARD SCHEMATIC G 6 CONTROL PC BOARD SCHEMATIC 44 G 7 CONTROL PC BOARD ASSEMBLY L11088 1 POWER SUPPLY PC BOARD 5 G 8 POWER SUPPLY PC BOARD ASSEMBLY G3632 2 SWITCH PC BOARD SCHEMATIC G 9 SWITCH PC BOARD ASSEMBLY G 10 DISPLAY PC BOARD SCHEMATIC G 11 DISPLAY PC BOARD ASSEMBLY G 12 LED SELECT PC BOARD 5 G 13 LED SELECT PC BOARD 5 G 14 LED POTENTIOMETER PC BOARD SCHEMATIC G 15 LED POTENTIOMETER PC BOARD ASSEMBLY G 16 SPI REMOTE PC BOARD 5 G 17 SPI REMOTE PC BOARD ASSEMBLY G 18 SNUBBER PC BOARD 5 G 19 SNUBBER PC BOARD 5 G 20 NOTE Many PC Board Assembli
5. Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase copy of Safety Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society Box 351040 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 FOR ENGINE IDE 1 h To avoid scalding do not remove the 1 Ql 0028 radiator pressure cap when the engine is powered equipment N EE g 1 a Turn the engine off before troubleshooting and maintenance 3 work unless the maintenance work requires it to be running ca 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 9 ELECTRIC AND Rs MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 1 Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel whe
6. WELDING SPARKS 2 53 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 Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc W
7. R11 150K BOARD RELAY SIGNAL 12VDC 1 120 2 07 1 400V 111206 CONTROL 4 2 8 FROM CONTROL BOARD SOFT START KY p 1 17 3 CAPACITOR PRECHARGE 1 400V 7 SIGNAL FROM CONTROL BOARD lt 3 2 0M2 Ds V F CONVERTER 1 300VDC CAP 5 89VDC VREF A 2 40KHZ 1 0 CHANGE ON CAP 8HZ R 143 02 23 2 LAST USED C 32 0 6 CR 2 RECONNECT 206 003 CNY17 3V MER 6 L 33K 7 5w l FILTER CAPACITOR PRIMARIES TRANSFORMER 3 3K n 7 E rti Y 7
8. 5 LED CIR BET EENS Racer 5 BORD BOARDO AOC ERS 5 HALF OF LEO MLET BE ULAR LH TH MC ERCAFSULATE AROUND BOSEOF COMPONENT COAT EKTERMAL PRE UI TH ERCP ULONON RTE TU FOR ORDERS ONL EX REFERENCE E25255 17 EET PER Ex LE SHIN XE HIC EHE a TRE IF FUB CU TIR TIT CT CITS Ta DR OR d M AR AA t Ferien e enu MIENTTHYE INVERTER WELDERS os EU LED P C BOARD ASSEMBLY 1 ASE FULL 190141 NOTE Lincoln Electric assumes no responsibility for resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not available from Lincoln Electric This information is pro vided for reference only 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 Improper PC board repairs could result in damage to the LINCOLN i machine V350 PRO oe ELECTRICAL DIAGRAMS oid SCHEMATIC SPI REMOTE PRINTED CIRCUIT BOARD LINCOLN Vaso PRO cle ELECTRICAL DIAGRAMS G 18 PC BOARD ASSEMBLY SPI REMOTE 2 777 li li
9. Switch AN 7 Terminal Primar o VN ao o 1 Or B Primary Current Feedback 5 o Supply nput Relay Control Auxiliary 8 Soft Start Control 115VAC 42VAC Transformer Capacitor Feedback 2 lo Machine Control Supply 15VDC 15VDC 5VDC Power oe Board SPI Supply 15VDC 5VDC Control Board RS232 Supply 5VDC RS232 SPI Communications amp 15VDC 5VDC Supply Y Y Remote Control amp Trigger Remote Mode Display Advanced Process gt Panel 6 Pin P Amphenol 8 Output Weld Control Terminals Optional Solenoid Output Potentiometer V350 PRO LINCOLN 2 2 THEORY OF OPERATION FIGURE E 2 INPUT VOLTAGE AND PRECHARGE Main Switch Board To Control Board L Positive Input Output Input switch Rectifier Current Terminal ensor pos Negative Reconnect gt Output oo Switch ENA Terminal 2 L Sm 2 Z Sensor EE 8 sS 115VAC Fan Supply i Primary Current Feedback 9 9 E Input Relay Control mi 2 5 3 Auxiliary 5 2 115VAC 42VAC Transformer 8 Capacitor Feedback 2 D S Machine Control Supply 15VDC 15VDC ONDE Out
10. Slide the copper tube into the brass plug TRIM Insert cable into copper tube SCREW BRASS PLUG COPPER TUBE 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 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 V350 PRO LINCOLN 64 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 Connect the work lead to the other terminal Welding cable must be sized for current and duty cycle of the application 3 Attach the single lead from the LN 25 control box to the work using the spring clip on the end of the lead This is only a control lead it carries no welding current 4 Set the voltmeter switch to the electrode polarity chosen 5 Set CONTROL SELECT to REMOTE Set the MODE to the CV WIRE position 7 Set WELD TERMINALS SELECT to the ON position If you are using an LN 25 without an internal con tactor the electrode will be HOT when the V350 PRO is ene
11. 1 Insulate each unused lead individually 2 Splice leads and insulate Figure C 6 Connection of LN 7 to V350 PRO using K867 adapter ELECTRODE CABLE TO LN 7 LN 7 1 81 o 1 CONTROL 14 PIN 115VAC BOX 2 0 2 4 0 4 K867 UNIVERSAL 21 K291 OR K404 ADAPTER PLUG GND BEN INPUT CABLE INVERTEC 5 a POWER SOURCE 77 0 77 K775 OPTIONAL 2 REMOTE CONTROL V350 PRO LINCOLN C 10 C 10 ACCESSORIES 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 terminal of the welder Connect the work cable to the terminal of the welder NOTE Figure C 7 shows the electrode connected for positive polarity To change polarity shut the welder off and reverse the electrode and work cables at the output terminals NOTE Welding cable must be sized for current and duty cycle of application 3 Connect the K591 control cable to the 24 42VAC 14 pin amphenol on the back of the V350 PRO and the input cable plug on the LN 742 Set the VOLTMETER switch to or depending on the polarity chosen Set the MODE to the CV WIRE position Set CONTROL SELECT to LOCAL Place the WELD TERMINA
12. 10 0K H c32 820pF 50V TRI D 21 1 3 00 4 A SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION 1 EARTH GROUND CONNECTION 7H FRAME CONNECTION SWITCH PCB SCHEMATIC SUBJECT 1 4W UNLESS OTHERWISE SPECIFIED CHK UNLESS OTHERWISE SPECIFIED 06 22 00 MFD 072 50 UNLESS OTHERWISE SPECIFIED L11487_1C Ohms 1 00 DATE CLEVELAND OHIO U S A 01 FILENAME THE LINCOLN ELECTRIC CO CAPACITORS RESISTORS DIODES THE LINCOLN ELECTRIC CO THE LINCOLN ELECTRIC CO DEGREE WITHOUT AFFECTING THE INTERCHANGEABILITY OF amp COMPLETE BOARD THIS DIAGRAM MAY TO AGREE NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE NUMBER ON HOLES SIZES PER 2056 ON 2 PLACE DECIMALS IS 02 WITH PUBLISHED STANDARDS 3 PLACE DECIMALS IS 002 AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF ON ALL ANGLES IS THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY UNLESS OTHERWISE SPECIFIED TOLERANCE MATERIAL TOLERANCE NOTE This diagram is for refere
13. TRANSFORMER 19 Main Switch Board Board Positive Input pu Output Input switch Rectifier Terminal Sensor O Negative Reconnect gt Output gt Switch 7 Terminal 270 ac 771 Primar L greet 5 1 Primary Current Feedback 5 o MENAGER SUR Input Relay Control 2E 22 Auxiliary 8 Soft Start Control 115VAC 42VAC Transformer Capacitor Feedback 2 Machine Control Supply 15VDC 15VDC 5 Power MEL SPI Supply 15VDC 5VDC Cono Board 9 RS232 Supply 5VDC 5232 SPI Communications amp 15VDC 5VDC Supply Remote Control amp Trigger Remote Display nd Panel Panel 6 Pin Amphenol 8 Output Weld 5 Control Terminals Optional Solenoid Output Potentiometer SWITCH BOARD amp main transformer The reverse directions of current MAIN TRANSFORMER flow through the main transformer primaries and the offset timing of the IGBT switching circuits induce an There is one switch board in the Invertec V350 Pro square wave output signal at the secondary of the This board incorporates two pairs of input capacitors Main transformer The two current trans
14. ir gp CINE ee 2 EF CRINE PER d tHe HET AL ES rtp qed OP m 7 s Ful Lit PT el CO vas t DEN E T H H i PEE H 522 7 5 H EENH d WE m chinh jura 37 7568 OH EEE FEEFEERE F PEE PECE EH 40 EIL PEHH HUF kJ PR T PITE RII HERE PRI We O AER FEEF CH MEHI bii PRE FH IHH HEE kT Dg Era HF 41 AOHH HH TEJ EE BEBE NOTE This diagram is for reference only may accurate for all machines covered by this manual LINCOLN V350 PRO of ELECTRICAL DIAGRAMS SCHEMATIC DIGITAL CONTROL BOARD 1 gt YW 2 R 1 MBT4401 C15 C93 C109 ABL 100pF ALE O 1uF 0 1uF 121 135 144 DATA 42 di 19 DATAO 18 DATA 16 DATAG MMBT4401 15 R14 3 IB XH y T m r ape DATAS C18 650 le 238 1 119 110 120 X10 z G11 V10 G12 V11 G13 120 128
15. BOSE OR ACER SUE BORPO HO LOYER PAL of LED RE OFS FIRAU SS AL ARS D PER OOP h t hol MSOF PEPER Oh IPE BONPD ASE COnnE CI OP CREASEO WI b EH 1 ER CAP L FOR BN d ENCAPSULATE ATH HJRISE AL 1 ATH EQUIVALENT 85 APPR O WED EY LHCOLN ELECTRIC COMPANY 2 COATE L 1 4 130 300 a pe DHCODE BLY PER ESF TEST PER E32 6 D eO E R PF ee LEE uer reme rami MISCELLANEOUS EXTREM SPI DISPLAY PC BOARD ASSEMBLY II ROT 1112055 NOTE Lincoln Electric assumes no responsibility for resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only 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 Improper PC board repairs could result in damage to the LINCOLN i machine V350 PRO G 13 ELECTRICAL DIAGRAMS G 13 SCHEMATIC LED SELECT PRINTED CIRCUIT BOARD LINCOLN B 5 LE 2 LED HANK 2 FAITES
16. DESCRIPTION This test will help determine if the current transducer and associated wiring are functioning correctly MATERIALS NEEDED Volt ohmmeter 5 16 Nut Driver Resistive Load Bank External DC Ammeter This procedure takes approximately 45 minutes to perform V350 PRO LINCOLN F 38 F 38 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST continued FIGURE F 10 Metal Plate Removal amp Plug J8 Location Plug J8 TEST PROCEDURE 6 Check for the correct DC supply voltages to the current transducer at plug J8 See Figure 1 Remove input power to the V350 PRO 11 2 Using the 5 16 nut driver remove the case A Pin 2 lead 802 to pin 6 lead 806 wraparound cover should read 15 VDC 3 Perform the Input Capacitor Discharge B Pin 4 lead 804 to pin 6 lead 806 should read 15 VDC 4 Locate plug J8 on the control board Do not 7 jf either of the supply voltages are low or miss remove the plug from the PC Board ing the control board may be faulty 5 Apply the correct input power to the V350 PRO FIGURE F 11 Plug J8 Viewed From Lead Side of Plug 802 804 801 O O O k Plug J8 806 V350 PRO LINCOLN 39 39 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST continued TABLE F 5 EXPECTED TRANSDUCER FEEDBACK OUTPUT LOAD CURRENT VOLTAGE 8 Check the feedback voltage from the current 9 If for any reason the machine cannot be transducer using a res
17. Figure C 2 V350 PRO LN 25 ACROSS THE ARC CONNECTION DIAGRAM WITH K857 REMOTE CONTROL 6 pin Amphenol K857 Remote Control EN 25 Wire Feeder Work Clip Lead To Work Electrode Cable NOTE Illustration shows electrode connected for negative polarity V350 PRO LINCOLN C 6 C 6 ACCESSORIES 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 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 Connect the work lead to the other terminal Welding cable must be sized for current and duty cycle of the application 3 Attach the single lead from the LN 25 control box to the work using the spring clip on the end of the lead This is only a control lead it carries no welding current 4 Set the voltmeter switch to the electrode polarity chosen 5 Set CONTROL SELECT to REMOTE 10 11 Set the MODE to the CV WIRE position Set WELD TERMINALS SELECT to the position Set the ARC CONTROL to the position and then adjust to suit Connect the K432 remote control cable to the LN 25 Connect the K876 adapter to the K432 and to the 24 42VAC 14 pin amphenol located at the rear of the V350 PRO Adjust the wire feed speed and voltage at the LN 25 NOT
18. LAEL MR PSC CN Wee ee US THE SL L ee T LPR REC MIAT L THE CARTES eT HN THe ECT Cee EARTE Ces 5 Le per MAT GUM CHIEN PMA B Rum huesssemenm TYPO Ve cx qoc e V 450 LED SELECT SCHEMATIC BOARD Jose Swe E 25259 1B0 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual FILENAMEs V350 PRO en ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY LED SELECT LI KE ROUE UD KE SI LEE h PCO PER FOREL SEE BECTROMCPLE FORI MFOEMOU TOM B cu Me e cont NE omes a CATHODE T TOM LT m ANODE ROUND ENLARGED DELAL LED ORIENTATION MANUFACTURE AS 9875 1 B PART HO IDENTIFICATION CODE ENCAFSULATE 2 ERIE HCOATACCEFTABLE PTE DO MATER RL ME IMSERTITEM2 BET GEM ROS OF LEDS ITEM 2 WET GE FLLE HU LED ENC GRS ULOTE LOCI HALF OF LE EMC
19. 1 gt _ 65 X22 TMS320F240 PORESET 7 XTAL1 CLKIN XTAL2 ADCSOC IOPCO CLKOUT IOPC1 XF IOPC2 BIO IOPC3 1 1 4 2 2 5 6 Z RESERVED WDDIST SPISTE IO 10 0K R91 10 0K R94 10 0K R95 10 0K R96 10 0K R98 w ADCIN8 IO PA3 ADCIN9 10 PA2 I ADCIN10 ADCIN11 ADCIN12 ADCIN13 ADCIN14 ADCIN15 TMRCLK IOPB7 E TMDIR IOPB6 T3PWM T3CMP IOPB5 72OUTPUT ON 3 T2PWM T2CMP IOPB4 4 T1PWM T1CMP IOPB3 PWM9 CMP9 10BP2 PWM8 CMP8 IOBP1 PWM7 CMP7 IOPBO PWM6 CMP6 PWMS CMP5 PWM4 CMP4 PWM3 CMP3 PWM2 CMP2 PWM1 CMP1 E SCIRXD IO SCITXD IO SPISIMO IO 101 10 STT ON 9 CMP4 CMP2 SPISOMI IOF SOICLK IO AAA 10 0K R243 10 0 R244 10 0K R245 10 0K R246 10 0K R247 AAA 10 0K R249 10 0K R250 9 N 5SPI 155 w BAV99LT D102 BAV99LT D104 BAVS9LT D106 DE BAV99LT D107 X33 AJ B1 74 245 A2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A8 Bett GND DIRE ENABLE VCC 2 em 0 1uF 1 13 1 NY ALS LECSZSWN
20. 4 Vo NOISE_GND NOISE_GN SINGLE THREE PHASE DETACT Vb INT Ac aH THERMOSTAT ET EQUIPMENT TYPE INVERTER WELDERS 3 PLACE DECIMALS IS 00 QUAL nee raa DIGITAL CONTROL SCHEMATIC 2 __ DATEI2 15 99 3789 100 1 NOTE This diagram is for reference only It may be accurate for all machines covered by this manual V350 PRO G 5 SCHEMATIC DIGITAL CONTROL PC BOARD 2 5 R1 2 21K C1 LED1 4 7uF XZ GREEN 35V via ASL MS 1666815 R31 2 21K GREEN C9 4 7 35V NOISE_GND 910 A8L MSL 65851 063 16 MC79LOSABD 1 0 688151 J8 6 7 NOISE_GND LINCOLN B GSPI CONTROL BOARD VOLTAGE SUPPLIE era MS 0665815 WA 0 147 GROUND TIE POINT Va VGsPi 4 5 100 SL 62658151 AGE C16 63 1 5920 ELECTRICAL DIAGRA
21. Pulsed MIG is an advanced form of welding that takes the best of all the other forms of transfer while minimiz ing or eliminating their disadvantages Unlike short cir cuit pulsed MIG does not create spatter or run the risk of cold lapping The welding positions in pulsed MIG are not limited as they are with globular or spray and its wire use is definitely more efficient Unlike the spray arc process pulsing offers controlled heat input that allows better welding on thin materials lower wire feed speeds and leads to less distortion and improved overall quality and appearance This is especially important with stain less nickel and other alloys that are sensitive to heat input In GMAW P mode arc control adjusts the background current and frequency of the wave When arc control goes up the frequency increases thus increasing the droplet transfer EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL lt x lt FREQUENCY SPRAY TRANSITION CURRENT V350 PRO LINCOLN 13 13 OPERATION PULSE ON PULSE GMAW PP Pulse on Pulse is a Lincoln process specifically designed for use in welding relatively thin less than 1 4 thick aluminum See the table below It gives weld beads with very consistent uniform ripple In Pulse on Pulse modes two distinct pulse types are used instead of the single pulse type normally used in GMAW P A number of high energy pul
22. arc and will minimize electrode sticking TIG GTAW The TIG mode features continuous control from 5 to 425 amps The TIG mode can be run in either the TIG touch start or high frequency optional equip ment required assisted start mode The Hot Start control selects the starting mode desired A setting of less than 5 the TIG lift start mode is selected The OCV is controlled below 10v and the short circuit TIG touch current is main tained at 25 amps independent of the preset current When the tungsten is lifted an arc is initiated and the output is regulated at the preset value Hot start settings between 0 and 5 regulate the arc initiation current A setting of 5 results in the most positive arc initiation A setting of 0 reduces hot start Hot Start settings between 5 and 10 select high fre quency assisted starting TIG mode In this range the OCV of the machine is controlled between 50 and 70 volts If using the Lincoln K930 1 TIG Module set the Hot start to 10 for maximum OCV The Arc Control is not used in the TIG mode TIG SOLENOID OPTION The Solenoid only operates when the V350 is in the TIG mode If the Weld Terminals are in Remote then the solenoid will open when the arc start switch is closed The solenoid will close after the arc switch has been opened and the post flow time expired If the Weld Terminals are turned ON then the sole noid will open when the electrode is touched to the work The ele
23. 48 u lusec 50 sec MINIMUM OUTPUT 24usec 2usec 94 sec 50 u sec MAXIMUM OUTPUT 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 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 MINIMUM OUTPUT By controlling the duration of the gate signal the IGBT is turned on and off for different durations during the cycle The top drawing in Figure E 7 shows the mini mum output signal possible over a 50 microsecond time period The positive portion of the signal represents one IGBT group conducting for one microsecond The negative portion is the other IGBT group The dwell time off time is 48 microseconds both IGBT groups off Since only two microseconds of the 50 microsecond time period is devoted to conducting the output power is minimized MAXIMUM OUTPUT By holding the gate signal on for 24 microseconds each and allowing only two microseconds of dwell time off time during the 50 microsecond cycle the output is maximized The darkened area under the top curve can be compared to the area under the bottom curve The more dark area that is under the
24. 8 Machine Control Supply 15VDC 15VDC 5VDC Power v Board Supply 15VDC 5VDC Control Board gt RS232 Supply 5VDC RS232 SPI Communications T amp 15VDC 5VDC Supply Y Remote Control amp Trigger Remote Display us Board Not ee Panel is in place Panel 6Pin E Amphenol 8 Output Weld O Control Terminals Optional Solenoid Output Potentiometer OUTPUT RECTIFIER AND CHOKE The output rectifier receives the AC output from the main transformer secondary and rectifies it to a DC voltage level Since the output choke is in series with the negative leg of the output rectifier and also in series with the welding load a filtered DC output is applied to the machine s output terminals NOTE Unshaded areas of Block Logic Diagram are the subject of discussion V350 PRO LINCOLN 6 6 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 Excessive tem peratures may be caused by a lack of cooling air or operating the machine beyond its duty cycle or output rating If excessive operating temperatures should occur the thermostats will prevent output from the machine The yellow thermal light located on the front of the m
25. NodE weld mode select push button to select the first weld mode Only the top weld mode indicator LED should be on all others should be off Press the weld mode select push button again to select NodE the second weld mode Only the second weld mode indicator LED should be on all others should be off Press the weld mode select push button again to select NodE the third weld mode Only the third weld mode indicator LED should be on all others should be off cator LED should be on all others should be off Press the weld mode select push button again to select NodE the fifth weld mode Only the bottom weld mode indica tor LED should be on all others should be off Press the weld mode select push button again and veri NodE fy that all weld mode indicator LEDs are off The test will automatically advance to step 25 V350 PRO LINCOLN A M Press the weld mode select push button again to select NodE the fourth weld mode Only the fourth weld mode indi 93 93 TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR Steps RedHead Acton Lft display Rt display NOTE If an Advanced Process Panel is not installed in the machine skip steps 13 24 Turn the Advanced Process Panel left encoder clockwise LEnc 100 until the value displayed on the Advanced Process Panel lower left display equals 100 Note that this should require exactly one revolution of the encoder knob Turn the Advanced Process Panel left encode
26. PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call
27. REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The V350 Pro does not have weld ing output The displays are lit Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Make sure the reconnect switch is configured correctly for the input voltage applied 2 Make sure the Weld Terminals Select is ON If the problem is solved the remote control device or associated circuitry may be faulty See the wiring diagram 3 Put the Control Select in the Local position If the problem is solved the remote control device or associated circuitry may be faulty 4 an error code is displayed see Fault Code Explanations RECOMMENDED COURSE OF ACTION 1 Check the reconnect switch and associated leads for loose or faulty connections See the wiring diagram 2 Perform the Main Switch Board Test Perform the 4 Perform the Module Test The control board may be faulty The input filter capacitors may be faulty Check and replace if necessary The remote board may be faulty The V350 Pro will not produce full output 1 The input voltage may be too low limiting the output capabili ty of the machine Make cer tain the input voltage is correct for the machine and the recon nect switch and jumper lead configuration 2 The welding current may be too high The machine will fold back to 100 amps if the weld
