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Lincoln Electric MULTI-WELD SVM151-A User's Manual

1. V FFFDBACK NC lt jeu LABELS vo THERMAL SENSE INI ov 2ATUR HERMAL LAMP A suayecr CUR LIM TIG FEEDBACK ETC THE LINCOLN ELECTRIC CO ANALOG WELD CONTROL ND OHIO U we SCALE NONE 1 pate 03 23 00 SUP S D G Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN E INCOLN S MULTI WELD 350 G ELECTRICAL DIAGRAMS CONTROL PC BOARD 5 Jumper in Plug COIL DRIVE CIRCUIT HOLD COIL MULTIARC FAN w SHORT CIRCUIT PROTECTION FOR AUX USE PULL TO COM TO REMAIN TO IDLE PULL COIL CIRC PCB METER_WELD_SIGNAL Return to Section TOC Return to Master TOC TO IDLE HOLD OIL
2. _ Return to Master TOC Return to Section TOC REFZ MIN POT ENABLE fpga LO PINCH PO o o 8 8 B L4 o o 2 o 8 B FORCE
3. REMOTE THE LINCOLN ELECTRIC yee ANALOG WELD CONTROL PCB EVELAND OHIO U S A SUBJECT SETPOINT PWM amp ARC CONTROL NONE AM SUP S D G Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 3 MULTI WELD 350 ELECTRICAL DIAGRAMS e SCHEMATIC CONTROL PC BOARD 3 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC RANGE END POINT CIRCUI 0 SUPPLY GN OUT DISCHG
4. e M PART NO ELECTRICAL DIAGRAMS PC BOARD REFERENCE DESIGNATORS DESCRIPTION S25000 28R7SMT R155 R156 R157 R158 R159 R160 G 8 IRESISTOR SMD METAL FILM 1 10W 28 70HM G3660 C WELD CONTROL PCB BLANK 524671 PLUG KEYING PLUG 525001 10005 R161 R162 R163 R164 R165 R166 RESISTOR SMD 1000HMS 1 4W 1206 1 TR M19436 2 POTTING TRAY 525001 12135 R167 R168 R169 RESISTOR SMD 121K 1 4W 1206 1 TR 58025 80 SELF TAPPING SCREW 525000 22115MT R170 R171 R172 R173 R174 RESISTOR SMD METAL FILM 1 10W 2 21K 1 E2527 EPOXY ENCAPSULATING RESIN E3539 ELECTRICAL INSULATING COMPOUND 525001 75005 R175 RESISTOR SMD 7500HMS 1 4W 1206 19 TR 524762 4 1 x30 SOFTWARE 525001 20025 R176 R177 R178 RESISTOR SMD 20K 1 4W 1206 1 TR 524763 4 1 X33 SOFTWARE 525000 33215 R179 R180 R181 R182 R183 IRESISTOR SMD METAL FILM 1 10W 3 32K 1 FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS 525004 24305 R184 R185 R186 R187 RESISTOR SMD 1W 2430HMS 1 525000 20025 R188 RESISTOR SMD METAL FILM 1 10W 20 0K 1 525020 35 1 2 3
5. fpga VOL ON HI SUPPLY ON TO ER 0022 50V 406680 13 ED 4 m METER TIOLD HI HOLD C OC 1 cNY17 3VC TO AMMETER INPU 010 PNE 5 4 ESET J VOLTMETER INPU 4 lb VOLTMETE V RIGHT DECIMAL PT gt 7 gt DECIMAL PT COMMON 728 Douger in Plug Vai URING HOLD Return to Section TOC Return to Master TOC METER PRESET CIRCUIT MAX_POT_END_PT 2 4100pF gt 1V 1000A 100 Sov MAX PRESET LEVEI REMOTE WELDING CONTACTOR CONTROL CIRCL 2 amp 4 CLOSURE FROM OL a
6. GE 1 OF 5 ANALOG WELD CONTROL PCB FPGA MEMORY amp INTERFAC SUP S D G Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 MULTI WELD 350 ELECTRICAL DIAGRAMS CONTROL PC BOARD 2 MAIN WELDING CONTROL W AUTOMATIC REMOTE LOCAL SETPOINT CIRCUIT MIN CURREN HOT_SETPOINT Return to Section TOC Return to Master TOC C AMPHENOL V PIPE ENABLE fpga 0 CVwithout PINCH POT STICK PIPE Tit XED_MIN_ ENABLE
7. o o 8 8 B L4 o o 2 o 8 B gt MIN POT END PT THE LINCOLN ELECTRIC CO i ANALOG WELD CONTROL PCB VERSION 21008 CLEVELAND OHIO U S A suasect POWER CONNECTIONS ECT 3 03 E SHT No G3661 2 NUMBER Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 3 MULTI WELD 350 ELECTRICAL DIAGRAMS 55 CONTROL PC BOARD 4 TOUCH START TIG CIRCUIT 5 REFERENCE SUPPLY OCV CONTROL CIRCUIT approx 78v CUR SENSE TIMED Dale 1206 Return to Section TOC Return to Master TOC SWITCH SENSE
8. Return to Section Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp MULTI WELD 350 ELECTRICAL DIAGRAMS G 14 PC BOARD ASSEMBLY ANALOG _ ojo 918 Blt PC BOARD REFERENCE em 5 NC a ds PART NO ES CNATORE DESCRIPTION 2 8 1 lexres 1 PCB BLANK NE 2 52467 t PLUG KEYING PLUG BE 194363 2 C ON 68025 80 SELF TAPPING SCREW i 5 _ 2527 1120 1 05 EPOXYENCAPSULATING RESIN D 6 539 ____ 5 __ ______________ INSULATING COMPOUND FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS 6 7 151349066 5 1 03 64 05 8 CAPACITOR 47 35V 10 151349025 CAPACITOR 4 7 35V 10 M 9 516668 11 C7 08 09 610 011 C12 C13 ICAPACITOR CEMO 0 1 50V 1096 111577 62 CAPACITOR PEMF 1 0 200V 109 E 1 15166684 2 15020 7 jCAPACITOR CEMO 2700PF 50 5 o gs i2 siea 2 oeoa OAPACITOR CEMO T00PF 100V 5 ee 8 din 13 em ____________ 00152000V M 14 513490 97 3 C18 C19 023 CAPACITOR 100 20 10 EEE CAPACITOR CEMO 150P 100V 5 FEE 16 Tig70547 1 Di DIODEAXLDS 4A200VUFR
9. LES ie ele s e 9 ons e ejoa e 9 B 8 e e e g ooje e s O_O fee 2 s e s e v ve lee we Or so sf 0 E zs E w glee 9 19 75 8
10. LO AT ENGINE 15 Dole 12 CIRCUIT JRRENT S TOROID SENSE AUX CIRCUIT Return to Master TOC Return to Section TOC TOROID CONNEC AUX CURREN SENSING CUR_SENSE INDICATES HERMAL SENSE CIRCU N ARC FORCE SENSE CIRC Ojo ojo Ele og o t gls ge E E BIZ o o HERMAL LIGHT MULTIARE TOD