28. SPI Communications amp 15VDC 5VDC Supply Remote Control amp Trigger Mode Advanced bus K Panel ps Process ETES dii Panel 6 Pin E E Amphenol 8 Output Weld Control Terminals Optional Solenoid Output Potentiometer POWER BOARD CONTROL BOARD AND SERIAL PERIPHERAL INTER FACE SPI COMMUNICATIONS POWER BOARD 28VAC auxiliary is rectified and filtered and applied to the power board The power board utilizing a switching power supply processes the 40VDC input and develops several regulated positive and negative DC supplies Three DC supplies are fed to the control board for machine control supplies Two positive DC voltages are coupled to the control board for the Serial Peripheral Communications SPI supplies A 5VDC is used for the RS232 connection supply An over or under input voltage detection and shutdown circuit is also part of the power board s circuitry The optional 12VDC gas solenoid is powered by the remote board CONTROL BOARD The control board performs the primary interfacing functions to establish and maintain output control of the V350 machine The control board sends and receives command signals from the mode or advanced process panel the display panel and the remote panel These communications are processed through a digi tal network called a Serial Peripheral Interface SPI This network digitally communicates
29. ae C130 22pF MMA 475 UNS PROPRIETARY INFORMATION MANUFACTURING TOLERANCE PER E205 MANUFACTURING TOLERANCE PER E2056 SNe Chg Sheet No xM5626 6 2 2000 ON 2 PLACE DECIMALS IS 02 ON PLACE DECIMALS IS 002 ON ALL ANGLES IS 5 OF DEGREE MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS PDONOTSCALE TIS DRAWING NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual D BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO U S A EQUIPMENT TYPE 2 s oe __ SCALE NONE INVERTER WELDERS DIGITAL CONTROL SCHEMATIC DATE 12 15 99 DRAWNGN G 3789 100 4 V350 PRO ELECTRICAL DIAGRAMS as SCHEMATIC POWER SUPPLY PRINTED CIRCUIT BOARD Nate COOP Supply NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual G 9 ELECTRICAL DIAGRAMS G 9 SCHEMATIC SWITCH PRINTED CIRCUIT BOARD C27 ois OCI4 022 1A Ji 30V 400V 1 6 q 277 7774 01 400V T T 29 Plane V FROM J22 J22 2 J22 C25 1 FAN CONTROL POSITVE INPUT RECTIFIER 209 3
30. 023 13 2 FILTER CAPACITOR Q zi 7 2215 5 gt PWM DRIVE 16 12 5 700 bd RECONNECT 203 202 9 4 R133 33K 5W 33K SW C16 50V 5W t ON R101 10 0 R106 2 10 0 _ us Ts 4700pF 50V R97 10 0 R99 10 0 FILTER CAPACITOR Le R130 9 R132 SW 1W PRIMARIES FILTER APACITOR NOTE 202 203 206 amp 207 BOLT WITH FILTER CAPS NEGATIVE 207 INPUT RECTIFIER R63 100K 150pFzi 100V GENERAL INFORMATION ELECTRICAL SYMBOLS PER 1537 022 33074A 33074A X2 08 11 11 400V V F CONVERTER 2 291 5 0 gt 5 89VDC AT VREF B 1 000KHZ 1VDC CHANGE ON CAP 847 R40 e
31. DSP DSP 012 125 DSP D11 AD DATATI N AD DATA10 AD DATA8 N AD DATA 44 AD DATAS AD DATA4 AD DATA3 AD DATA2 5V R104 Es 10 0 164 00 199 98 97 196 195 194 168 ADDR7 167 05 204 173 171 169 70 17 78 179 NC173 10172 10171 GND170 10169 10168 10167 10166 CCLK SGCK4 DOUT DIN 10152 10151 10150 10149 10148 10147 10146 10145 NC144 GND143 10142 10141 NC140 10139 10138 10137 10136 10135 10134 10133 10132 GND131 VCC130 10129 10128 10127 10126 10125 10124 10123 10122 NC121 10120 10119 GND118 10117 GND1 DON R173 10 0K MISO MO SCK SPI CS2 SPI CS3 DSP MP DSP DS DSP READY Vb BD ID 03 AD DATA13 AD DATA12 4 APT DSP 4 DSP A DSP A6 DSP A7 DSP BIO DSP A13 DSP 14 DSP A15 FUNCEN 88 102 103 21041 31150 HOLD PE sox3 qwP 5 GND SI AT25128 FPGA BAD SPIMOSI FPGA DONE 1 0 1uF C138 O 1uF C139 0 1uF C114 0 1uF C84 DSP DO DSP 01 1 DSP 02 SP 03 12 DSP D4 15 83 DSP
32. Driver Flathead Screwdriver Phillips Head Screwdriver This procedure takes approximately 30 minutes to perform V350 PRO LINCOLN 56 TROUBLESHOOTING 8 REPAIR DISPLAY BOARD REMOVAL amp REPLACEMENT continued FIGURE F 20 DISPLAY BOARD LOCATION Display NC Mode Board or Advanced Process Board PROCEDURE 3 Perform the Input Filter Capacitor 1 Remove input power to the V350 PRO Discharge Procedure detailed earlier in this section 2 Using a 5 16 nut driver remove the case wraparound cover 4 Locate the display board behind the front panel of the machine See Figure F 20 V350 PRO LINCOLN 57 57 TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL amp REPLACEMENT continued FIGURE F 21 CASE FRONT SCREW LOCATION Amps voLTs CONTROL WELD TERMINALS LOCAL es OUTPUT ON SELECT SELECT L Pia KR ADJUST ATTRIBUTE Flathead Screws Phillips Head Screws 5 16 Screws 5 Using a 5 16 nut driver remove the two 8 The front of the machine may now gently be screws from the bottom of the front of the pulled forward to gain access to the display machine See Figure F 21 Board Note The front of the machine canno
33. ESOC THC AMAL F L eee PERTE TJ i MAREM COTE TE NUT IHN THE FEET ERTE lt TOHRU THE CMR ORT FILEWAME 1 hue quee rs iu SUBJECT LED PUT SCHEMATIC femm ae 525258 NOTE This diagram is for reference only It may not accurate for all machines covered by this manual LINCOLN B V350 PRO 4216 ELECTRICAL DIAGRAMS G 16 PC BOARD ASSEMBLY LED POTENTIOMETER acus mto FROME RAKES ECM D DOLI D NNI PANEL SEE ELECTROMICFILE FCRI ee ADD TONAL INFORMA TOH SOA THOUEEF Ep een i POR LEEDS gt Rm ECS MIC P CEE REEFETANC 0 HUE MANUFACTURE 5 19 74 41 2 PART IDENTIFICATION CODE ENCAFPSULATE LJ THE R44 2 COAT EFTAB LE M DO ROT COMTI ENG AL HB THERE WIET BE MORE THON BET
34. Electrical Code all local codes and the information detailed below When received directly from the factory multiple volt age machines are internally connected for 460VAC If 460VAC is the desired input then the machine may be connected to the power system without any setup required inside the machine Initial 200VAC 415VAC and 575VAC operation will require an Input voltage panel setup Open the access panel on the rear of the machine For 200 or 230 Position the large switch to 200 230 For higher voltages Position the large switch to 380 575 Move the A lead to the appropriate terminal POWER CORD CONNECTION A 10 ft power cord is provided and wired into the machine Follow the power cord connection instruc tions CAUTION Incorrect connection may result in equipment damage RED WHITE OR BROWN Single Phase Input Connect green lead to ground per National Electrical Code Connect black and white leads to power Wrap red lead with tape to provide 600V insulation Three Phase Input Connect green lead to ground per National Electric Code Connect black red and white leads to power CONNECTIONS OF WIRE FEEDERS TO V350 PRO LN 25 Connection Instructions Factory Construction amp Advanced Process versions can be connected Not recommended for Pulse Welding with the Advanced Process Model Turn the Invertec power switch off Connectthe electrode cable to the output termi
35. MOV S for damage TP1 TP2 TP3 Replace if nec essary Figure F 3 Input Rectifier Small Lead H1 3 16 ALLEN BOLTS 207 207 209 Small Lead a FRONT To Circuit Breaker HEAR V350 PRO LINCOLN 23 23 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST CONTINUED Table F2 Input Rectifier Test Points TEST POINT TERMINALS ANALOG METER X10 RANGE PROBE PROBE Acceptable Meter Readings Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms A B C A B C A B C Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms 9 If the input rectifier does not meet the 11 If the input rectifier is faulty see the acceptable readings outlined in Table F 2 Input Rectifier Bridge Removal amp the component may be faulty Replace Replacement procedure Note Before replacing the input rectifier 12 Replace the case wraparound cover check the input power switch and per form the Main Switch Board Test Also check for leaky or faulty filter capacitors 10 If the input rectifier is good be sure to reconnect leads 207 207A and 209 to the correct terminals and torque to 31 inch Ibs Apply si
36. PRO LINCOLN 94 94 TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR E Expected Results Required Acti Verify that the Advanced Process Panel upper right dis play contains the following pattern and that the bright ness of the characters is uniform 0123456789ABCDEF Press and release the Advanced Process Panel Memory button to advance to the next step Verify that the Advanced Process Panel lower right dis dISP play contains the following pattern and that the bright ness of the characters is uniform 0123456789ABCDEF Press and release the Advanced Process Panel Memory button to advance to the next step The weld terminals ON and REMOTE LEDs should 5045 on both be off Press the weld terminals push button to select weld terminals studs ON and verify that the weld terminals ON LED turns on Press the weld terminals push button again to select SudS weld terminals REMOTE and verify that the weld ter minals ON LED turns off and that the weld terminals REMOTE LED turns on 27 Press the weld terminals push button again and verify that both of the weld terminals LEDs are off The LOCAL and REMOTE workpoint source LEDs NM should both be off Press the workpoint source push button to select LOCAL and verify that the workpoint source LOCAL LED turns on and that the HEMOTE workpoint source LED remains off Press the wor
37. Pinch Min min pinch softest arc Max max pinch crispest arc ADVANCED PULSE PANEL WELDING PROGRAMS 60 425 amps The gouging mode is a low power version of other Lincoln welding GMAW Power 1 18 No Units equipment gouging programs for example a PowerWave 455 Refer to the detailed explanation at the end of this section This mode does not allow preset voltage In the short arc GMAW mode the set KW will not equal the actual Volts Amps The set power is regulated only when an arc is present During shorting the output is allowed to increase to clear the short V350 PRO LINCOLN OPERATION PULSE PROGRAMS Range COMMENTS 030 Steel 65 1200 The V350 pulse programs are non synergic and allow independent 035 Steel 55 800 control of the wire feed speed at the wire feeder and the arc 045 Steel 50 700 length The Output Control Knob on the V350 adjusts an SPD 052 Steel 75 550 value Similar to trim the SPD value indicates the relative arc 045 Metal Core 50 650 length setting The SPD value displayed on the V350 may not 052 Metal Core 50 500 match the actual wire feed speed The value of SPD is meant 030 Stainless Ar Blends 85 770 to be a point at which to set the arc length relative to the wire feed 030 Stainless He Ar CO2 110 770 speed and should be set the same as actual speed for a starting 035 Stainless Ar Blends 65 770 point Depending on the application the
38. V350 PRO LINCOLN D 4 Section 1 Section 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION Theory of Operation Section E General Descriptio 2 Input Line Voltage Auxiliary Transformer and E 2 Switch Board and Main Transformer iii E 3 Power board Control Board and SPI Communications sisi E 4 Output Rectifier and E 5 Thermal Protection iussi eere cre or pede rete ku ne Le E 6 Protection ioci LER ECRIRE KE EE CARERE E 6 Over current Protectiori eiae ocior ceni ee ier xen ERE E 6 Under Over Voltage Protection sisi E 6 Insulated Gate Bipolar Transistor IGBT Operation issus E 7 Pulse Width Modulation cortina Eme sex un er EE E 8 Minimum Maximum 8 FIGURE E 1 V350 PRO BLOCK LOGIC DIAGRAM 3 Control Main Switch Board Board o L N 7 ad Positive Input pu Output Input switch Rectifier Cen Terminal Sensor Z V O Negative Reconnect Output
39. arc at low procedure settings which are needed to weld thin metal without pop outs or burning through For Aluminum welding it provides excellent control and the ability to maintain constant arc length This results in improved welding performance in two primary types of applications Short Arc MIG at low procedure settings Aluminum MIG welding Power Mode is a method of high speed regulation of the output power whenever an arc is established It provides a fast response to changes in the arc The higher the Power Mode Setting the longer the arc If a welding procedure is not established the best way to determine the Power Mode Setting is by experimenta tion until the desired output result is established In the Power Mode variables need to be set Wire Feed Speed Output Arc Control Setting up a Power Mode procedure is similar to set ting a CV MIG procedure Select a shielding gas appropriate for a short arc process e For steel use 75 25 Ar CO2 shield gas For Stainless select a Helium blend Tri Mix For Aluminum use 100 Ar Start by setting the wire feed speed based upon mate rial thickness and appropriate travel speed Then adjust the Output knob as follows For steel listen for the traditional frying egg sound of a good short arc MIG procedure to know you have the process set correctly For aluminum simply adjust the Output knob until the desired arc length is obtained Note the Vo
40. augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR contre les chutes dans le cas ou on recoit un choc Ne jamais LES MACHINES SOUDER enrouler le c ble lectrode autour de n importe quelle partie du TRANSFORMATEU R ET 2 Dans le cas de travail au dessus du niveau du sol se prot ger corps REDRESSEUR Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter
41. button till the digital window reads Save to MEM M2 Press the Memory button again and the New Welding process is saved in M2 Adjust the output control to the correct wire feed set ting and the V350 PRO is ready to weld again Note The wire feed speed setting is not stored in memory and will need to be reset Adjust the Arc Control and note that the M1 goes away indicating that the V350 PRO settings no longer match what is stored in memory Going back to the original settings will not bring the M1 back You will need to push the Memory button to recall the original settings in M1 Note After all memory s M1 thru M8 are used and the welder needs to store another welding process a new welding process will overwrite what was originally in the memory and will read Save to MEM M1 Overwrite M1 which stored Pulse Mig is Overwritten with the new welding process LN 10 DH 10 Wire Feeder Compatibility Note The LN 10 and DH 10 feeders can be used to pulse weld and in the power mode with the panel The dis plays on the LN 10 amp DH 10 do not show the wire feed speed or power 8 HOT START and ARC CONTROL features have different functions depending on the welding Mode that is active Each feature is described under the welding mode heading See Item 7 or 7 A for specified Mode Operations See Figure 1 2 V350 PRO LINCOLN 7 WELD MODE DETAILS Stick Soft Stick Crisp GTAW Tig
42. check the plug connections to the SPI network PC boards If the connections are OK and the resistance is high or open the SPI cable may be faulty 10 11 12 13 14 15 16 17 Reconnect the plug into the control board and perform the Display Board Replacement With plug J3 still removed from the control board carefully apply the correct input power to V350 PRO Turn on the machine Carefully check for the presence of 15VDC from plug J3 pin 1 to plug J3 pin 10 at the control board receptacle See Figure F 15 Carefully check for the presence of 5VDC from plug J3 pin 2 to plug J3 pin 10 at the control board receptacle See Figure F 15 If either of these voltages are low or not pre sent the control board may be faulty Replace Also Perform the Power Board Test Remove the input power to the V350 PRO machine Replace plug J3 into the control board Replace any cable ties previously removed Replace the case wrap around cover FIGURE F 15 Plug J3 Pin 1 Pin 2 10 V350 PRO LINCOLN 47 47 TROUBLESHOOTING AND REPAIR VOLTAGE AND CURRENT CALIBRATION 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 saf
43. damage to equipment 4 Locate the main switch board and all associat ed plug and lead connections See figure F 22 See Wiring Diagram V350 PRO Using a 5 16 and 3 8 nut driver remove the input lead shield from the area at the bottom of the main switch board Using a 7 16 socket remove leads 201 202 203 204 205 206 207 208 209 from the switch board Note lead terminal locations and washer positions upon removal Locate and disconnect the three harness plugs associated with the main switch board Plugs J20 J21 J22 See Figure F 22 Locate the eight capacitor terminals and remove the nuts using a 7 16 socket or nut driver Note the position of the washers behind each nut for replacement LINCOLN 61 10 11 12 TROUBLESHOOTING amp REPAIR MAIN SWITCH BOARD REMOVAL amp REPLACEMENT continued FIGURE F 23 3 16 ALLEN BOLT LOCATION Using a 3 16 allen wrench remove four allen bolts and washers as shown in Figure 23 At this point the board is ready for removal Carefully remove the board from the 4 nylon mounting pins Note Depress the retaining pins on the sides of the nylon mounts to release the board See Figure F 24 Carefully maneuver the board out of the machine Apply a thin coat of Penetrox A 13 to the IGBT heatsinks on the back of the new switch boards mating surfaces Note Keep compound away from the mounting ho
44. des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier V350 PRO er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place LINCOLN MASTER TABLE OF FOR ALL SECTIONS Page i iv rar re nr Ce Section A Operation Section 55 0 Section Section D The
45. electrode lead around your body 2 4 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source 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 Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically
46. frame to prevent static build up Be sure not to touch any electrically live parts at the same time Devices Handle only at Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag 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 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal stri
47. ing current exceeds 450 amps 3 Make sure the machine is in Local output control If the problem is resolved the Remote control board or the external remote control unit may be faulty 1 Perform the Output Rectifier 2 Perform the Main Switch Board Test Perform the 4 Perform the Current Transducer Test If the preset function is not performing properly the status panel board or the output control may be faulty The control board may be faulty CAUTION 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 V350 PRO LINCOLN 5 6 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The machine regularly overheats and the yellow thermal light is ON indicating a thermal overload POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS 1 Check the 3 5 amp circuit breaker CB2 Reset if tripped The welding application may be exceeding the recommended duty cycle of the V350 Pro Dirt and dust may have clogged the cooling channels inside the machine intake and exhaust louvers may be blocked due to inade quate clearance around the machine Make certain the fan as needed FA N is ope
48. not remove plugs from the power board See Figure F 4 Carefully apply the correct input voltage to the V350 PRO Carefully test for the correct voltages at the power board See Table F 3 T If the 40VDC is low or not present at plug J41 check the rectifier bridge and C5 filter capacitor See Wiring Diagram Also per form the Auxiliary Transformer Test If any of the DC voltages are low or not present at plugs J42 or J43 the power board may be faulty Remove the input power to the V350 PRO Replace the case wraparound cover using a 5 16 nut driver Figure F 4 Power Board Plug Location J41 J42 J43 V350 PRO LINCOLN 27 CHECK POINT LOCATION POWER PC BOARD CONNECTOR PLUG J41 POWER PC BOARD CONNECTOR PLUG J42 POWER PC BOARD CONNECTOR PLUG J42 POWER PC BOARD CONNECTOR PLUG J42 POWER PC BOARD CONNECTOR PLUG J43 POWER PC BOARD CONNECTOR PLUG J43 POWER PC BOARD CONNECTOR PLUG J43 F 27 TROUBLESHOOTING amp REPAIR POWER BOARD TEST CONTINUED Table F 3 Power Board Voltage Checks TEST DESCRIPTION CHECK 40VDC SUPPLY FROM RECT BRIDGE TO POWER BD CHECK 15VDC SUPPLY FROM POWER PC BOARD CHECK 5VDC SUPPLY FROM POWER PC BOARD CHECK 15VDC SUPPLY FROM POWER PC BOARD CHECK 5VDC SPI SUPPLY FROM POWER BOARD CHECK 5VDC RS232 SUPPLY FROM POWER PC
49. style connector lead 75 is pin C lead 76 is pin B and lead 77 is pin A Potentiometer Control The total resistance should be between 2000 ohms 2K and 10 000 ohms 10K The machine output will be at minimum when lead 76 wiper is at the end of the potentiometer that is connected to 75 The machine s output will increase as the wiper of the potentiometer is moved to the end that is connected to 77 Note In TIG mode moving the lead 76 wiper to lead 77 would produce the cur rent 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 The supply must be an isolated supply Not refer enced to earth ground any auxiliary power from the Invertec V350 Pro or the welding output The supply should be capable of supplying at least 20mA 0 volts supplied to 76 will set the Invertec V350 Pro to minimum output for the mode that has been selected while 10 volts supplied to 76 will set the Invertec V350 Pro to the maximum output for the mode Note In TIG mode 10 volts supplied to lead 76 would produce the current that has been set by the Invertec V350 Pro s front panel Output Control Types of Remote WELD TERMINAL Control The Invertec V350 Pro s Weld Terminals can be con trolled from each of the MS style connectors The circuit has a nominal OCV of 15VDC and requires a dry contact closure less than 100 ohms to ac
50. the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will drain off any charge stored in the four large capacitors that are part of the switch board assembly This procedure MUST be performed as a safety pre caution before conducting any test or repair procedure that requires you to touch inter nal components of the machine MATERIALS NEEDED 5 16 Nut Driver Insulated Pliers Insulated Gloves High Wattage Resistor 25 1000 ohms and 25 watts minimum DC Volt Meter This procedure takes approximately 20 minutes to perform V350 PRO LINCOLN 16 16 TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE continued A WARNING ELECTRIC SHOCK can kill e Have an electrician install and service this equipment 9 Do not touch electrically hot parts Turn the input power off at the fuse box before working on equipment e Prior to performing preventative maintenance perform the following capacitor discharge procedure to avoid electric shock DISCHARGE PROCEDURE 1 Remove the input power to the V350 PRO 2 Using the 5 16 wrench remove the screws from the case wraparound cover Be careful not to make contact with the capacitor terminals located at the top and bottom of the switch board 4 Obtain high resistance and high wattage resistor 25 1
51. the Wire Feeder Remote Adapter this form the V350 Pro provides the hardware to power and connect to 24 42 or 115 VAC wire feeders The advanced process model is the factory model with an advanced process panel installed in place of the standard mode panel In this form the V350 Pro provides access to the 5 standard weld modes Stick Soft Stick Crisp TIG CV Wire CV Innershield gouge constant power and pulse MIG weld modes DUTY CYCLE The V350 Pro is rated at 350 amps 60 duty cycle based on a 10 minute cycle It is also rated at 300 amps 100 duty cycle OPERATIONAL FEATURES and CONTROLS UPPER CONTROL PANEL 1 AMPS Meter Prior to STICK or TIG operation current flow the meter displays preset current value 2 amps or 3 whichever is greater Prior to CV operation the meter displays four dash es indicating non presettable AMPS During welding this meter displays actual average amps After welding the meter holds the actual current value for 5 seconds Output adjustment while in the hold period results in the prior to operation char acteristics stated above The displays blink indicat ing that the machine is in the Hold period 2 VOLT METER Prior to CV operation current flow the meter dis plays desired preset voltage value 5V Prior to STICK or TIG operation the meter displays the Open Circuit Voltage of the Power Source or four dashes if the output ha
52. the actual output voltage reading on the test volt meter is 20volts 5 volts Wait for the machine s output to be automati cally turned off and then back on Adjust the Output Control knob again if neces sary to make the actual voltage output 20 volts 5 volts Wait for the machine s output to be automati cally turned off and then back on Repeat the above two steps if necessary Press and release the Mode Select Memory button to save the calibration NOTE If the Mode Select Memory button is not pressed within 30 seconds after adjusting the Output Control knob the machine will leave the calibration mode and use the previous cal ibration settings LINCOLN 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 Press and hold in the Mode Select Memory button Turn on the V350 PRO Rotate the Output Control knob until the display reads cur CAL Release the Mode Select Memory button The left display will change to IcAL to indicate that current calibration is progress The right display will scroll the following message Adj oCP SorEAL cur 300A Adjust the Output Control knob until the actual output current reading on the test ammeter is 300amps 2A Wait for the machines output to be automat
53. the applied input voltage If the machine is being operated with single phase input voltage make sure the red lead is not connected See thel nstallation 1 Perform the Transformer Test 2 Perform the Power Board Test 3 The control rectifier and or asso ciated filter capacitor C5 may be faulty Check and replace as necessary 4 Perform The SPI Cable Resistance and Voltage Test 5 The Control Board may be faulty The main input fuses or breaker repeatedly fail Make certain the fuses or break ers are sized properly Make sure the reconnect switch and jumper lead is configured correctly for the applied input voltage The welding procedure may be drawing too much input current or the duty cycle may be too high Reduce the welding cur rent and or reduce the duty cycle 1 Check the reconnect switches and associated wiring See the Wiring Diagram 2 Perform the Input Rectifier 3 Perform the Switch Board 4 Perform the Output Diode Module Test 5 The Input Filter Capacitors may be faulty Check and if any are faulty replace all four CAUTION 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 V350 PRO LINCOLN 5 F 5 TROUBLESHOOTING amp
54. to Operation Section of this manual for normal operation characteristics Check for proper current and voltage calibration Check for loose or faulty plug connections between the remote board and the weld out put controls See the wiring dia gram The Remote Board may be faulty The control board may be faulty CAUTION 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 V350 PRO LINCOLN 8 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The display is not functioning prop erly POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Refer to the of this manual for normal opera tion characteristics Check for proper current and voltage calibration TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Check for loose or faulty plug connections between the Display board and the control board See the wiring diagram 2 The display board may be faulty 3 The control board may be faulty fault or error code is displayed 1 See the Fault Code Explanations 1 See Fault Code Explanations For no apparent reason the welding characteristics have change 1 Check the weldi
55. to and from the control board the users commands and various machine status messages The software that is con tained within the control board processes and com pares these commands with the voltage and current feedback information it receives from the output cur rent sensor and the output voltage sensing leads The appropriate pulse width modulation PWM signals See Pulse Width Modulation in this section are sent to the switch board IGBTs In this manner the digital ly controlled high speed welding waveform is created and regulated The control board also monitors the thermostats the main transformer primary currents and the input capacitor voltages NOTE Unshaded areas of Block Logic Diagram are the subject of discussion V350 PRO LINCOLN THEORY OF OPERATION Main Switch Board FIGURE 5 OUTPUT RECTIFIER AND To Control Board Positive Input AS 2 Output Input switch Rectifier 57 Terminal Sensor 257 Negative Reconnect Output Switch 7 Terminal EE m gt TT Primary 2 Sensor m O Primary Current Feedback 5 E Input Relay Control gi Auxiliary 8 Soft Start Control 5 g 115VAC 42VAC Transformer Capacitor Feedback 2 E 8
56. your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual 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 WELD DESCRIPTION This test will help determine if there is a possible open in the SPI cable and also determine if the correct supply voltages are being applied to the boards in the SPI network MATERIALS NEEDED Volt Ohmmeter 5 16 Nut Driver This procedure takes approximately 35 minutes to perform V350 PRO LINCOLN 46 TROUBLESHOOTING AND REPAIR SPI CABLE RESISTANCE AND VOLTAGE TEST continued TEST PROCEDURE Remove the input power to the V350 PRO Using the 5 16 nut driver remove the case wraparound cover Perform the Capacitor Discharge Procedure 4 Perform the Do not remove the SPI ribbon cable connecting the display board to the remote status boards Locate and remove plug J3 from the control board See Figure F 15 Check the resistance and continuity of the SPI cable by testing with the ohmmeter from each pin on plug J3 to the corresponding pins on plug 434 See the Wiring Diagram The resistance reading pin to corresponding pin should be zero ohms or very low resis tance If the resistance reading is high or open
57. 000 ohms and 25 watts minimum This resistor is not with the machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE Locate the eight capacitor terminals shown in fig ure Using electrically insulated gloves and pliers hold the body of the resistor with the pliers and con nect the resistor leads across the two capacitor terminals Hold the resistor in place for 10 sec onds DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS Repeat the discharge procedure for the other three capacitors Check the voltage across the terminals of all capacitors with a DC voltmeter Polarity of the capacitor terminals is marked on the PC board above the terminals Voltage should be zero any voltage remains repeat this capacitor dis charge procedure FIGURE F 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS EIGHT CAPACITOR TERMINALS L POWER RESISTOR 9 INSULATED PLIERS ES INSULATED Sh a GLOVES V350 PRO LINCOLN 17 TROUBLESHOOTING amp REPAIR MAIN SWITCH BOARD TEST 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 precau
58. 1 800 833 9353 WELD V350 PRO LINCOLN F 2 F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING TN ELECTRIC SHOCK kill Have 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 CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the ATTENTION equipment frame Static Sensitive t you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the
59. 3 XTAL1 P1 6 AD14 2 LA p L ZUIN00 91 T P1 7 AD15 XTAL2 20 VSS2 vss1 23 N 82527 x A DATA 0 15 CAN COMMUNICATION CIRCUITRY R191 10 0K R194 475 5CAN 4 J11 o AZO 08668151 R177 1 00K LED8 GREEN 3 J11 35 3 GCAN X29 1 4 DI 2 21 RE 8 RO VCC _ A c121 7 WGCAN B GND 2 96 Y 3 OCI3 HCPL 0601 Vo ISOLATION BARRRIER WGCAN MAX485 TRANSCEIVER a el 026481151 0269815 WGCAN COMMUNICATION CIRCUITRY NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual DESIGN INFORMATION REFERENCE DRAWNBY ENGINEER T KOOKEN EQUIPMENT TYPE INVERTER WELDERS SUBJECT DIGITAL CONTROL SCHEMATIC SCALE NONE G 5 DAIEI2 15 99 3789 100 2 V350 PRO a ELECTRICAL DIAGRAMS n SCHEMATIC DIGITAL CONTROL PC BOARD 3 D99 E1 dec MURS320T3 MURS320T 0100 LUF 22uF 0 1uF 1 20V uc Z Va AD DATA 0 13 4 gt 2 N iN 15 AD DAT
60. 350 PRO LINCOLN F 68 F 68 NOTES V350 PRO LINCOLN F 69 F 69 TROUBLESHOOTING amp REPAIR REMOTE BOARD REMOVAL AND REPLACEMENT 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 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 WELD DESCRIPTION The following procedure will aid the technician in removing the status board for maintenance or replacement MATERIALS NEEDED 5 16 Nut Driver Flathead Screwdriver Phillips Head Screwdriver This procedure takes approximately 30 minutes to perform V350 PRO LINCOLN F 70 F 70 TROUBLESHOOTING amp REPAIR REMOTE BOARD REMOVAL AND REPLACEMENT continued PROCEDURE 3 Perform the nput Filter Capacitor Discharge 1 Remove input power to the V350 PRO Procedure detailed earlier in this section 2 Using a 5 16 nut driver remove the case wrap Locate the remote board behind the front panel of around cover the machine See Figure F 2
61. 4 X27 sa NS LED7 TPUCH3 DCOCSB 21 TACK ADDRT HL PCOCSS 22 cs 2 3 v6c2 194 100 TPUGHS C910 23 ADDS LCZSZSINW 820pF LEZGZSINW Dope 1 R183 7 TEUCHE 250053 4 CS 3 ADDR5 26 DRS 3 Vb b 739 TPUCH8 PC2CS5 FC2 3 FUNCEN qr FUNCEN 4 ADDRS v EMO 139 ADDRS 138 DATAT 7 ADDR9 z TPUCH11 138 DATA ADDR9 20 12 13 ADDR ial TPUCH13 138 DATAS ADDR11 TPUCH14 TPUCH15 NN VAOISE_GND OV NORMA 5V FAULT 7 V 22 1K NOISE R203 cAPB OV 130 DATA7 ADDRTS 2 CAPBOV i CLK 8 s 50 5 lt L 3 POSINOSI ir 1 PQSZSCK 154 DATATON RER 9 3 0 SS CAPBUV CAPB UV TMS 33 z PQS4PCS1 22 ADDR 1 19 uper DATATS C69 PQSGPCS3 OR Ans POSATAD 116 DATATE WE TS eg E Leiter PU id cut LECSZSWW 820pF LECSZSWW doopF 15V 13 MC68332PV UB GND2 CAPA UV FET MN CNT FAULT INT PWRDN INT MN OUT 8 16 a DISABLE 455 LATCH7 1017A S 4 10 0 1C46 LEZSZSNN AVS LEZSZSW
62. 50 Pro are available from the factory for both the CE and ROW versions Options for K1728 1 Factory and K1728 3 CE V350 s TIG Gas Control Kit K1762 2 Advanced Process Panel K1763 1 Options for all models of V350 PRO Undercarriage K1764 1 Valet Style Undercarriage K1838 1 Welding Cable Connectors e K852 70 1 0 2 0 cable e K852 95 2 0 3 0 cable FACTORY VERSION and ADVANCED PROCESS VERSION K857 Remote Output Control K814 Arc Start Switch K812 Hand Operated Amptrol K870 Foot Operated Amptrol Note All of the above remote controls connect directly to the 6 pin MS style connector with either a K864 or K876 adapter and connect it to the 14 pin wire feeder MS style connector See Diagram in Section F 1 K930 TIG Module K428 K446 K449 LN 25 K617 1 or 2 K618 1 or 2 LN 742 K440 1 K567 1 LN 7 GMA K1559 1 K1564 1 LN 10 K1499 1 K1521 1 DH 10 K1587 1 Cobramatic Not recommended for pulse welding V350 PRO LINCOLN ACCESSORIES QUICK DISCONNECT PLUGS quick disconnect system is used for the welding cable connections The K852 70 is designed to accept a welding cable size of 1 0 to 2 0 1 2 3 4 5 Remove 25mm 1 in of welding cable insulation Slide rubber boot onto cable end The boot end may be trimmed to match the cable diameter Soap or other lubricant will help to slide the boot over the cable BOOT WELDING CABLE _ 25 mm Tin
63. 9 FIGURE F 29 REMOTE BOARD LOCATION Remote Board Mode Board or Advanced Process Board V350 PRO LINCOLN F 71 F 71 TROUBLESHOOTING amp REPAIR REMOTE BOARD REMOVAL AND REPLACEMENT continued 5 Using 5 16 nut driver remove the two screws 8 The front of the machine may now gently be pulled from the bottom front of the machine See Figure forward to gain access to the remote Board F 30 Note The front of the machine cannot be removed completely only pulled forward a few inches 6 Using a flat head screwdriver remove the two screws and their washers from around the input 9 The remote board is now accessible to replace power switch See Figure F 30 7 Using a phillips head screwdriver remove the four screws from around the two welder output termi nals on the front of the machine See Figure F 30 FIGURE F 30 FRONT SCREW REMOVAL AMPS VoLrs CONTROL WELD TERMINALS ete ice SELECT SELECT c 11 24 6 u Flathead Screws Phillips Head Screws m 5 16 Screws V350 PRO LINCOLN F 72 10 11 12 13 14 15 16 F 72 TROUBLESHOOTING amp REPAIR REMOTE BOARD REMOVAL AND REPLACEMENT continued Remove plug J37 from the displa
64. 9 16 wrench remove the nuts and their washers behind the two knobs previously removed 15 Perform the Remote Board Removal Procedure Start at step 10 16 Using a phillips head screwdriver remove the two phillips head mounting screws at the bot tom of the Advanced Process board 17 Remove the Advanced Process board V350 PRO LINCOLN 67 18 19 20 21 22 23 24 67 TROUBLESHOOTING amp REPAIR ADVANCED PROCESS PANEL REMOVAL AND REPLACEMENT continued FIGURE F 28 SCREW IN CAP Replace the Advanced Process board Replace the two phillips head screws at the bottom of the advanced process board Perform the Remote Board Replacement Replace the 9 16 nuts and their washers behind the Adjust and Select knobs Using a small screwdriver replace the two knobs previously removed Replace the three 5 16 screws previously removed from the front of the machine located around the Advanced Process board Reconnect plug J33 previously removed 25 26 27 28 Small Flathead Screwdriver Replace the four phillips head screws removed from the front of the machine located around the two welder output terminals Replace the two flat head screws and their washers from around the input power switch Using a 5 16 nut driver replace the two screws previously removed from the bottom front of the machine Replace the case wraparound cover V
65. AFEULUTE ARO UND CO T E TEHAL FIRE CL TH FOR OR ORS ONL EC HEMTI REFERENCE 52559 18 ETF Oe OR EIE TLC TTC RCE CLR RETE RECUERDE GER AT RTC IE FUB HG Ce LIT Ta CECI EGUPMENTTYFE INVERTER 5 F LED SELECT BD 5 H W BLE FUL 0 3 21 2001 TT NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only 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 Improper PC board repairs could result in damage to the LINCOLN machine V350 PRO iis ELECTRICAL DIAGRAMS Gis SCHEMATIC LED POTENTIOMETER PRINTED CIRCUIT BOARD 657525 15 WE PE MEE E CONTRE 1 THE EQ AC 2 MET TO LEGS SHOT THE PEHEN THE LINCOUUELECTAL CL OEELA MR
66. AO i J10A V 089 CAD DATAT 58 13 AD DATAZ VDD C52 071 s 12 AD DATAS 083 DATA CS AGND2 H V 5V DATASI 0 10 AD DATAS SHDKGND3 0 1uF DES 9 AD DATAS 1 2 08 12 SDI AGNDA 6 DATA SDO DGND 5 5 AD DATAS 088 2 DATAS AD8408ARU 10 27 X8Np1 obi ADDAA CONVERSION VA Vb DATAT 14 AGND2 DB11 CLK VDD DGND DB12 DATA 18 Rs AGND1 8 AGND2 BUSY DB13 S G HDKGND3 AD7863ARS 2 SDI AGND4 SDO DGND AD8403ARU10 S8 SNI 072 assESNI yy 74 a R160 055 O1uF C127 LOZESENN MURS320T3 x12 mus FRIMARY CURRENT SENSE AD DATAO 15 Scc 8 AD DATAT 120K ne 1 FLOW STT IOUT1 7 gt VREF ANA MMBT4401 3 4 VA Vb MURRET di D51 m a lt AD DATA4 5 AD DGND 7 f AGND AD 10 08 5 DATATI FROM 2nd LEM DA CS AD7945BRS 4 gt 8403 10 VA R63 33 2K
67. BOARD CHECK 15VDC SPI SUPPLY FROM POWER PC BOARD NORMAL ACCEPTABLE LEAD NO VOLTAGE OR IDENTITY READING 65 38 42 VDC 66 412 15 VDC 410 408 5 VDC 410 CONNECTOR PLUG PIN NO 403 5 VDC 401 4 406 5 VDC 406 6 12 L 402 3 5 411 4 15 VDC 410 Y 401 402 401 V350 PRO LINCOLN 28 28 NOTES V350 PRO LINCOLN 29 29 TROUBLESHOOTING amp REPAIR OUTPUT DIODE MODULES TEST 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 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 WELD DESCRIPTION This test will help determine if any of the output diodes are shorted MATERIALS NEEDED Analog Voltmeter Ohmmeter Wiring Diagram This procedure takes approximately 20 minutes to perform V350 PRO LINCO
68. DRE TREDECIM Section C Cobramatic amp Tig Module Connection Instructions C 2 Options ACCeSSOLrIGS C 2 Quick Disconnect PIUQS citet ce rite in Ev C 3 Connection of Lincoln Electric Wire 5 C 4 Thru C 11 V350 PRO LN 25 with Optional 6 Pin K441 1 Remote C 4 V350 PRO LN 25 with Optional 6 Pin K857 Remote C 5 LN 25 with K431 Remote C 6 V350 PRO LN 25 with K867 Adapter sisi C 7 V350 PRO LN 7 with K480 Control Cable issus C 8 V350 PRO LN 7 with K867 Adapter siens C 9 350 10 V350 PRO LN 10 with K1505 Control Cable ss C 11 V350 PRO LINCOLN 2 ACCESSORIES Cobramatic Connection Instructions 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 3 Connect the electrode cable to the output terminal of the polarity required by electrode Connect the work lead to the other terminal 4 Set the meter polarity switch on the front of the Invertec to coincide with wire feeder polarity used 5 Ifa remote control such as K857 is to be used with the Cobramatic the remote can be connected directly to the 6pin amphenol on the front of the Invert
69. E Optional Solenoid is rectified and the resultant 40VDC is applied to the power board The input voltage is rectified by the input rectifier and the resultant DC voltage is applied to the switch board through the reconnect switch assembly located at the rear of the machine The reconnect switch connect the two pairs of input capacitors either in a parallel lower voltage or series higher voltage configuration to accommodate the applied input voltage During the precharge time the DC input voltage is applied to the input capacitors through a current limit ing circuit The input capacitors are charged slowly and current limited voltage to frequency converter circuit located on the switch board monitors the capacitor voltages This signal is coupled to the con trol board measure frequency not voltage to check signal When the input capacitors have charged to an acceptable level the control board energizes the input relays that are located on the switch board making all of the input power without current limiting available to the input capacitors f the capacitors become under or over voltage the control board will de ener gize the input relays and the V350 output will be dis abled Other possible faults may also cause the input relays to drop out NOTE Unshaded areas of Block Logic Diagram are the subject of discussion V350 PRO LINCOLN THEORY OF OPERATION FIGURE E 3 SWITCH BOARD amp
70. E Figure C 4 for connection Using K867 adapter Figure C 3 LN 25 with K431 Remote Option to the V350 PRO ELECTRODE CABLE TO LN 25 TO WORK AMPHENOL 14 PIN 24 42VAC INVERTEC POWER SOURCE LN 25 WITH 6 PIN AMPHENOL OPTION 4 K876 ADAPTER K432 REMOTE CONTROL CABLE NOTE Illustration shows electrode connected for positive polarity V350 PRO LINCOLN 7 7 ACCESSORIES CONNECTION OF THE K867 ADAPTER FOR USE WITH LN 25 WITH K431 OPTION V350 PRO 1 Insulate each unused lead individually 2 Remove 6 pin plug from K432 cable in order to connect 867 adapter 3 Label each lead A thru F as they are removed from the 6 pin plug 4 Splice leads and insulate Figure C 4 Connection of LN 25 to V350 PRO using K867 adapter ELECTRODE CABLE TO ee B 41 LN 25 WITH 14 PIN GND o K431 OPTION TO WORK 24 42VAC AMPHENOL SPARE o D 75 0o K867 ADAPTER T6 i B K432 REMOTE 77 o C CONTROL CABLE INVERTEC POWER SOURCE 4 V350 PRO LINCOLN C 8 C 8 ACCESSORIES CONNECTION OF THE LN 7 TO THE V350 PRO USING K480 CONTROL CABLE SEE FIGURE 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 K291 OR K404 INPUT CABLE REFER TO THE CONNECTION OF THE LN 7 USING K867 UNIVERSAL ADAPTER 1 Remove input p
71. EXPLODING PARTS can cause injury Failed parts can explode or cause other parts to explode when power is applied Always wear a face shield and long sleeves when servicing See additional warning information throughout this Operator s Manual CAPACITOR DISCHARGE PROCEDURE 1 Obtain a power resistor 25 ohms 25 watts 2 Hold resistor body with electrically insulated glove DO NOT TOUCH TERMINALS Connect the resis tor terminals across the two studs in the position shown Hold in each position for 1 second Repeat for all four capacitors RESISTOR 3 Use a DC voltmeter to check that voltage is not present across the terminals on all four capaci tors VISUAL INSPECTION Clean interior of machine with a low pressure air stream Make a thorough inspection of all compo nents Look for signs of overheating broken leads or other obvious problems Many problems can be uncovered with a good visual inspection ROUTINE MAINTENANCE 1 Every 6 months or so the machine should be cleaned with a low pressure airstream Keeping the machine clean will result in cooler operation and higher reliability Be sure to clean these areas All printed circuit boards Power switch Main transformer Input rectifier Auxiliary Transformer Reconnect Switch Area Fan Blow air through the rear louvers 2 Examine the sheet metal case for dents or breakage Repair the case as required Keep the cas
72. F SAVING WELDING MODES TO MEM ORY The following example is how to select Pulse MIG using 035 steel and store it into memory 1 Turn the Select knob until welding process is dis played LEFT WINDOW RIGHT WINDOW Pulse MIG Argon Blends Steel 035 2 Wait two seconds and the right window will display Arc Control on the second line on the right side Pulse MIG Argon Blends Steel 035 Arc Cntr lt 3 SPd is displayed in the upper right Volts window The left Amps window matches the desired wire feed speed that is set on the wire feeder Adjust the Output knob until desired number is displayed 4 Start welding If the arc length is too short turn the Output knob up If the arc length is too long turn the Output knob down The Arc Control which is displayed in the right digital window can be used to fine tune the arc length and characteristics 5 After all adjustments have been made press and hold the Memory button until the display changes The right and the left window will display what memory to save in lets say M1 To store in M1 push the Memory button again to save the Pulse Mig mode to memory M1 6 The display in the digital windows will read as follows M1 Pulse MIG Argon Blends Steel 035 Arc Cntrl 1 2 7 Saving or entering a second welding mode to a memory M2 Turn the Select knob until the desired welding process mode is displayed in right digital window Then follow steps 1 thru 6 Press the Memory
73. HOOTING amp REPAIR OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT continued Under the copper plate previously removed there is an allen bolt Remove it using a 9 64 allen wrench See Figure F 39 Using a 7 16 socket remove the mounting bolts at the top and bottom of the modules See Figure F 39 The output rectifier modules are ready for removal and or replacement Before replacing the diode module apply a thin even coat of Penetrox A 13 heatsink compound to the bottom surface of the diode module Note Keep the compound away from the mounting holes Press the module firmly against the sink while aligning the mounting holes Insert each outer screw through a spring washer and then a plain washer and into the holes Start threading all three screws into the heat sink 2 or 3 turns by hand 13 14 15 16 15 16 17 The screw threads may catch on the threads of the heat sink so be sure to get the face of the screw into contact with the surface of the module using just hand torque Using a 7 16 socket tighten each mounting bolt to between 5 and 10 inch pounds Tighten the center allen screw to between 12 and 18 inch pounds Tighten each mounting bolt again 30 to 40 inch pounds this time Replace leads X2 X4 20 40 to their original terminals in their proper positions Torque bolts to 30 40 Inch Pounds Perform the Snubber Board Replacement Procedure detailed earlie
74. LECTRICAL DIAGRAMS G 20 PC BOARD ASSEMBLY SNUBBER 3 ITEM Li PART NO DESCRIPTION 20500 4 CAPACITOR PPMF 0047 1000V BOX T14648 20 RESISTOR WW 5W 150 5 SQ R2 R4 2 T14648 25 RESISTOR WW 5W 10 5 SQ nl PART NO DESCRIPTION QTY 19532 P C BOARD BLANK 1 13157 16 TAB TERMINAL 1 9147 11 EYELET FEMALE 4 2 79147 15 EYELET MALE 4 B1 Lo NOTES N A FEMALE EYELET TO BE AGAINST THE COPPER SIDE AS SHOWN BOXCP4 EYELET MUST NOT SPIN AFTER CLINCHING N B SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET AND ALL AROUND EYELET ON COPPER SIDE ONLY NO ICICLES OR SOLDER BLOBS PERMITTED SIDE EYELET DETAIL MANUFACTURED AS SNUBBER ENCAPSULATE WITH E1844 2 COATS TEST PER E3817 SN 1911 19532 1 0 IDENTIFICATION CODE THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO U S A MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS 02 6 2 2000 XM5626 EQUIPMENT TYPE INVERTER WELDERS XC UF ON ALLANGLES In S OF 02 SUBJECT SNUBBER BOARD ASSEMBLY ON ALL ANGLES IS 5 OF DEGREE _DATE 10 6 99 19532 1
75. LN F 30 F 30 TROUBLESHOOTING amp REPAIR OUTPUT DIODE MODULES TEST continued FIGURE F 5 Machine Output Terminals AMPS VoLrs CONTROL WELD TERMINALS REMOTE REMOTE LOCAL OUTPUT ON SELECT SELECT ILE LL e i NEGATIVE POSITIVE OUTPUT OUTPUT TERMINAL TERMINAL TEST PROCEDURE 4 Using the analog ohmmeter test for more 1 Remove input power to the V350 PRO than 200 ohms resistance between positive 2 Locate the output terminals on the front and negative output terminals Positive test panel of the machine See Figure 5 lead to the positive terminal Negative test 3 Remove any output cables and load from the E to the negative terminal output terminals NOTE The polarity of the test leads is most important If the test leads polarity is not cor rect the test will have erroneous results V350 PRO LINCOLN 31 31 TROUBLESHOOTING amp REPAIR OUTPUT DIODE MODULES TEST continued Figure F 6 Terminal Probes If 200 ohms is measured then the output diodes are not shorted NOTE There is a 250 ohm resistor across the welding output terminals If less than 200 ohms is measured one or more diodes or the snubber board may be faulty Perform the Filter Capa
76. LS SELECT in the REMOTE position Adjust wire feed speed at the LN 742 Set the ARC control at 0 initially and adjust to suit Figure C 7 V350 PRO LN 742 Connection Diagram 14 PIN AMPHENOL 24 42VAC AT REAR OF MACHINE V350 PRO TO WORK TO LN 742 INPUT CABLE PLUG K591 CONTROL CABLE ELECTRODE CABLE TO WIRE FEED UNIT LINCOLN 11 ACCESSORIES 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 the rear of the V350 PRO 3 Connect the electrode cable to the output terminal of polarity required by the electrode Connect the work lead to the other terminal 4 Set the meter polarity switch on the front of the V350 PRO to coincide with wire feeder polarity used 5 Set CONTROL SELECT to REMOTE 6 Set the MODE to the CV WIRE position 7 Set the WELD TERMINALS SELECT to the REMOTE position 8 Set the ARC CONTROL to the 0 position and then adjust to suit 9 Set wire feed speed and voltage at the LN 10 NOTE The voltage set point displayed on the V350 PRO should be ignored when operating in the remote control mode with the LN 10 10 See the LN 10 manual for detail
77. MS x16 MC145407 150pF 66 gag 22 9 LLagbzsZzsn D58 NZ isv 1 2 MMSZ5248BT1 Vers232 RS232 RXD gt 1 4 X10 RS232 TXD OCI2 HCPL 0601 GRS232 1 Q 10V S232 10VI RS232 13 1 C66 C62 2 pm our 5VRS232 4 10uF 16V 2 1 3 145407 63 Our 16V 16V GRs232 V ET dar Vers232 X16 8 MC 145407 X16 10 MC 145407 1 N 5VRS232 052 Ys WVGRs232 L148 cSZSNN MMSZ5248BT1 5VRS232 145407 X16 16 61 IC145407 0 1uF 35V rq R131 1 00 LED6 MS 026 lt 8 16 X GREEN 16 STATUS A STATUS LE CIRCUITRY 15v ER 221K 27 ASL MS E LEGSANSE NOISE_GND LED9 GREEN 3 4 HH 2 Re Me 37 1566851 V NOISE_GND FULL DUPLEX RS232 COMMUNICATION LIN 5CAN R195 475 ADDR 1 18 Vb 22pF WRH P2 7 INT P2 6 CLKOU ADO RDY MISO AD1 R W AD2 P1 0 AD8 P1 1 AD9 D3 AD4 MOSI P1 2 AD10 AD5 P1 3 AD11 9 AD6 SCLK P1 4 AD12 AD7 P1 5 AD1
78. OLN machine V350 PRO e ELECTRICAL DIAGRAMS G 11 SCHEMATIC DISPLAY PRINTED CIRCUIT BOARD nb L I 1 Al FIR Lu L 1 E L TIE 1 LINCOLN E Vaso PRO cle ELECTRICAL DIAGRAMS G 12 PC BOARD ASSEMBLY DISPLAY npnnuarrcBonmmBBnnimEron LE 1127 ee MPa OP FE 104 21262 7 04 04 C D cls D LE Dn DAs 2 oe Ce A A mee rer RES m e RE IA FR REA ET FEN D 72 META P EPA CE uu rar ESSI M ME REY LU ree unma pessimi RE VA FEM FE EEE ESSI HD HE ALTE PA EE 2 CE 1 1 recessu RE ACTE dL em rem men LES OLN EASE ECM ED HOES OPE 15 Cow YA Ih ERS Mal a CAN TOM pers 10 DHe BYTIA un ELE CIBO LY PORE ROWS ng 10 Tiho LED 2024203 HO LE DF FROM IPE Pic IPERE BORE Rtn DOD EE I VE ER SPER amp hD
79. OLN ELECTRIC Excellent appearance of the weld bead Improved cleaning action Reduced porosity Table B 2 shows WFS and Trim settings for common aluminum types and wire sizes when welding with Pulse on Pulse The welds made to obtain the values in the table were fillet welds in the flat position The val ues in the table can be helpful as a starting point to establish a welding procedure From there adjust ments need to be made to set the proper procedure for each specific application out of position other types of joints etc The comments on the table below show values of WFS below which it is not recommended to weld The rea son is that below these values the weld transfer will change from spray arc to a short arc which is not advisable when welding aluminum WELDING PROCEDURES FOR PULSE ON PULSE MATERIAL Aluminum 4043 Aluminum 4043 Aluminum 5356 Aluminum 5356 GAS 100 Ar 100 Ar 100 Ar 100 Ar WIRE E4043 E4043 E5356 E5356 WIRE SIZE 0 035 3 64 0 035 3 64 40 9 14 ga 250 0 200 0 230 0 22510 o zu E 10 ga 400 0 280 0 425 0 400 0 wy o 316 550 0 340 0 670 0 500 0 sr 84 1 4 600 0 400 0 700 0 550 0 COMMENTS Not Recommended Not Recommended Not Recommended Not Recommended below 200 WFS below 100 WFS below 200 WFS below 200 WFS V350 PRO LINCOLN NOTES V350 PRO LINCOLN TABLE OF CONTENTS ACCESSORIES SECTION OR
80. RMAL This status light indicates when the power source has been driven into thermal overload If the output terminals were the ON light will blink indicating that the output will be turned back on once the unit cools down to an accept able temperature level If the unit was operating in the REMOTE mode the trigger will need to be opened before or after the thermal has cleared and closed after the machine has cooled down to an acceptable temperature to establish output 6 CONTROL REMOTE LOCAL Two status lights indicate the location of output control as pre determined by the power sources auto configure sys tem The LOCAL display will be lit when control is at the power source The REMOTE display will be lit when a remote pot control is detected These Output Control configurations can be overridden switched with the CONTROL push button When changed the unit will power up in the configuration it was in when it was last powered down 7 WELD MODE SELECT FACTORY AND CONSTRUCTION See Figure B 1 The Mode Control button selects from the following welding modes CC STICK SOFT The Stick Soft process features con tinuous control ranging from 5 to 425 amps This mode was intended for most SMAW applications and Arc Gouging Arc Gouging Setting the output of the Stick Soft mode to 425 amps will enable the arc gouging mode The actual output current will depend on the size of carbon used The recomme
81. SPD value can be adjust 035 Stainless Ar CO2 75 770 ed to obtain the desired arc length Refer to the detailed explana 045 Stainless Ar Blends 50 600 tion at the end of this section 045 Stainless He Ar CO2 50 600 035 Aluminum 4043 100 700 The operation of the Arc Control knob on the V350 is similar to the 035 Aluminum 5356 115 740 PowerWave series As Arc Control is increased the frequency is 3 64 Aluminum 4043 80 550 increased and the background reduced Decreasing Arc Control will 3 64 Aluminum 5356 85 700 reduce frequency and increase background current Arc Control 1 16 Aluminum 4043 75 325 acts to fine tune the arc plasma to the specific application 1 16 Aluminum 5356 75 450 Preferred gas selections Steel Argon Blends Argon with CO2 additions from 2 to 20 or Oxygen additions from 2 to 5 Stainless Argon Blends Argon with Oxygen additions up to 2 Stainless He Ar CO2 90 Helium 7 1 2 Argon 2 1 2 CO2 Aluminum 100 Argon 035 Nickel Alloys Non Adaptive The Nickel Alloy pulse programs are non adaptive The operator 045 Nickel Alloys Non Adaptive sets the output control knob to deliver the correct arc length at desired wire feed speed and stick out While welding the operator manipulates the stick out to maintain the correct arc length This method of operation produces very stable arc performance consid ering the nature of nickel alloys Preferred gas Argon Helium Blends for the best resul
82. SVM158 A April 2002 INVERTEL V35U PRU For use with machine code numbers 10873 10874 10876 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 READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful SERVICE MANUAL LINCOLN Copyright 2002 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 216 486 1751 WEB SITE www lincolnelectric com WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING
83. VAL AND REPLACEMENT continued 9 Apply a thin coat of Penetrox A 13 heatsink com 11 Reconnect the previously removed leads to their pound to the point of contact between the input proper locations Torque to 31 inch pounds rectifier and the mounting surface 12 Cover the input rectifier and its six terminals with 10 Secure the new input bridge into its proper posi silicon sealant tion with the two 3 16 in allen mounting screws previously removed Torque to 44 inch pounds 13 Replace the case wraparound cover FIGURE F 37 INPUT RECTIFIER CLOSE UP small Lead H1 To Auxiliary Transformer 3 16 ALLEN BOLTS 207 207 209 Small Lead FRONT To Circuit Breaker REAR V350 PRO LINCOLN 82 82 NOTES V350 PRO LINCOLN 83 TROUBLESHOOTING amp OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT 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 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
84. achine will be illuminated The thermostats are self resetting once the machine cools sufficiently If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally the power switch may be left on and the reset should occur within a 15 minute period PROTECTIVE CIRCUITS Protective circuits are designed into the V350 PRO to sense trouble and shut down the machine before damage occurs to the machine s internal components OVER CURRENT PROTECTION If the average current exceeds 450 amps for one sec ond then the output will be limited to 100 amps until the load is removed If the peak current exceeds 600 amps for 150 ms the output will be limited to 100 amps until the load is removed UNDER OVER VOLTAGE PROTECTION Protective circuits are included on the switch and con trol boards to monitor the voltage across the input capacitors In the event that a capacitor pair voltage is too high or too low the machine output will be dis abled The protection circuits will prevent output if any of the following conditions exist 1 Voltage across a capacitor pair exceeds 467 volts High line surges or improper input voltage connections 2 Voltage across a capacitor pair is under 190 volts Due to improper input voltage connections 3 Internal component damage V350 PRO LINCOLN 7 7 THEORY OF OPERATION INSULATED GATE BIPOLAR TRANSISTOR IGBT OPERATION An IGBT i
85. age is being displayed perform all the checks for the faults before replacing the printed circuit board V350 PRO LINCOLN TROUBLESHOOTING amp REPAIR FAULT CODES DESCRIPTION CORRECTIVE SERVICE FACILITY CORRECTIVE DEFINITION ACTION ACTION 35 Capacitor bank Make sure the reconnect There may be a problem B lower is over switches are configured with the V F signals from voltage for the input voltage the main switch board to being applied to the the control board machine The machine is self clearing when Perform the Main Switch condition ceases Perform the Power The control board may be faulty 37 The soft start Turn the machine off and There may be a problem function failed back on to reset the machine with the V F signals from the main switch board to the control board Perform Switch Board Test Perform the Board Test The control board may be faulty NOTE If more than one fault message is being displayed perform all the checks for the faults before replacing the printed circuit board V350 PRO LINCOLN 12 F 12 TROUBLESHOOTING amp REPAIR FAULT CODES DESCRIPTION CORRECTIVE SERVICE FACILITY CORRECTIVE DEFINITION ACTION ACTION 39 Electrical glitch on the Possibly caused by Perform the Main Switch primary over current fault external electrical detector circuit noise or signal level Make sure the V350 Pro Perform the Power
86. anta freee FP DH LD F Th LE LE E A BA PAF ee FF O FEE EH EHE UD DIA A FHF P EE JE DL 1 EL FEIER DAR OH H THF EF HJ Fi 9 O EE rE PPEP HEF b CH ME PR HEAR UR CAAH HI LH FEE E E FH A dH Fa HA I HPHE E 9 EI Mule M aree MITT UM HIH kh H UH B ERE EH ER CE I THU EIRE EI EH Mp pU PR CH HT MEER BC BPCO LEP TIC REFERENCE L TER 1 A I DO e HH FERE th 11 EMCHF UTH TS run NON TES TFER 1 57 NOTE Lincoln Electric assumes no responsibility resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not available from Lincoln Electric This information is pro vided for reference only 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 Improper PC board repairs could result in damage to the LINC
87. assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the output rectifier modules for maintenance or replacement MATERIALS NEEDED 3 16 Allen wrench 9 64 Allen wrench 5 16 Nut Driver 7 16 Wrench Flathead Screwdriver Penetrox A 13 Heatsink Compound Thin Knife Screwdriver This procedure takes approximately 30 minutes to perform V350 PRO LINCOLN 84 84 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT continued PROCEDURE 1 2 3 Output Diode Remove input power to the V350 PRO Using a 5 16 nut driver remove the case wrap around cover Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section Locate the output diode modules located behind the snubber board See figure F 38 Before the output rectifier modules can be reached the Snubber Board Removal Procedure must be performed After the snubber board is removed remove the four leads connected to the modules using a 3 16 allen wrench These leads are X4 X2 20 40 Note their positions for reassembly Remove the copper plates from the tops of the modules FIGURE F 38 OUTPUT RECTIFIER MODULE LEAD LOCATIONS Modules LEFT SIDE V350 PRO LINCOLN 85 10 11 12 3 16 Allen 9 64 Allen F 85 TROUBLES
88. ble to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the input rectifier for maintenance or replacement MATERIALS NEEDED 3 16 Allen wrench 5 16 Nut Driver Flathead Screwdriver Penetrox A 13 Heatsink Compound Silicon Sealant This procedure takes approximately 30 minutes to perform V350 PRO LINCOLN 80 80 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER REMOVAL AND PROCEDURE 1 2 3 Remove input power to the V350 PRO 6 Using a 5 16 nut driver remove the case wraparound cover Perform the nput Filter Capacitor Discharge T detailed earlier in this section Locate the input rectifier See figure F 36 Carefully remove the silicon sealant insulating the six input rectifier terminals REPLACEMENT continued Remove the six screws from the terminals using a flathead screwdriver Carefully note the position of all leads and their positions upon removal See Using a 3 16 in allen wrench remove the two mounting screws and washers from the input bridge See Figure F 37 Remove the input bridge FIGURE F 36 INPUT RECTIFIER LOCATION INPUT RECTIFIER V350 PRO LINCOLN 81 F 81 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER REMO
89. ch connected to the 6 pin amphenol 6 oFF connector off This will only appear if a potentiometer is still connect dcon 6 roCP ed to the 6 amphenol connector If this message appears disconnect the potentiometer from the 6 pin amphenol connector This will only appear if a potentiometer is already con dcon 1 14 nected to the 14 amphenol connector If this mes sage appears disconnect the potentiometer from the 14 pin amphenol connector 40 Connect a remote output control potentiometer to the con 14 Pln roCP 14 pin amphenol connector 41 Adjust the remote output control potentiometer connect 14 roCP HI ed to the 14 pin amphenol connector to its highest set ting Adjust the remote output control potentiometer connect 14 roCP Lo ed to the 14 pin amphenol connector to its lowest set ting This will only appear if a trigger switch is already con 14 rlgr OFF nected to the 14 pin amphenol connector and the trig ger switch is presently on Turn the trigger switch con nected to the 14 pin amphenol connector off 44 Turn the trigger switch connected to the 14 pin amphe 14 PIn on nol connector on 5 4 Turn the trigger switch connected to the 14 pin amphe 14 rlgr oFF nol connector off V350 PRO LINCOLN TROUBLESHOOTING AND Expected Results Required Action P L
90. citor Discharge Procedure detailed earlier in this section Locate the output diode modules and snub ber board See Figure F 7 Test all output diode modules individually NOTE This may require the disassembly of the leads and the snubber board from the diode modules Refer to the Output Diode Modules Removal and Replacement Procedure for detailed instructions V350 PRO LINCOLN TROUBLESHOOTING amp REPAIR OUTPUT DIODE MODULES TEST continued Figure F 7 Snubber and Output Diode Locations Output Diode Modules 5 Snubber ET Board LEFT SIDE V350 PRO LINCOLN F 33 F 33 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER TEST 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 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 WELD DESCRIPTION This procedure will determine if the correct voltage is being applied to the primary of auxil iary transformer and also
91. ctrode needs to remain in contact with the work to allow for gas coverage before attempting to start the arc The solenoid will close after the arc has been broken and the post flow time expired OPERATION idi CV WIRE The CV WIRE mode features continuous control from 10 to 40 volts The mode was intended for most GMAW FCAW and MCAW applications The Hot Start control is not used in the CV WIRE mode The Arc Control regulates pinch effect At the mini mum setting 10 minimizes pinch and results in a soft arc Low pinch settings are preferable for weld ing with gas mixes containing mostly inert gases At the maximum setting 10 maximizes pinch effect and results in a crisp arc High pinch settings are preferable for welding FCAW and GMAW with 2 CV INNERSHEILD The CV INNERSHEILD mode features continuous control from 10 to 45 volts This mode was designed for self shielded flux cored wires that require tight voltage control The Hot Start control is not active in the CV FLUX CORED mode The Arc Control regulates pinch effect At the mini mum setting 10 minimizes pinch and results in a soft arc At the maximum setting 10 maximizes pinch effect and results in a crisp arc Most self shielded wires work well at an Arc Control setting of 5 V350 PRO LINCOLN 5 OPERATION 7A ADVANCED PROCESS PANEL See Figure B 2 To program Welding modes SELECT knob is used to Scroll through all Welding
92. curve indi cates that more power is present lAn IGBT group modules feeding one winding IGBT primary consists of two transformer V350 PRO LINCOLN Section F 1 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION Troubleshooting amp Repair Section Section F How to Use Troubleshooting Guide F 2 PC Board Troubleshooting Procedures and Replacement F 3 Troubleshooting GUJE seese etie tribute canst rete F 4 Test Procedures Input Filter Capacitor Discharge Procedure ss F 15 Main Switch Board Test F 17 Input Rectifier Test iecit F 21 Power Board TeSt i F 25 Output Diode Modules Test deep easet F 29 Auxiliary Transformer Test cien ed ER Ee ieee F 33 Current Transducer TeSt eine tre deer mie ce F 37 Fan Control and Motor Test iii F 41 SPI Cable Resistance and Voltage Test F 45 Voltage and Current Calibration F 47 Replacement Procedures Control Board Removal and Replacement F 51 Display Board Removal and Replacement ss F 55 Main Switch Board Removal and Replacement F 59 Advanced Process Panel Removal and Replacement F 63 Rem
93. cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 V350 PRO LINCOLN PR CAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter
94. d Call 1 800 833 9353 WELD V350 PRO LINCOLN F 7 F 7 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The machine s welding output is very high and uncontrollable POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Put the Control Select in the Local position If the problem is solved the remote control device or associated circuitry may be faulty Check for proper current and voltage calibration TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Perform the Transducer Test the output is normal when the Control Select is in the Local position but the output is very high in the Remote position the remote board may be faulty Perform The SPI Cable Resistance and Voltage Test The control board may be faulty The Weld Mode Select does not function properly Refer to Operation Section of this manual for normal operation characteristics NOTE The mode panel is not pre sent if the advanced process panel is installed Check for loose or faulty plug connections between the con trol board and the mode select panel See the wiring diagram Perform the SPI Cable Resistance and Voltage Test The Mode Select Panel board may be faulty The control board may be faulty The output control and or Weld Terminals Select functions do not operate properly Refer
95. de 200 8 5 With the machine in mode 200 apply a resistive load to the welding output terminals approxi mately 087 ohms set the machine output to 9 300 amps and enable the Weld Terminals Weld Terminals Select 6 Using the test meters note the output voltage and current 11 7 The V350 PRO voltmeter must match the test meter reading to within 1 volt 8 The V350 PRO ammeter must match the test meter within 5 amps 9 Ifthe voltmeter does not meet the specification then proceed to the Voltage Calibration 10 If the ammeter does not meet the specification then proceed to the Current Calibration NOTE Before attempting to calibrate the voltage or current setting of the V350 PRO be sure to read the entire voltage or current calibration section If the steps are not completed quickly the machine will automatically leave the calibration mode with out changing the calibration settings The voltage and current calibration settings of the V350 PRO are completely independent of each other Adjusting one will not affect the other V350 PRO VOLTAGE CALIBRATION 1 Connect the resistive load band approximate ly 087 ohms and test voltmeter to the welding output terminals Press and hold in the Mode Select Memory button Turn on the V350 PRO Rotate the Output Control knob until the dis play reads vol cAL Release the Mode Select Memory button Adjust the output control knob until
96. des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on
97. e 5 5 R51 2 IBERR 4 gt CONTROL AA zea FREEZE 87 4 75 1627 1 MTM 14 257 1666815 5 R257 gas 98a BR CSO 100pF cat 142 51 BAVIOLT TE28FB00B5 B90 Vb BERR PE T NOISE 7 BERR IPIPE DSO FREEZE FREEZE IFETCH ps 78 T R11 R41 V RW 4 SRES LEVEL IN NOISE GND DSACKPEO 115 4 5 MA DONE DONE DSACKPE1 39 ADDR1 40 ADDR2 475 5 MC AVEGPE2 RMGPE3 Sca 4 ALS R187 BAV99 105 9 DS PES 26 7K 5120 LEZSZSINW R84 5121 PE7 ADD 45 ADDR7 46 ADDR8 A 50 ADDR10 51 ADDR 52 ADDR12 56 ADDR13 475 PFO MODCLK OV NORMA 1 101 PF1IRQ1 NOISE_GND nva PF2 IRQ2 5V FAULT GND V IRES gt FPGA INT FPGA INT 98 PF4 IRQ4 INT CAN INT CAN 97 IRQS CAPA_OV PFE IRQ6 PF7 IRQ7 MICRO CONTROLLER 5V 64 ADDR18 FAULT lt 18 6 ADDR CAPAUV CAPA UV IRLR120N SIGNAL TPUCHO pcacse 19 5 ADDR19 TPUCH1 910 RED TPUCH2 4 87 20 g VEP CTRL gt
98. e in good condition to insure that high voltage parts are protected and correct spacings are maintained All external sheet metal screws must be in place to insure case strength and electrical ground continuity PERIODIC 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 continue to produce this low current until the protection circuit is reset Reset occurs when the output load is removed Thermal Protection Thermostats protect the machine from excessive operating temperatures Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating If excessive operating temperature should occur the thermostat will prevent output voltage or current The meter will remain energized during this time Thermostats are self resetting once the machine cools sufficiently If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally the Power Switch may be left on and the reset should occur within a 15 minute peri od V350 PRO LINCOLN D 3 D 3 MAINTENANCE FIGURE D 1 MAJOR COMPONENT LOCATIONS 1 Center Panel 2 Base Assembly 3 Case Back 4 Case Front 5 Case Wraparound V350 PRO LINCOLN 0 4 NOTES
99. ear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c za CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the
100. ease observe all safety notes and precautions detailed throughout this manual 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 WELD DESCRIPTION The following procedure will aid the technician in removing the snubber board for mainte nance or replacement MATERIALS NEEDED 5 16 Nut Driver 7 16 Socket or Nut Driver This procedure takes approximately 15 minutes to perform V350 PRO LINCOLN 74 74 TROUBLESHOOTING amp REPAIR SNUBBER BOARD REMOVAL AND REPLACEMENT continued PROCEDURE 1 Remove input power to the V350 PRO 3 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section 2 Using a 5 16 nut driver remove the case wrap around cover 4 Locate the snubber board See Figure F 32 FIGURE F 32 SNUBBER BOARD LOCATION Snubber Board LEFT SIDE 5 Remove small lead B1 from the board See 7 Carefully remove the snubber board Figure F 33 8 Replace the snubber board 6 Remove the four bolts using a 7 16 socket Two of these bolts have leads 30 and 10 connected 9 Replace the bolts leads and washers previously to them Note the position of all leads and associ removed Torque bolt to 30 40 Inch Lbs ated wa
101. ec or use a K864 adapter to connect the cobramatic and the remote to the 24 42VAC 14 pin wire feeder amphenol connector on the rear of the Invertec TIG Module K930 2 The TIG Module connects to the V350 Pro Factory or CE versions with a K936 1 9 14 pin control cable Connect the K936 1 to the 115VAC Wire Feeder Amphenol on the rear of the V350 Pro The TIG Module can also be used with the V350 Construction version A K936 4 control cable is required to supply 115VAC to the TIG Module from an external 115VAC supply General Instructions for Connection of Wire Feeders to V350 Pro Wire feeders other than LN 7 and LN 25 may be used provided that the auxiliary power supply capacity of the V350 Pro is not exceeded K867 universal adapter plug is required See connection diagram 19406 and 19386 at the back of this manual for more information Remote Control of Invertec Remote Control K857 Hand Amptrol K963 and Foot Amptrol K870 OPTIONS ACCESSORIES Construction Version K1728 2 All welding modes for this model run with local out put control and weld terminals ON e g Stick TIG LN25 off the arc K930 1 K428 K446 K449 TIG Module LN 25 Off the Arc CE Version K1728 3 The CE version is the Factory version with the addition of power line filtering allowing the machine to comply with the European and Australian EMC emission requirements Field Installed Options Accessories Two versions of the V3
102. er FIGURE F 42 OUTPUT HEATSINK MOUNTING SCREW LOCATION 3 8 MOUNTING V350 PRO LINCOLN 91 21 22 23 24 25 26 27 28 29 91 TROUBLESHOOTING amp REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT continued Replace the current transducer Replace the two 3 8 mounting nuts previously removed Reconnect plug J90 to the current transducer Replace any necessary cable ties previously cut From the rear of the machine replace the heavy flex lead to the bottom of the output diode heatsink assembly using a 1 2 wrench Note Don t forget to include all washers Replace the output diode heatsink assembly pre viously removed using a 3 8 wrench Note Be sure to place insulation in its original location Replace leads X2 20 X4 40 previously removed from the two output diode modules Torque to 30 40 inch lbs Perform the Snubber Board Replacement The rear of the machine may now be placed back into its original position V350 PRO 30 31 32 33 34 35 36 37 Using a 3 8 wrench replace leads 202 203 206 and 207 previously removed from the reconnect switches Tighten the metal nut previously removed from the inside of the rear wall on the back of the machine Channel locks may be necessary Replace the large plastic nu
103. er 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 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 WELD DESCRIPTION This test will help determine if the input rectifier has shorted or open diodes MATERIALS NEEDED Analog Voltmeter Ohmmeter Multimeter 5 16 Nut Driver Phillips Head Screwdriver Wiring Diagram This procedure takes approximately 25 minutes to perform V350 PRO LINCOLN F 22 1 To Auxiliary Transformer TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST CONTINUED TEST PROCEDURE Remove input power to the V350 PRO machine Using a 5 16 nut driver remove the case wraparound cover Perform the Capacitor Discharge Procedure detailed earlier in this section Locate the input rectifier and associated leads See Figure F 3 Carefully remove the silicone sealant from leads 207 207A and 209 6 8 Using phillips head screwdriver remove leads 207 207A and 209 from the input rectifier Use the analog ohmmeter to perform the tests detailed in Table 2 See the Wiring Diagram Visually inspect the three
104. es B 9 Types of Remote Weld Terminal nennen B 9 Auxillary EUER B 10 e B 10 Recommend d PrOGeSSOS citi otra aA B 10 Descriptions of Special Welding Processes Available on this B 11 V350 PRO LINCOLN OPERATION 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 FUMES AND GASES can be dangerous 9 Keep your head out of fumes AR Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or DE explosion Keep flammable material away Do not weld on closed containers ARC RAYS can burn eyes and skin Wear eye ear and body protection 2 See additional warning information at front of this operators manual GENERAL DESCRIPTION The Invertec V350 Pro offers multi process CV CC and DC welding and is rated 350 amps 34 volts at a 60 duty cycle The V350 Pro is available in either a Construction version no wire feeder connection and auxiliary power and a Factory amp Advanced Process versions includes wire feeder connection and related power factory model is the construction model with the addition of
105. es are now totally encapsulated and are therefore considered to be unservice able The Assembly numbers are provided on this page but the actual drawings are no longer included V350 PRO LINCOLN 2 WIRING DIAGRAM INVERTEC V350 PRO PET PH HR OHIO OP CAH FFF PEH CHE Pe EF p rie p Hr VER ET 1 HIF kh HIF EMO Bo EIRE EACC LINCOLN B ti fe iF FOR ELECTRICAL DIAGRAMS WIRING DIAGRAM INVERTEC V330 IF HA OO eS EIC Tee PO bF Pri C E ihh DEEE EL ACIER EREPRISEERH HO ee ee PUE OB FL ER E WF ki i F F H E i HH 1 mul 2d 15 O F Oe 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 ELECTRICAL DIAGRAMS G 3 SCHEMATIC COMPLETE MACHINE EHH L H E LI Gom
106. ety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual 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 WELD DESCRIPTION This test will help determine if the machine is capable of producing welding output and to check and adjust if necessary the voltage and or current calibration MATERIALS NEEDED Resistive Load Bank Calibrated Test Voltmeter Calibrated Test Ammeter This procedure takes approximately 20 minutes to perform V350 PRO LINCOLN 48 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 2 1 Press and hold in the Mode Select button 2 Turn on the V350 PRO 3 Rotate the output knob while still holding the mode select button in until the displays read mode 200 NOTE Machines with an Advanced Process Panels do not have a mode select button Use the same procedure except hold in the Memory button on the advanced process panel instead of the mode select but ton 7 4 Release the Mode Select Memory button and the machine will be in mo
107. fore you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the control board for maintenance or replacement MATERIALS NEEDED 5 16 Nut Driver 3 8 Nut Driver Flathead Screwdriver Phillips Head Screwdriver This procedure takes approximately 30 minutes to perform V350 PRO LINCOLN F 52 F 52 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT continued FIGURE F 16 CONTROL BOARD LOCATION Control Board PROCEDURE 1 Remove input power to the V350 PRO 4 Locate the control board behind the front panel of the machine See Figure F 16 2 Using a 5 16 nut driver remove the case wrap around cover 5 Using a 5 16 nut driver remove the two screws from the bottom of the front of the machine See 3 Perform the Input Filter Capacitor Discharge Figure 17 Procedure detailed earlier in this section FIGURE F 17 CASE FRONT SCREW REMOVAL N Flathead Screws Phillips Head Screws 5 16 Screws V350 PRO LINCOLN F 53 F 53 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT continued FIGURE F 18 CONTROL BOARD ALL PLUG LOCATIONS 8 The front of the mac
108. form this installation Connect the green yellow lead of the power cord to ground per U S National Electrical Code SELECT SUITABLE LOCATION The Invertec V350 PRO will operate in harsh environ ments Even so it is important that simple preventative measures are followed in order to assure long life and reliable operation The machine must be located where there is free cir culation of clean air such that air movement in the back out the sides and bottom will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown Keep machine dry Shelter from rain and snow Do not place on wet ground or in puddles DO NOT MOUNT OVER COMBUSTIBLE SURFACES CAUTION Where there is a combustible surface directly under stationary or fixed electrical equipment that surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not less than 5 90 150mm beyond the equipment on all sides STACKING V350 PRO cannot be stacked TILTING Place the machine directly on a secure level surface or on a recommended undercarriage The machine may topple over if this procedure is not followed INPUT AND GROUNDING CONNECTIONS Only a qualified electrician should connect the Invertec V350 PRO Installation should be made in accordance with the appropriate National
109. formers two insulated gate bipolar transistor switching located on the switch board monitor these primary circuits fan motor drive circuit and a voltage fre Currents If the primary currents become abnormally quency capacitor feedback circuit The two capaci high the control board will shut off the IGBTs thus dis tors in a pair are always in series with each other bling the machine output The DC current flow When the reconnect switch is in the lower voltage through each primary winding is clamped back to position the capacitor pairs are in parallel Thus two respective input capacitor when the IGBTs are series capacitors in parallel with two series capacitors turned off This is needed due to the inductance of the When the reconnect switch is in the high voltage posi transformer primary winding The firing of the two tion the two capacitor pairs in series Thus four SWitch boards occurs during halves of a 50 microsec capacitors in series This is required to accommodate interval creating a constant 20 KHZ output In the higher input voltages some low open circuit Tig modes the firing frequency is reduced 5KHZ When the input capacitors are fully charged they act as power supplies for the IGBT switching circuits Invertec V350 Pro has a FA N fan as needed cir When welding output is required the Insulated Gate The fan operates when the welding output ter Bipolar Transis
110. ft Lft display Rt display Ht display This will only appear if a potentiometer is still connect dcon 14 ed to the 14 pin amphenol connector If this message appears disconnect the potentiometer from the 14 pin amphenol connector Test steps 21 24 verify the functionality of the gas sole noid If an oscilloscope is available verify that the cur rent flowing through the gas solenoid is zero before the solenoid is energized increases to approximately 700 pull in current remains at 700 mA for approxi mately 150 msec and decreases to approximately 200mA hold current Press the local remote pushbut ton to turn the gas solenoid on lt 150msec gt 200 Or the signal can be verified by measuring 12 3 VDC 5V from lead 553A to 554A Lead 553A should be positive Press the local remote pushbutton again to turn the gas solenoid off After completing all of the above tests the following will appear on the display Verify this message appears for approximately 3 sec DIAg PASS onds V350 PRO LINCOLN G 1 ELECTRICAL DIAGRAMS 6 1 TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION ELECTRICAL DIAGRAMS SECTION G WIRING DIAGRAM 2 ice saad ieee Agia ne CER G 2 MACHINE SCHEMATIC opoe m a RR we eae E RERO ae X UE ae Pe G 3 CONTROL PC BOARD SCHEMATIC 1
111. he case wrap around cover 4 Locate the power board See Figure F 34 V350 PRO LINCOLN F 77 F 77 TROUBLESHOOTING amp REPAIR POWER BOARD REMOVAL AND REPLACEMENT continued Locate the three plug connections J41 J42 and J43 See figure F 35 Carefully remove the three plugs from the power board Remove the three nuts and at the corners of the board using a 3 8 nut driver Board is ready for removal Remove the power board 10 11 12 Replace with new power board Secure the new power board into its proper posi tion with the three 3 8 nuts previously removed Replace the three plugs previously removed Plugs 941 J42 and J43 Replace the case wraparound cover FIGURE F 35 POWER BOARD LEAD LOCATION J42 J41 J43 m V350 PRO LINCOLN F 78 F 78 NOTES V350 PRO LINCOLN F 79 F 79 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT 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 If for any reason you do not understand the test procedures or are una
112. hine may now gently be pulled forward to gain access to the display Board Note A CAUTION The front of the machine cannot be removed com pletely only pulled forward a few inches Observe static precautions detailed in 9 Beginning at the right side of the control board Board Troubleshooting Procedures at the remove plugs J10A and J10B Note Be sure to beginning of this section label each plugs position upon removal See Figure F 18 6 Using flat head screwdriver remove the two 10 Working your way across the top of the board screws and their washers from above and below from right to left label and remove plugs J9 J8 the input power switch See Figure 17 J7 J6 and J5 See Figure F 18 7 Using a phillips head screwdriver remove the four 11 Working your way down the left side of the board screws from around the two welder output termi label and remove plugs J4 and J3 See Figure nals on the front of the machine See Figure 17 F 18 V350 PRO LINCOLN 54 12 13 15 16 17 18 54 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT continued Using a 3 8 nut driver remove the two mounting nuts from the top two corners of the control board See Figure F 19 Cut any necessary cable ties 14 Replace the control board FIGURE F 19 CONTROL BOARD MOUNTING SCREW LOCATION Mounting Nuts 3 8 Replace the two 3 8 mounting nuts at the top two corner
113. hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 8 Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 plates to protect your eyes sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 Welding may produce f
114. i L T TT TT PTT TE CSI IE LIL PLUS CO ibi I COLE TL u Lr 1 A L INIST ER a E LR CRT 1 ee ee SFE PCR LP l T rL l Lr T l T ee ee T T oJ SLL PE FR PPT TTF IDE D ISF TS LIT LEE 11 1 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is pro vided for reference only 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 Improper PC board repairs could result in damage to the LINCOLN i machine V350 PRO ELECTRICAL DIAGRAMS udis SCHEMATIC SNUBBER PRINTED CIRCUIT BOARD C4 0047 1000 V 6 2 2000 524761 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual G 20 E
115. ically turned off and then back on V350 PRO 10 11 12 13 14 15 Adjust the Output Control knob again if necessary to make the actual output cur rent reading on the test ammeter 300 amps 2A Wait for the machines output to be auto matically turned off and then back on Repeat the above two steps if necessary Press and release the Mode Select Memory button to save the calibra tion The left display will scroll the message IcAL SAVEd The machine will reset to normal operation NOTE If the Mode Select Memory button is not pressed within 30 seconds after adjusting the Output Control knob the machine will leave the calibration mode and use the previous calibration settings LINCOLN F 49 50 50 NOTES V350 PRO LINCOLN 51 51 TROUBLESHOOTING amp REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT 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 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 be
116. ication of K291 or K404 LN 7 input cable with K867 Universal Adapter Plug If a remote control such as K857 is to be used with the LN 7 the remote can be connected directly to the 6 pin MS style connector on the front of the Invertec or use a K864 adapter to connect the LN 7 and the remote to the 14 pin MS style connector See connection diagram 19901 N 10 Connection Instructions An LN 10 can only be used with the Factory amp Advanced Process versions of the 350 Pro Turn the Invertec power switch off Connect the K1505 control cable from the LN 10 to the 14 pin MS style connector Connect the electrode cable to the output terminal of polarity required by the electrode Connect the work lead to the other terminal Set the meter polarity switch on the front of the Invertec to coincide with wire feeder polarity used See the LN 10 manual for details on accessing Control DIP Switch LN 742 Connection Instructions An LN 742 can only be used with the Factory amp Advanced Process versions of the 350 Pro Turn the Invertec power switch off Either a K591 or a K593 Input cable assembly is required to connect the LN 742 to the Invertec Connect the control cable from the LN 742 to the 14 pin MS style connector Connect the electrode cable to the output terminal of the polarity required by electrode Connect the work lead to the other terminal Set the meter polarity switch on the front of the Invertec
117. if the correct voltage is being induced on the secondary windings of the transformer MATERIALS NEEDED Volt ohmmeter Multimeter 5 16 Nut Driver Wiring Diagram This procedure takes approximately 25 minutes to perform V350 PRO LINCOLN 34 34 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER TEST continued FIGURE F 8 Auxiliary Transformer Auxiliary Transformer Secondary Lead Plugs P52 TEST PROCEDURE 1 Remove input power to the V350 PRO 4 Locate the auxiliary transformer See Figure F 8 2 Using a 5 16 nut driver remove the case wraparound cover 5 Locate the secondary leads and plug P52 s See Figure F 8 and F 9 3 Perform the Input Capacitor Discharge Procedure detailed earlier in this section FIGURE F 9 Plug Lead Connections Viewed From Transformer Lead Side of Plug 532 42 24 31 54 541 V350 PRO LINCOLN 35 LEAD IDENTIFICATION F 35 TROUBLESHOOTING amp REPAIR AUXILIARY TRANSFORMER NO 1 TEST continued TABLE F 4 NORMAL EXPECTED VOLTAGE 31 TO 532 115 VAC 42 TO 541 42 VAC 24 TO 541 24 VAC 54 TO 541 28 VAC 7 Carefully apply the correct input voltage to the V350 PRO and check for the correct sec ondary voltages per table F4 Make sure the reconnect jumper lead and switch are config ured correctly for the input voltage being applied Make sure circuit breaker CB3 is functi
118. iled explanation at the end of this section ADVANCED PROCESS PANEL VERSION FIGURE B 2 DT KNOB 1 CONTROL Toca LOCAL output ON SELECT VOLTS WELD TERMINALS REMOTE SELECT MEMORY SELECT SELECT ADJUST D CX eig MEMORY BUTTON M1 THRU M8 SELECT KNOB SCOLLS WELDING PROCESSES ADJUST KNOB 0 THRU 10 HOT START 10 THRU 0 AND 0 THRU 10 ARC CONTROL SELECT BUTTON HOT START OR ARC CONTROL V350 PRO LINCOLN 6 6 OPERATION CONTROLS The MEMORY button and SELECT knob are used together to select a welding process and store it in memory 1 thru M8 The SELECT knob scrolls through the welding process modes and memory M1 thru M8 The MEMORY button stores the welding process in memory SELECT button The right button selects between the Hot Start or Arc Control The will indicate the active feature shown below Right Digital Window Hot Stat 10 to 0 10 Arc Control 0 to 10 ADJUST knob adjusts the desired settings for the Hot Start or Arc Control feature that is active WELDING PROCESS MODES AVAILABLE Stick SMAW TIG GTAW Gouge CAG CV MIG GMAW CV Flux Core Pulse MIG ELECTRODE MATERIAL Steel Metal Core Stainless Aluminum Nickel EXAMPLE O
119. is grounded correctly The machine is self clearing when There may be a problem condition ceases with the primary current sensors CT located on the main switch board See the wiring diagram The control board may be faulty 43 Capacitor banks A Make sure the recon There may be a problem lower and B upper nect switches are con with the V F signals from are not balanced figured for the input the main switch board to voltage being applied to the control board the machine The machine is self clearing Perform the Main Switch when condition ceases The capacitor s may be faulty Check and replace if necessary 44 The machine has Make sure the V350 Pro Perform the Power detected a fault in the is grounded correctly central processing unit CPU The machine is self clearing when condition ceases The control board or associated wiring may be faulty See the wiring diagram NOTE If more than one fault message is being displayed perform all the checks for the faults before replacing the printed circuit board V350 PRO LINCOLN 13 TROUBLESHOOTING amp REPAIR F 13 FAULT CODES DESCRIPTION CORRECTIVE SERVICE FACILITY RRECTIVE DEFINITION ACTION EN 47 Electrical glitch on the Possibly caused by an There may be a problem V F signals from the main switch board to the control board external electrical noise or signal level Make sure the V350 Pro is gro
120. istive load bank and loaded to 300 amps Table F 5 shows what with the V350 PRO in mode 200 Mode 200 is feedback voltage is produced at various cur a constant current test mode This mode can rent loads be accessed from the front panel of the V350 18 if the corect supalv valladescare apbied to by pressing and holding the Mode Select but ges epee the current transducer and with the machine ton while turning the machine on NOTE NP UC loaded the feedback voltage is missing or Machines with an Advanced Process Panels correct the current transducer may be faulty do not have a mode select button Use the Before replacing the current transducer check same procedure except hold in the Memory the leads and plugs between the control board button on the advanced process panel instead J8 and the current transducer J90 See The of the mode select button Then rotate the Wiring Diagram For access plug J90 output knob while still holding the Mode Select M the current transducer refer to button in until the displays read Mode 200 Transducer Removal and Replacement Release the Mode Select Button and the machine will be in mode 200 With the V350 PRO in mode 200 apply the grid load across 11 Remove input power to the V350 PRO aa lace the control box top and any cable ties put to 300 amps and enable WELD TERMI i 2 22 ae P y NALS Adjust the grid load to obtain 300 P
121. itches are configured for the input voltage being applied to the machine The machine is self clearing when condition ceases with the V F signals from the main switch board to the control board Perform the Main Switch Board Test Perform the Power Board Test The control board may be faulty NOTE If more than one fault message is being displayed perform all the checks for the faults before replacing the printed circuit board V350 PRO LINCOLN 10 10 TROUBLESHOOTING amp REPAIR FAULT CODES DESCRIPTION CORRECTIVE SERVICE FACILITY CORRECTIVE DEFINITION ACTION ACTION 33 Capacitor bank Make sure the reconnect There may be a problem B upper is under switches are configured with the V F signals from voltage for the input voltage the main switch board to being applied to the the control board machine The machine is self clearing when Perform the Main Switch condition ceases Perform the Power The control board may be faulty 34 Capacitor bank Make sure the reconnect There may be a problem A lower is over voltage switches are configured for the input voltage being applied to the machine The machine is self clearing when condition ceases with the V F signals from the main switch board to the control board Perform the Main Switch Board Test Perform the Power Board Test The control board may be faulty NOTE If more than one fault mess
122. kpoint source pushbutton again to select LorE workpoint source REMOTE and verify that the work point source LOCAL LED turns off and the workpoint source workpoint source LED turns on 30 Press the workpoint source pushbutton again and verify LorE cLr that both workpoint source LEDs are off This will only appear if a potentiometer is already con dcon 16 roCP nected to the 6 amphenol connector on the front of the machine If this message appears disconnect the potentiometer from the 6 pin amphenol connector Connect a remote output control potentiometer to the 6 6 PIn roCP pin amphenol connector on the front of the machine V350 PRO LINCOLN 95 95 TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR Expected Results 9 Lit display Rt display Adjust the remote output control potentiometer connect 6 roCP HI ed to the 6 amphenol connector to its highest set ting Adjust the remote output control potentiometer connect 6 PIn Lo ed to the 6 amphenol connector to its lowest set ting This will only appear if a trigger switch is already con 6 rlgr oFF nected to the 6 pin amphenol connector on the front of the machine and the trigger switch is presently on Turn the trigger switch connected to the 6 pin amphenol connector off Turn the trigger switch connected to the 6 pin amphenol 6 Rigr on connector on Turn the trigger swit
123. les Mount the new board on the nylon mount ing pins 13 14 15 16 17 18 Replace the four allen bolts and washers previously removed Replace the eight capacitor terminal nuts washers and necessary leads previously removed Reconnect the three harness plugs previous ly removed Reconnect the nine leads 8201 4209 that were previously removed Pre torque all screws to 25 inch 16 before tightening to 44 inch lbs Replace the case wraparound cover FIGURE F 24 NYLON MOUNTING PIN DEPRESS LOCKING TAB ON MOUNTING PIN V350 PRO LINCOLN F 61 62 62 NOTES V350 PRO LINCOLN F 63 F 63 TROUBLESHOOTING amp REPAIR ADVANCED PROCESS PANEL REMOVAL AND REPLACEMENT 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 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 WELD DESCRIPTION The following procedure will aid the technician in removi
124. licone sealant V350 PRO LINCOLN 24 24 NOTES V350 PRO LINCOLN 25 25 TROUBLESHOOTING amp REPAIR POWER BOARD TEST 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 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 WELD DESCRIPTION This test will help determine if the power board is receiving the correct voltages and also if the power board is regulating and producing the correct DC voltages MATERIALS NEEDED Volt Ohmmeter 5 16 Nut Driver Wiring Diagram This procedure takes approximately 30 minutes to perform V350 PRO LINCOLN 26 1 e TROUBLESHOOTING amp REPAIR POWER BOARD TEST CONTINUED TEST PROCEDURE Remove input power to the V350 PRO machine Using a 5 16 nut driver remove the case wraparou nd cover Perform the Capacitor Discharge Procedure detailed earlier in this section Locate the power board and plugs J41 J42 and J43 Do
125. lter Capacitor Discharge machine 2 Using the 5 16 nut driver remove the case 4 Locate plug J22 on the main switch board Do wraparound cover not remove the plug from the board See Figure 12 FIGURE F 12 PLUG 422 LOCATION 5 Carefully apply the correct input power to the 6 Carefully check for 115VAC at plug J22 pin 2 machine to J22 pin 3 leads 32A to 31B C See Figure 13 WARNING HIGH VOLTAGE 1 PRE SENT AT THE MAIN SWITCH BOARD FIGURE F 13 PLUG J22 Fan Lead Lead 32A Lead 31B C Fan Lead Plug J22 V350 PRO LINCOLN 43 7 F 43 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST continued If the 115VAC is low or not present check cir cuit breaker CB2 located on the front panel If the circuit breaker is OK perform The Check plug J22 circuit breaker CB2 and associated leads for loose or faulty connections See the Wiring Diagram Energize the weld output terminals Select Weld Terminals ON and carefully check for 115VAC at plug J22 pin 1 to J22 pin 4 fan leads If the 115VAC is pre sent and the fan is not running then the fan motor may be faulty Also check the associat ed leads between plug J22 and the fan motor for loose or faulty connections See the Wiring Diagram WARNING HIGH VOLTAGE IS PRESENT AT THE SWITCH BOARD If the 115VAC is NOT present in the p
126. lts display is simply a relative number and DOES NOT correspond to voltage Some procedure recommendations appear in the table below Recommended Welding Procedures for Power Mode MATERIAL Aluminum 4043 Aluminum 5356 Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Stainless Steel Stainless Steel WIRE E4043 E5356 L56 L56 L56 L56 E308L E308L 22 ga 125 12 25 125 11 75 Not Recommended 100 0 8 Not Recommended mio O 20ga 150 2 5 150 2 3 120 1 0 120 1 0 100 0 7 100 1 0 80 1 5 50 0 5 2 E 18 ga 200 3 75 200 3 0 140 17 140 1 5 110 1 5 110 1 5 100 2 5 110 2 0 110 2 0 16 300 7 75 300 6 85 190 2 0 190 2 0 125 2 0 125 20 125 3 0 140 2 5 130 27 V350 PRO LINCOLN 12 12 OPERATION PULSE WELDING GMAW P The pulsed arc process is by definition a spray trans fer process wherein spray transfer occurs in pulses at regularly spaced intervals In the time between pulses the welding current is reduced and no metal transfer occurs Pulsed arc transfer is obtained by operating a power source between low and high current levels The high current level or pulse forces an electrode drop to the workpiece The low current level or background main tains the arc between pulses See Figure below
127. mode Range 5 425 amps 5 425 amps 5 425 amps 10 45 volts 10 45 volts OPERATION Comments The stick soft mode is the best selection for general stick applications Arc Control Arc Force Hot Start Initial hot start current min start a match set amps Max greatest hot start current During hot start arc force is set at high andis fast response For gouging applications Turn current up to 425 amps The stick crisp mode features an aggressive arc force routine well suit ed for Exx10 11 series electrodes Arc Control Arc Force Hot Start Initial hot start current Mid range welding current and will vary up and down with knobcontrol During hot start arc force is set at high and is fast response For gouging applications Turn current up to 425 amps The tig mode produces a soft steady constant current waveform for either touch start or high frequency assisted start DC GTAW applica tions Hot Start Min to Mid range Touch start with low OCV Mid to Max range High frequency assistedstarting with adjustable OCV up to 70 volts The GMAW CV mode is the best selection for general MIG welding Metal core and gas shielded applications Arc Control Pinch Min min pinch softest arc Max max pinch crispest arc The FCAW SS mode is designed for Self Shielded Innershield products that require tight voltage control For example the NR 203 series or NR 207 Arc Control
128. modes The MEMORY but ton is used to store and access Welding modes into locations M1 thru M8 Modes In addition to the 5 welding modes described in SEC TION 7 the Advanced Process Panel allows you to select the Following additional modes Power Mode In the Power Mode The work point will be in the Volts window The Amp window will have CP displayed indicating Constant Power Once current starts flowing and during the 5 second Hold feature the displays will show Volts and Amps respectively Refer to the detailed expla nation at the end of this section Gouge Air Carbon Arc Cutting CAC A is a physical means of removing base metal or weld metal by using a car bon electrode an electric arc and compressed air Pulsed Modes In Pulse Modes The work point will be in the Amps window and should be set close to the wire feed speed of the wire feeder in inches per minute The Volts window will have SPd displayed indicating Wire Feed Speed Once current starts flowing and during the 5 second Hold feature the displays will show amps and volts Pulse Mode features that are displayed while select ing a Welding pulse mode are listed below Steel 030 035 045 052 Argon Blends Stainless Steel 030 035 045 Argon Blends amp Helium Argon Blends Aluminum 035 3 64 1 16 4043 amp 5356 Metal Core 045 052 Argon Blends Nickel 035 045 Argon Helium blends Refer to the deta
129. n filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts Exposure to EMF fields in welding may have other health when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN 8 effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 4 2 Never coil the
130. nal of polar ity required by electrode Connect the work lead to the other terminal LN 25 with Remote Control options can be used with the Factory Advanced Process version of the V350 The 6 Pin K444 1 and 14 pin K444 2 remotes can be connected directly to the 6 pin amp 14 pin MS style connectors The 42 Volt Remote Voltage and Output Control K624 1 Kit can be connected to the V350 s 14 pin MS style connector using Remote Control Cable assembly K627 LN 25s with a K431 1 remote kit can be connected to the V350 s 14 pin MS style connector using a K432 cable and K876 adapter See connection diagram 19899 Or the K432 cable could be modified with a K867 Universal Adapter Plug See connection diagram 19405 to connect it to the V350 s 14 pin MS style connector V350 PRO LINCOLN 4 L A 4 INSTALLATION N 7 Connection Instructions An LN 7 can only be used with the Factory amp Advanced Process versions of the 350 Pro L Turn the Invertec power switch off Connect the K480 control cable from the LN 7 to the 14 pin MS style connector Connect the electrode cable to the output terminal of the polarity required by electrode Connect the work lead to the other terminal Set the meter polarity switch on the front of the Invertec to coincide with wire feeder polarity used The wire feeder will now display the welding voltage If K480 is not available see connection diagram 19404 for modif
131. nce only It may not be accurate for all machines covered by this manual EN 168 V350 PRO 6 10 ELECTRICAL DIAGRAMS G 10 PC BOARD ASSEMBLY SWITCH on Ian ee Ce im unm irr me iim im Ian finis immer rm iro ns n im im jmmmrm ri uan or rmn im huno or pusu RCE emen CIE ELITE CRTC Inim ra julie PES CITOYENS Oe Co COTE TTC IT ee ND 1 CCC COX aa ee pee ui ui ir um ur ur CS o Cs A gm E MUFACE ee Cs GHD DEHTFIGATICH COTE me foe D Lia ere ee jumrm ee ere FI UN ur nn fus eee MI 4 r lumrmTLLE34HELLUIR AN C LR LL H enc
132. nded maximum size carbon is 5 16 The Hot Start control regulates the starting current at arc initiation Hot Start can be adjusted from min imum 0 with no additional current added at arc start to maximum 10 with double the preset cur rent or 425 amps max of machine added for the first second after arc initiation The Arc Control regulates the Arc Force to adjust the short circuit current The minimum setting 10 will produce a soft arc and will produce minimal spatter The maximum setting 410 will produce a crisp arc and will minimize electrode sticking CC STICK CRISP The Stick Crisp mode features tinuous control from 5 to 425 amps This mode was intended primarily for pipe welding applications The Hot Start control regulates the starting current at arc initiation Hot Start can adjust starting current up or down by 2596 of the preset value The recom mended setting for Hot Start is 5 where the initial cur rent is equal to the preset current Hidden Middle Control Panel Mode Panel FIGURE B 1 WS 22 5 V350 PRO LINCOLN 5 B 4 The Arc Control regulates the Arc Force to adjust the short circuit current The minimum setting 10 will produce a soft arc and will produce minimal spat ter The maximum setting 10 will produce a crisp
133. ng cables for loose or faulty connection Make sure the machine s mode and output are set correctly for the process being used CV CC TIG etc Mig welding make sure the shielding gas and wire speed are correct for the process being used Check for proper current and voltage calibration the Voltage ana Calibration 1 Perform Current Procedure 2 Perform the Transducer Test 3 Perform the Output Diode Module Test 4 The control board may be faulty 5 The advanced process panel If used may be faulty CAUTION 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 V350 PRO LINCOLN TROUBLESHOOTING amp REPAIR FAULT CODES DESCRIPTION CORRECTIVE SERVICE FACILITY CORRECTIVE DEFINITION ACTION ACTION 31 Main transformer Turn the machine off and Perform the Main Switch primary over current back on to reset the machine If condition persists contact an Perform the Power authorized Lincoln Field Service Facility There may be a problem with the primary current sensors CT located on the main switch board See the Wiring diagram The control board may be faulty 32 Capacitor bank A Make sure the reconnect There may be a problem lower is under voltage sw
134. ng the mode board for maintenance or replacement MATERIALS NEEDED 5 16 Nut Driver Small Flathead Screwdriver Flathead Screwdriver Small Phillips Head Screwdriver Phillips Head Screwdriver 9 16 Wrench This procedure takes approximately 40 minutes to perform V350 PRO LINCOLN 64 64 TROUBLESHOOTING amp REPAIR ADVANCED PROCESS PANEL REMOVAL AND REPLACEMENT continued FIGURE F 25 MODE BOARD LOCATION Display Board Mode Board or Advanced Process Board PROCEDURE 3 Perform the Input Filter Capacitor 1 Remove input power to the V350 PRO Discharge Procedure detailed earlier in this section 2 Using a 5 16 nut driver remove the case wraparound cover 4 Locate the advanced process board behind the front panel of the machine See Figure 25 V350 PRO LINCOLN F 65 F 65 TROUBLESHOOTING amp REPAIR ADVANCED PROCESS PANEL REMOVAL AND REPLACEMENT continued FIGURE F 26 CASE FRONT SCREW REMOVAL AMPS VOLTS CONTROL WELD TERMINALS REMOTE REMOTE LOCAL OUTPUT ON SELECT SELECT LOPI SELECT KNOB ADJUST ATTRIBUTE Flathead Screws Phillips Head lt 7 Screws D 5 16 Screws 5 Using a 5 16 nut driver remove the two screws 7 Using a phillips head sc
135. ntrol pots should be kept identical on the two machines V350 PRO LINCOLN 6 NOTES V350 PRO LINCOLN A 6 Section B 1 Section B 1 TABLE OF CONTENTS OPERATION SECTION Section Safety PreCautlOnS tst steep cease o ERE SER ER a B 2 General Description sise B 2 Duty Cy Cle nnm B 2 Operational Features and Controls sise B 2 Weld EHRES B 3 Serum B 3 CriSp caste C sens B 3 MICE B 4 4 SV IAMONSION 4 Advanced Process Panel ucc rp netus O 5 5 M B 6 Electrode Material cela 6 Hot Start amp Arc Control arna S aE ETARE Ea AANE SETANS B 6 Weld Mode Details B 7 Pulse 5 eicit d eei i lae eta E B 8 Lower FON cR 9 Ae o Fes fa seats Ges cues B 9 B 9 erc diuelcq B 9 Types of Remote Output Control issu
136. o ne 58 K 7 TIOVVL 09 3 MC33074AD R138 49 9 3 NAA 9 9 1 2W HV DES VOLTAGE R125 C56 3500 VOLTS 7OV 0 9V ON CONNECTOR D27UF IRF7103 1 lt GAIN lt 11 IDEAL V_AD m me 2 5V 70 ArcVOLTS AS 1 AS Mall LECSZSW LEZSZSIN 12925 eus T Lens T L AVS j Ms SONS cva OLTAGE FEEDBAC CONTAINS PROPRIE Y INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND 15 NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO U S A home Po EQUPHENT TYPE INVERTER WELDERS ONS PLAGE DECIMALS S 00 XNS625 632 2000 DRAWNBY 1 pru te SUBJECT DIGITAL CONTROL SCHEMATIC amp emos 12 15 99 DRAWNGNo 3789 100 3 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN V350 PRO G 7 SCHEMATIC DIGITAL CONTROL PC BOARD 4 ELECTRICAL DIAGRAMS C98 C100 DATA 5 DATA13 TACK ADDR1 ADDR2 ADDRS ADDR6 ADDR8 ADDRO ADDR10 0 1uF 0 1uF 75 0 1uF 0 1uF DSP SCK7 SPI LATCH7 AD AD DATAO DSP 00 Eee el DSP A0 DSP D9 23 DSP D10 145 33
137. of the rear assembly See Figure F 41 202 203 206 207 from the reconnect switches See Figure F 41 8 Locate the steel nut located directly on the other side of the rear assembly behind the plastic nut that was previously removed See Figure F 41 FIGURE F 41 LEAD LOCATIONS V V350 PRO LINCOLN 90 90 TROUBLESHOOTING amp REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT continued 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 Carefully swing the rear of the machine open to the left while facing the rear of the machine Perform the Snubber Board Removal Remove leads X2 and 20 from the output diode module Remove leads X4 and 40 from the other output diode module 16 17 18 19 20 Using a 3 8 wrench remove the three mounting screws from the output diode heatsink assembly Take note placement of insulation for reassembly See Figure F 42 Cut any necessary cable ties and carefully remove the heavy lead from the diode heatsink using a 1 2 nut driver Remove the output diode heatsink assembly through the rear of the machine Remove plug J90 from the current transducer Using a 3 8 nut driver remove the two mounting nuts from the current transduc
138. oning properly NOTE The secondary voltages will vary if the input line voltage varies If the correct secondary voltages are present the auxiliary transformer is functioning proper ly If any of the secondary voltages are miss ing or low check to make certain the primary is configured correctly for the input voltage applied See Wiring Diagram WARNING High voltage is present at primary of Auxiliary Transformer 9 If the correct input voltage is applied to the primary and the secondary voltage s are not correct the auxiliary transformer may be faulty 10 Remove the input power to the V350 PRO 11 Install the case wraparound cover using a 5 16 nut driver V350 PRO LINCOLN F 36 F 36 NOTES V350 PRO LINCOLN 37 37 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST 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 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 WELD
139. ory of Operation Section E Troubleshooting and Section F How to Use Troubleshooting F 2 Troubleshooting rentals Ca uUa F 4 Test Procedure Si adessent F 15 Replacement Procedures ss sise F 51 Electrical 5 Section Parts Manual RR ERREUR M rene 401 Series V350 PRO LINCOLN SectionA 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION Installation Technical S PCCIICATIONS i ERES A 2 rie ren atti omens eee leet Un ae A 3 Input Grounding Connectlorns uoto E ere x Ra A 3 Power Cord Connec ON oiii re oer A 3 Connection of Wire Feeders eee A 3 A 4 Cobramatic Connection Instructions ss A 4 Parallel erit ete Rr ree RR ERE A 5 V350 PRO LINCOLN 2 INSTALLATION 2 TECHNICAL SPECIFICATIONS INVERTEC V350 PRO INPUT AC VOLTAGE amp DC OUTPUT Rated DC Output Weight Dimensions Open Amps Volt g with Cord HxWxD Circuit Duty C
140. ote Board Removal and Replacement F 69 Snubber Board Removal and Replacement ss F 73 Power Board Removal and Replacement sse F 75 Input Rectifier Removal and Replacement ss F 79 Output Rectifier Modules Removal and Replacement F 83 Current Transducer Removal and Replacement ss F 87 Retest after eo F 92 V350 PRO LINCOLN F 2 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE CAUTION 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into three main categories Output Problems Function Problems and LED Function Problems Step 2
141. ower to the V350 PRO 2 Connect the electrode cable from the K480 control cable to the terminal of the welder and to the LN 7 wire feeder Connect the work cable to the terminal of the welder NOTE Figure C 5 shows the electrode connected for positive polarity To change polarity shut the welder off and reverse the electrode and work cables at the output terminals NOTE Welding cable must be sized for current and duty cycle of application 3 Connect the input cable from the K480 control cable to the 115VAC 14 pin amphenol on the V350 PRO and the input cable plug on the LN 7 Set the VOLTMETER switch to or depending on the polarity chosen Set CONTROL SELECT to REMOTE Set the MODE to the CV WIRE position Place the WELD TERMINALS SELECT in the REMOTE position Adjust wire feed speed at the LN 7 and adjust the welding voltage with the optional remote control if used Set the ARC control at O initially and adjust to suit Figure C 5 V350 PRO LN 7 with K480 Control Cable Connection Diagram 14 PIN AMPHENOL 115VAC AT REAR OF MACHINE 6 PIN AMPHENOL K480 CONTROL CABLE TO LN 7 INPUT CABLE PLUG OPTIONAL K857 REMOTE CONTROL ELECTRODE CABLE TO WIRE FEED UNIT TO WORK V350 PRO LINCOLN C 9 ACCESSORIES d CONNECTION OF THE K867 ADAPTER FOR USE WITH THE K291 OR K404 INPUT CABLES AND LN 7
142. ps b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims V350 PRO LINCOLN 4 4 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical damage is evident when the sheet metal cover is removed POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Contact your local authorized Lincoln Electric Field Service Facility for technical assistance TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Contact the Lincoln Electric Service Department 1 800 833 9353 WELD The machine is dead no output no displays Make sure the input line breaker switch is in the ON position Check the 3 5 amp circuit break er CB3 Reset if tripped Check the main input line fuses If open replace Check the 3 5 amp circuit break er CB2 Reset if tripped Check the 6 amp circuit breaker CB1 Reset if tripped Make sure the reconnect switch and jumper lead is configured correctly for
143. put Control Terminals Output Potentiometer GENERAL DESCRIPTION The Invertec V350 Pro is an inverter based welding power source that offers multi mode constant voltage CV and constant current CC welding and is rated at 350 amps 34VDC at a 60 duty cycle The Invertec V350 Pro is available in a construction version no wire feeder connection or auxiliary power a factory ver sion that includes a wire feeder connection and relat ed power an advanced process version and a rack version INPUT LINE VOLTAGE AUXILIARY TRANSFORMER amp PRECHARGE The Invertec V350 Pro can be connected for a variety of three phase or single phase input voltages The ini tial power is applied to the V350 through a line switch located on the front of the machine Two phases of the input voltage are applied to the auxiliary transformer The auxiliary transformer develops four different sec ondary voltages The 115VAC is used to power the fan motor and also is applied to the 14 pin amphenol type connector for wirefeeder operation The 24VAC and 42VAC voltages are also applied to the 14 pin amphe nol type connector to power wirefeeders The 28VAC Power Board SPI Supply 15VDC 5VDC Control Board RS232 Supply 5 VDC ts gt RS232 SPI Communications amp 15VDC 5VDC Supply x Ad d Remote Control amp Tri Moog i itn mote rigger Remote lel mesa Display Process Board Not used if APP Panel is in place Le Panel m
144. r counter LEnc clockwise until the value displayed on the Advanced Process Panel lower left display equals zero Note that this should require exactly one revolution of the encoder knob Turn the Advanced Process Panel right encoder clockwise rEnc 100 until the value displayed on the Advanced Process Panel lower left display equals 100 Note that this should require exactly one revolution of the encoder knob Turn the Advanced Process Panel right encoder counter rEnc clockwise until the value displayed on the Advanced Process Panel lower left display equals zero Note that this should require exactly one revolution of the encoder knob 17 Press and hold the Advanced Process Panel Memory but EorY OFF ton until the right display changes to on Release the Advanced Process Panel Memory button Press and hold the Advanced Process Panel Select button Release the Advanced Process Panel Select button Verify that the Advanced Process Panel upper left display dISP contains the following pattern and that the brightness of the characters is uniform 0123456789ABCDEF Press and release the Advanced Process Panel Memory button to advance to the next step Verify that the Advanced Process Panel lower left display diSP contains the following pattern and that the brightness of the characters is uniform 0123456789ABCDEF Press and release the Advanced Process Panel Memory button to advance to the next step V350
145. r in this section Replace the case wraparound cover FIGURE F 39 OUTPUT RECTIFIER MODULE MOUNTING BOLT LOCATIONS Mounting 40 20 Bolts Bolts X4 X2 Bolts Mounting Bolts V350 PRO LINCOLN F 86 F 86 NOTES V350 PRO LINCOLN 87 87 TROUBLESHOOTING amp REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT 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 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 WELD DESCRIPTION The following procedure will aid the technician in removing the current transducer for maintenance or replacement MATERIALS NEEDED 5 16 Nut Driver 1 4 Nut Driver 1 2 Nut driver 3 8 Nut Driver Channel Locks Flathead Screwdriver Phillips Head Screwdriver Hammer Crescent Wrench Pliers This procedure takes approximately 45 minutes to perfo
146. rating properly The fan should operate when welding voltage is present and or when there is an over temperature condition TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 The 115VAC fan motor is con trolled by the control board via the main switch board Perform the A thermostat or associated cir cuitry may be faulty See the wiring diagram One normally closed thermostat is located on the output choke and the other is located on the main switch board heat sink See the wiring diagram Note Removal Procedure will be required to gain access to the heat sink thermostat An attached wire feeder will not function correctly Make certain the wire feeder control cable is connected to the correct 14 amphenol type plug 115 or 24 42VAC for the wire feeder being used See the connection diagram If wirefeeder has DIP switch be sure it is set correct ly 2 Check the two circuit breakers located at the rear of the machine Reset if tripped The wire feeder or control cable may be faulty 1 Perform the Transformer Test 2 Check the leads between the 14 pin amphenol type plugs and the auxiliary transformer for loose or faulty connections CAUTION 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 procee
147. revious Step then proceed to the fan control test FAN CONTROL TEST PROCEDURE 1 Locate plug J20 on the switch board Do not remove the plug from the switch board See Figure F 12 F 14 Energize the weld output terminals Select Weld Terminals ON and carefully check for 15VDC at plug J20 6 to J20 pin 2 leads 715 to 716 See Figure 14 If the 15VDC is present and the fan is not running then the switch board may be faulty If the 15VDC is not present when the weld terminals are energized then the control board may be faulty Also check plugs J20 J7 and all asso ciated leads for loose or faulty connections See the Wiring Diagram WARNING HIGH VOLTAGE IS PRESENT AT THE SWITCH BOARD Remove the input power to the V350 PRO Note The fan motor may be accessed by the removal of the rear panel detailed in Current Transducer Removal Replacement Procedure 4 Replace the case wrap around cover FIGURE F 14 PLUG J20 Lead 716 Plug J20 Lead 715 V350 PRO LINCOLN 44 44 NOTES V350 PRO LINCOLN 45 45 TROUBLESHOOTING AND REPAIR SPI CABLE RESISTANCE AND VOLTAGE TEST 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
148. rewdriver remove the from the bottom of the front of the machine four screws from around the two welder output See Figure F 26 terminals on the front of the machine See Figure F 26 6 Using a flat head screwdriver remove the two screws and their washers from above and 8 The front of the machine may now gently be below the input power switch See Figure pulled forward to gain access to the mode F 26 board Note The front of the machine cannot be removed completely only pulled forward a few inches V350 PRO LINCOLN F 66 F 66 TROUBLESHOOTING amp REPAIR ADVANCED PROCESS PANEL REMOVAL AND REPLACEMENT continued FIGURE F 27 CASE FRONT AMPS VOLTS CONTROL WELD TERMINALS LOCAL ON SELECT SELECT 4 5 16 Screws Om Adjust Knob Select Knob QD D 9 Remove plug J33 from the remote board See the Wiring Diagram 10 Open the cover of the weld mode display on the front of the machine 11 Using a 5 16 nut driver remove the three 5 16 screws as shown in Figure F 27 12 Place both knobs in the six o clock position 13 Using small flathead screwdriver loosen the screw in the Select knob and the Adjust knob The knobs should slide off of their shafts See Figure F 28 14 Using a
149. rgized 8 Set the ARC CONTROL to the O position and then adjust to suit Figure C 1 V350 PRO LN 25 ACROSS THE ARC CONNECTION DIAGRAM 6 pin Amphenol Optional K444 1 Remote Control LN 25 Wire Feeder Work Clip Lead To Work Electrode Cable NOTE Illustration shows electrode connected for negative polarity V350 PRO LINCOLN 5 5 ACCESSORIES 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 Welding cable must be sized for current and duty cycle of the application 3 Connect the K857 remote control to the 6 pin amphenol on the V350 PRO 4 Attach the single lead from the LN 25 control box to the work using the spring clip on the end of the lead This is only a control lead it carries no welding current 5 Set the voltmeter switch to the electrode polarity chosen 6 Set CONTROL SELECT to REMOTE 7 Set the MODE to the CV WIRE position 8 Set WELD TERMINALS SELECT to the ON position A CAUTION If you are using an LN 25 without an internal con tactor the electrode will be HOT when the V350 PRO is energized 9 Set the ARC CONTROL to the position and then adjust to suit
150. rm V350 PRO LINCOLN F 88 F 88 TROUBLESHOOTING amp REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT continued PROCEDURE 4 Using a 5 16 nut driver remove the four screws from the bottom and right side of the rear assem 1 Remove input power to the V350 PRO bly See Figure F 40 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 FIGURE F 40 CASE BACK SCREW LOCATIONS HEAR Plastic Nut p 5 16 Mounting Screws V350 PRO LINCOLN TROUBLESHOOTING amp REPAIR i CURRENT TRANSDUCER REMOVAL AND REPLACEMENT continued 5 Label and remove the five leads connected to the 9 Using a hammer and a flathead screwdriver firmly reconnect panel Pliers may be necessary tap the metal nut from the bottom of one of its ribs This tapping will loosen the nut Note Be sure to 6 Label and remove the two leads connected to the tap from the bottom so the nut loosens in a counter CB2 circuit breaker clockwise fashion if viewed from the front of the machine 7 Using a crescent wrench remove the large plastic nut from around the input power line located at bot 10 Using a 3 8 nut driver label and remove leads tom
151. rmed 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 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 WELD DESCRIPTION The following procedure will aid the technician in removing the main switch board for main tenance or replacement MATERIALS NEEDED 5 16 Nut Driver Flathead Screwdriver 7 16 mm Socket 3 16 Allen Wrench 3 8 Nut Driver This procedure takes approximately 35 minutes to perform V350 PRO LINCOLN 60 60 TROUBLESHOOTING amp REPAIR MAIN SWITCH BOARD REMOVAL amp REPLACEMENT continued FIGURE F 22 MAIN SWITCH BOARD LEAD LOCATIONS PROCEDURE 1 2 3 Remove the input power to the V350 PRO Using a 5 16 nut driver remove the case wrap around cover Perform the Input Filter Capacitor Discharge detailed earlier in this section CAUTION Observe static precautions detailed in PC Board Troubleshooting Procedures at the beginning of this section Failure to do so can result in perma nent
152. s a type of transistor IGBT are semiconduc tors well suited for high frequency switching and high current applications Example A in Figure E 6 shows an IGBT in passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain ter minal of the IGBT may be connected to a voltage sup ply but since there is no conduction the circuit will not supply current to components connected to the source The circuit is turned OFF like a light switch Example B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the source is applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply con nected to the drain terminal will allow the IGBT to con duct and supply current to the circuit components coupled to the source Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present This is similar to turning ON a light switch FIGURE E 6 IGBT GATE lt BODY REGION POSITIVE VOLTAGE APPLIED GATE SOURCE 0222 BODY REGION n lt DRAIN DRIFT REGION lt DRAIN DRIFT REGION i PP mseorne raven aver DRAIN DRAIN A PASSIVE B ACTIVE V350 PRO LINCOLN E 8 E 8 THEORY OF OPERATION FIGURE E 7 TYPICAL IGBT OUTPUTS lusec
153. s not been turned on During welding this meter displays actual average volts After welding the meter holds the actual voltage value for 5 seconds The displays blink indicating that the machine is in the Hold period Output adjustment while in the hold period results in the prior to operation characteristics stated above 3 OUTPUT CONTROL Output control is conducted via a single turn poten tiometer Adjustment is indicated by the meters as stated above When in TIG modes this control sets the maximum welding current Full depression of a foot or hand Amptrol results in the preset level of current 4 WELD TERMINALS REMOTE ON Two status lights indicate the location of trigger con trol as determined by the WELD TERMINALS push button If trigger control is local weld terminals on the ON display will be lit f trigger control is remote weld terminals remotely controlled the REMOTE display will be lit V350 PRO LINCOLN 3 OPERATION The unit will power up in pre determined preferred trigger modes STICK ON CV REMOTE TIG REMOTE if remote output controls are attached to the machine TIG ON if remote output controls are not attached to the machine For all 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 THE
154. s of the control board Replace any previously removed cable ties Replace plugs J3 J4 45 J6 J7 48 J9 J10B and J10A previously removed 21 Replace the two screws and their washers from above and below the input power switch 22 V350 PRO 20 Replace the four screws from around the two welder output terminals on the front of the machine Replace the two case front mounting screws at the bottom of the front of the machine Replace the case wraparound cover Perform the Voltage and Current Calibration Procedure LINCOLN F 55 F 55 TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT 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 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 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the display board for maintenance or replacement MATERIALS NEEDED 5 16 Nut
155. s on accessing the control DIP switch 11 The control DIP switch inside the LN 10 should be set per the instructions in the LN 10 manual Figure C 8 LN 10 V350 PRO 14 PIN AMPHENOL 24 42VAC AT REAR OF MACHINE TO WORK TO LN 10 K1505 ELECTRODE CABLE TO LN 10 V350 PRO LINCOLN NOTES V350 PRO LINCOLN Section 0 1 Section 0 1 TABLE OF CONTENTS MAINTENANCE Maintenance Section D Capacitor Discharge Procedure ies D 2 Visual ELLE D 2 Routine SAER D 2 REDE RE HAE LEER RR Rina nad D 2 Major Component LOCations cose ho ERE HIR EXER RR RARE cours RERRRRXERA D 3 V350 PRO LINCOLN D 2 D 2 MAINTENANCE 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 problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop 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 AL a BE
156. ses are used to obtain spray transfer and transfer metal across the arc Such pulses are shown in the figure below After a number N of such pulses depending on the wire feed speed used an identical number N of low energy pulses are performed These low energy pulses shown in the figure below do not transfer any filler metal across the arc and help to cool the arc and keep the heat input low N PULSES 1 PULSES HIGH LOW PULSES PULSES PEAK BACKGROUND AMPS TIME The Peak Current Background Current and Frequency are identical for the high energy and low energy pulses In addition to cooling the weld down the major effect of the low energy pulses is that they form a weld ripple Since they occur at very regular time intervals the weld bead obtained is very uniform with a very consistent ripple pattern In fact the bead has its best appearance if no oscillation of the welding gun whipping is used See the figure below When Arc Control is used in the Pulse on Pulse modes it does the same things it does in the other pulsed modes decreasing the Arc Control decreases the droplet transfer and weld deposition rate Increasing the Arc Control increases the droplet transfer and weld deposition rate Since Arc Control varies weld droplet transfer rate the Arc Control can be used to vary the ripple spacing in the weld bead BENEFITS OF PULSE ON PULSE FROM LINC
157. shers upon removal 10 Replace the case wraparound cover FIGURE F 33 SNUBBER BOARD LEADS CLOSE UP Lead 20 V350 PRO LINCOLN F 75 F 75 TROUBLESHOOTING amp REPAIR POWER BOARD REMOVAL AND REPLACEMENT 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 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 WELD DESCRIPTION The following procedure will aid the technician in removing the power board for maintenance or replacement MATERIALS NEEDED 5 16 Nut Driver 3 8 Nut Driver This procedure takes approximately 20 minutes to perform V350 PRO LINCOLN 76 F 76 TROUBLESHOOTING amp 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 3 Perform the nput Filter Capacitor Discharge Procedure detailed earlier in this section 2 Using a 5 16 nut driver remove t
158. t be removed completely only pulled forward a 6 Using a flat head screwdriver remove the two few inches screws and their washers from above and below the input power switch See Figure 9 The display board is now accessible to F 21 replace 7 Using a phillips head screwdriver remove the four screws from around the two welder out put terminals on the front of the machine See Figure F 21 V350 PRO LINCOLN 58 10 11 12 13 14 58 TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL amp REPLACEMENT continued Remove plug J37 from the display board See the Wiring Diagram Remove plug J3 originating from the control board located directly across from the display board See the Wiring Diagram Remove the display board Note Gentle prying from behind the board may be required Replace the display board Replace plugs J3 and J37 previously removed 15 Replace the four phillips head screws removed 16 17 18 from the front of the machine located around the two welder output terminals Replace the two flat head screws and their wash ers mounting the input power switch Using a 5 16 nut driver replace the two screws previously removed from the bottom front of the machine Replace the case wraparound cover V350 PRO LINCOLN F 59 F 59 TROUBLESHOOTING amp REPAIR MAIN SWITCH BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be perfo
159. t between the 6 and 14 pin MS style connectors CV modes The remote will default to the 14 pin MS style con nector if a remote is connected If no remote is con nected to the 14 pin MS style connector then the remote will default to the 6 pin MS style connector if a remote is connected to it all of the CV modes the WELD TERMINAL con trol will default to REMOTE TIG mode The remote will default to the 6 pin MS style if a remote control is connected to the 6 pin MS style and to the 14 pin MS style connector If a remote is not connected to the 6 pin MS style connector then the remote will default to the 14 pin MS style con nector if a remote is connected remote control is connected to any of the MS style connectors the WELD TERMINAL control will default to REMOTE If there are not any remote con trol devices attached the WELD TERMINAL control will default to ON CC Stick modes The remote will default to only the 6 pin MS style connector if a remote is connected to it The WELD TERMINAL control will default to ON with or without a remote connected Types of Remote OUTPUT CONTROL The Invertec V350 Pro s Output Control can be con trolled by either a potentiometer connected between 77 amp 75 with the wiper connected to 76 or a OV to 10V DC supply connected between 76 amp 75 76 needs to be positive 14 Pin Ms style connector lead 75 is pin G lead 76 is pin F and lead 77 is pin E 6 Pin Ms
160. t from around input power line located at the back of the machine Replace the five leads to the reconnect panel in their proper locations Replace the two CB2 circuit breaker leads previ ously removed Using a 5 16 nut driver replace the four screws at the bottom and right side of the rear assembly Replace the case wraparound cover Perform the Voltage and Current Calibration LINCOLN 92 92 TROUBLESHOOTING AND REPAIR RETEST AFTER 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 Press and hold the MODE SELECT button or the MEMORY button if an advanced process panel is installed while applying power to the machine Rotate the output control knob until the display reads SPIdIAG Release the MODE SELECT button Test ee Expected Results qu Lit display display Adjust the output control potentiometer to its highest oCP HI setting completely clockwise Adjust the output control potentiometer to its lowest oCP setting completely counterclockwise NOTE standard Mode Select Panel is not installed in the machine skip st 3 Adjust the hot start potentiometer to its highest setting HSP 4 ___ the hot start potentiometer to is lowest setting Ai weld mode indicator LEDs should be off Press the
161. tions detailed throughout this manual 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 WELD DESCRIPTION This test will help determine if the power section of the switch boards are functioning cor rectly This test will NOT indicate if the entire PC board is functional This resistance test is preferable to a voltage test with the machine energized because this board can be damaged easily In addition it is dangerous to work on this board with the machine energized MATERIALS NEEDED Analog Volt Ohmmeter 5 16 in Wrench 7 16 in Wrench This procedure takes approximately 30 minutes to perform V350 PRO LINCOLN 18 18 TROUBLESHOOTING amp 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 V350 PRO Using a 7 16 wrench locate label and remove leads 201 202 203 204 205 206 207 and 208 from the switch board Note lead and washer placement for reassembly Clear leads Using the Analog ohmmeter perform the resis tance tests detailed in Table F 1 Refer
162. tivate the output of the Invertec V350 Pro 14 Pin MS style connector the Weld Terminals are controlled from pin C lead 2 and pin D lead 4 Pin C is positive 6 Pin MS style connector the Weld Terminals are controlled from pin D lead 2 and pin E lead 4 In the 6 pin MS style connector pin D is positive V350 PRO LINCOLN OPERATION AUXILIARY POWER 115VAC 42VAC and 24VAC power is available from the 14 pin MS style connector The Construction model of the Invertec V350 Pro does not have the 14 pin MS style connector These supplies are intended to supply power for auxiliary equipment like wire feeders and the TIG Module 115VAC supply is rated at 2 amps and is protected by a 3 5 amp breaker 42 VAC supply is rated at 5 5 amps and is protected by a 6 amp breaker 24 VAC supply is rated at 5 5 amps and is protected by a 6 amp breaker LIMITATIONS The V350 Pro is not recommended for processes other than those listed The V350 Pro can only be used with the recom mended equipment and options RECOMMENDED PROCESSES Properly equipped the Invertec V350 Pro supports GMAW P FCAW SMAW GTAW and CAC A processes for a variety of materials including mild steel stainless steel cored wires and aluminum V350 PRO LINCOLN 11 OPERATION SPECIAL WELDING PROCESSES AVAILABLE ON THIS MACHINE POWER MODE The Power Mode process was developed by Lincoln to maintain a stable and smooth
163. to coincide with wire feeder polarity used The wire feeder will now display the welding volt age If a remote control such as K857 is to be used with the LN 742 the remote can be connected directly to the 6 pin MS style connector on the front of the Invertec or use a K864 adapter to connect the LN 742 and the remote to the 14 pin MS style connector Cobramatic Connection Instructions A Cobramatic can only be used with the Factory amp Advanced Process versions of the 350 Pro Turn the Invertec power switch off Connect the control cable from the Cobramatic to the 14 pin MS style connector Connect the electrode cable to the output terminal of the polarity required by electrode Connect the work lead to the other terminal Set the meter polarity switch on the front of the Invertec to coincide with wire feeder polarity used If a remote control such as K857 is to be used with the Cobramatic the remote can be connected directly to the 6 pin MS style connector on the front of the Invertec or use a K864 adapter to connect the cobramatic and the remote to the 14 pin MS style connector TIG Module K930 2 The TIG Module connects to the Factory and Advanced Process V350 Pro versions with a K936 1 9 14 pin control cable Connect the K936 1 to the MS style connector The TIG Module can also be used with the V350 Pro Construction version A K936 4 control cable is required to supply 115VAC to the TIG Module from an e
164. to fig ure F2 for test point locations Note Test using an Analog ohmmeter on the Rx1 range Make sure the test probes are making electri cal contact with the conductor surfaces on the PC board LINCOLN 19 6 19 TROUBLESHOOTING amp REPAIR MAIN SWITCH BOARD TEST continued If any test fails replace the switch board See 8 Main Switch Board Removal and Replacement If the switch board resistance tests are OK check connections on plugs J20 J21 J22 and all asso ciated wiring See wiring diagram Reconnect leads 201 202 203 204 205 206 207 and 208 to the switch board Ensure that the leads are installed in their proper locations Pre Torque all leads nuts to 25 inch lbs before tight ening them to 44 inch lbs Replace the case wraparound cover using a 5 16 nut driver TABLE F 1 SWITCH BOARD RESISTANCE TEST APPLY POSITIVE TEST APPLY NEGATIVE TEST NORMAL PROBE TO TERMINAL PROBE TO TERMINAL RESISTANCE READING V350 PRO Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms LINCOLN 20 20 NOTES V350 PRO LINCOLN F 21 F 21 TROUBLESHOOTING amp REPAIR INPUT RECTIFIER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in dang
165. tors switch the DC power from the input Minals are energized or when a thermal over tempera capacitors on and off thus supplying a pulsed DC ture condition exists Once the fan is activated it will current to the main transformer primary windings See remain on for a minimum of five minutes The fan dri IGBT Operation Discussion and Diagrams in this ver circuit is housed on the switch board but it is acti section Each IGBT switching circuit feeds current to Vated from a control board signal a separate oppositely wound primary winding in the NOTE Unshaded areas of Block Logic Diagram are the subject of discussion V350 PRO LINCOLN 4 4 THEORY OF OPERATION FIGURE E 4 POWER BOARD CONTROL BOARD AND SERIAL PERIPHERAL INTERFACE SPI COMMUNICATIONS To Control Board Main Switch Board AZ Positive Input FR Output Input switch Rectifier RE Terminal Sensor ZA Negative Reconnect Output gt Switch Terminal T 2 Sensor o CE at 9 Primary Current Feedback 5 5 Input Relay Control 8 8 Soft Start Control 5 5 V F Capacitor Feedback 2 o Machine Control Supply 15VDC 15VDC 5VDC Power hae Board SPI Supply 15VDC 5 Control Board gt RS232 Supply 5VDC RS232
166. ts add helium to the argon base from 0 25 PULSE ON PULSE Arc Control Pulse on Pulse frequency For faster travel 4x Pulse Pulse 85 400 speed welds the arc control should be increased 5x Pulse on Pulse 130 700 For larger puddle slower travel speeds the arc control 5x Pulse on Pulse 100 550 should be decreased Refer to the detailed explanation at the end of this section IPM INCHES PER MINUTE V350 PRO LINCOLN 9 OPERATION LOWER CASE PANEL The output studs line switch and remote connector are located on the lower case front 9 Both terminals are Twist Mate connectors The Negative terminal is configured to accept the pass through gas system 10 The METER POLARITY switch is located above the output connectors The switch provides a work connection for wire feeder voltmeters Place the switch in the position of the electrode polarity indi cated by the decal The switch does not change the welding polarity 11 6 pin MS style connector for remote control 12 14 pin MS style connector for wire feeder connec tion and remote control REMOTE CONTROL of the OUTPUT CONTROL and WELD TERMINALS The Invertec V350 Pro has auto sensing of remote out put controls after connecting or removing a remote the Invertec V350 Pro did not configure the way you would like the local or remote control settings can be changed by pushing the OUTPUT CONTROL or WELD TERMINAL button A user cannot selec
167. umes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Mar 95
168. unded correctly The machine is self clearing when condition ceases with the V F signals from the main switch board to the control board Perform the Main Switch Board Test Perform the Board Test The control board may be faulty bad node HEHH The selected weld mode does not exist in the weld table that is presently loaded in the machine Press the Mode Select button to select a different welding mode If new software was just installed try reinstalling the software or put the original software back Perform the Board Test Perform the SPI Cable Resistance and Voltage The control board may be faulty NOTE If more than one fault message is being displayed perform all the checks for the faults before replacing the printed circuit board V350 PRO LINCOLN NOTES V350 PRO LINCOLN 15 15 TROUBLESHOOTING amp REPAIR INPUT FILTER CAPACITOR DISCHARGE 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact
169. xternal 115VAC supply General Instructions for Connection of Wire Feeders to V350 Pro Wire feeders other than those listed above may be used provided that the auxiliary power supply rating of the V350 Pro is not exceeded K867 universal adapter plug is required See connection diagram S24985 on page F 4 REMOTE CONTROL OF INVERTEC Remote Control K857 Hand Amptrol K963 and Foot Amptrol K870 UNDERCARRIAGE MOUNTINGS MOUNTING HOLE LOCATIONS NOTE MOUNTING SCREWS CAN NOT PROTRUDE MORE THAN 0 5 INCHES INSIDE THE MACHINE 9 9 3 50 sa e rm HHH d MEC 10 00 11 84 4 01 M19527 V350 PRO LINCOLN 5 INSTALLATION PARALLEL OPERATION The V350 Pro can be paralleled in CC mode For best results the currents of each machine should be rea sonably well shared an example with two machines set up in parallel for a 400 amp procedure each machine should be set to deliver approximately 200 amps not 300 amps from one and 100 amps from the other This will minimize nuisance shutdown con ditions In general more than two machines in paral lel will not be effective due to the voltage requirements of procedures in that power range To set machine outputs start with output control pots and arc control pots in identical positions Use the output control pots to balance the currents and main tain the desired current The arc co
170. y amps the external ammeter and check 13 Install the case wraparound cover using the feedback voltages per Table F 5 5 16 nut driver A Pin 1 lead 801 to Pin 6 lead 806 should read 2 4 VDC machine loaded to 300 amps V350 PRO LINCOLN 40 40 NOTES V350 PRO LINCOLN 41 41 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST 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 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 WELD DESCRIPTION This test will help determine if the fan motor control board switch board or associated leads and connectors are functioning correctly MATERIALS NEEDED Voltmeter 5 16 Nut Driver This procedure takes approximately 40 minutes to perform V350 PRO LINCOLN 42 42 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST continued TEST PROCEDURE 1 Remove the input power to the V350 PRO Perform the Input Fi
171. y board See Wiring Diagram Remove plugs 133 J333 J331 from the remote board Using a flat head screwdriver remove the two mounting screws and washers from the bottom of the remote board See Figure F 31 Remove the remote board Replace the remote board Replace the two flat head mounting screws and washers previously removed from the bottom of the remote board Replace plugs J331 J333 J33 and previously removed from the remote board 17 18 20 21 Replace plug J37 previously removed from the display board Replace the four phillips head screws removed from the front of the machine located around the two welder output terminals Replace the two flat head screws and their wash ers from around the input power switch Using a 5 16 nut driver replace the two screws previously removed from the bottom front of the machine Replace the case wraparound cover FIGURE F 31 REMOTE BOARD PLUG LOCATION J33 Remote Board Co J333 Flathead Mounting Screws V350 PRO 4331 LINCOLN 73 F 73 TROUBLESHOOTING amp REPAIR SNUBBER BOARD REMOVAL AND REPLACEMENT 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 pl
172. ycle Voltage Construction 81 0 lbs 350A 34V 60 36 7 kg 14 8 x 18 83 x 208 230 27 8 380 400 Factory 373 x 338 x 415 460 81 0 Ibs 706 mm 575 300A 32V 100 36 7 kg Process 60 50 Hz Advanced Process 81 5 Ibs 37 0 kg Overall Length Including Handle 27 8 706mm V350 PRO INPUT CURRENT Recommemded Fuse Sizes Base On The U S National Electrical Code And Maximum Machine Outputs 32Volts 100 34Volts 60 Recommended Recommended 230 1 69 85 4 125 Note 2 Recommended Recommended Recommended Recommended 80A Note 2 70A 50A as y O 415 1 41 64 460 1 36 42 575 1 Note 2 Note 2 Note 1 Not rated is indicated by 4 x s in the box on the rating plate Note 2 When operating on these inputs the line cord should be changed to an input conductor of 6 AWG or larger OUTPUT CABLES CONNECTIONS AND LIMITATIONS Select The output cable size based upon the following chart Cable sizes for Combined Length of Electrode and Work Cable Copper 75C rated DUTY CYCLE CURRENT LENGTH UP TO 200FT 61m 200 250 FT 61 76m 100 300 1 0 1 0 60 350 1 0 2 0 V350 PRO LINCOLN A 3 A 3 INSTALLATION SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can 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 per

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