11. 50V 1ms Retum to Master TOC 5 5 9 8 This is the typical CV open circuit out put voltage generated from a properly operating machine that each vertical division represents 50 volts and that each horizontal division rep 9 8 resents 1 millisecond in time F AE 5 8 SCOPE SETTINGS 8 8 Volts Div 50V Div 5 5 Horizontal Sweep 1 ms Div Coupling DC gc Trigger Internal Retum to Section TOC Retum to Master TOC MULTI WELD 350 LINCOLN Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 34 TROUBLESHOOTING amp REPAIR CASE FRONT ASSEMBLY 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 trou bleshooting assistance befo
12. F 48 Power Capacitor Removal and F 51 Chopper PC Board and Diode Module Removal and Replacement F 54 Diode Module Removal and Replacement sse F 57 Retest After tnter E Saee XR TERR ARBRES REM e RENE F 60 8 8 MULTI WELD 350 LINCOLN 5 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty 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 malfunc tions Simply follow the three step procedure list ed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exh
13. o E 5 B Return to Section TOC Return to Master TOC Q 7 52 2 THEORY OF OPERATION FIGURE E 7 TYPICAL IGBT OUTPUTS MINIMUM OUTPUT 2 usec Dwell or Off Time 48 u sec 50 sec MAXIMUM OUTPUT PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the cycle Changing the pulse width is known as MODU LATION Pulse Width Modulation PWM is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine MINIMUM OUTPUT By controlling the duration of the gate signal the IGBT is turned on and off for different durations during a cycle The top drawing shows the minimum output sig nal possible over a 50 microsecond time period 48 sec Dwell or Off me 50 usec The positive portion of the signal represents one IGBT group conducting for 2 microsecond The dwell time off time is 48 microseconds Since only 2 microseconds of the 50 microsecond time period is devoted to conduct ing the output power is minimized MAXIMUM OUTPUT By holding the gate signals on for 48 microseconds and allowing only 2 microseconds of dwell time off time during the 50 microsecond cycle the output is maxi mized The darkened area under the top curve can be compared to the area under the bottom curve The more darkened
14. B 9 Far as Needed FAN B 9 Over Voltage enne nennen nnn B 9 Over Gurrent Y B 9 5 Over Temperature Shutdown sss nennen nensi B 9 8 5 8 8 i ux MULTI WELD 350 LINCOLN 8 Retum to Section TOC Return to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC B 2 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine SAFETY INSTRUCTIONS WE ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrodes with your skin or wet clothing e Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES CAN BE DANGEROUS Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone E WELDING SPARKS CAN CAUSE nh FIRE OR EXPLOSION Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS CAN BURN Wear eye ear and body protection Observe additional Safety Guidelines detailed in the beginning of this manual MULTI WELD 350 LINCOLN 8 B 2 Retum to Section Return to Section TOC 8
15. cue m PARALLEL Constant Voltage CV mode for positive polarity cored and solid wire welding with arc powered feed ers such as the LN 25 Portable The Multi Weld 350 can be moved quickly The light weight Converter is easy to carry or pull and is small enough to fit through a 15 38 cm diameter or 12 x 16 31x 41 cm elliptical man hole The Converter is powered by the welding cable from the DC power source without the safety hazard of high AC input supply voltages Welding controls are near the arc without long con trol cables and a receptacle is provided for an optional remote for even closer user output control MULTI WELD 350 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Return to Section to Master TOC to Master TOC Y 4 2 5 rA Retum to Master TOC OPERATION Simple Easy installation with 10 ft 3 m work clip lead and user preference quick connect pig tails for input and electrode weld cables Easy setup with only a few intuitive welding controls and lit displays This includes a single Power Mode switch with Input level light and a single presettable Output Control with separate digital meters for Amps and Volts featuring post weld five second memory display Easy Service with quick to replace cable pig tails and plug in assembly modules including accessi
16. Pn Section B g Safety 6 a 2 8 Product 8 1 1610 e B 3 E Recommended Equipment and B 4 4 Multi System Power Source B 4 Distibutlom MINIM UII INE B 4 Pig Tail Leads and entente nnne B 4 Remote Output Control Options B 5 CV Mode Wire Welding B 5 CC Mode Stick Welding and Gouging ssssssssssssseeeeee enne B 5 5 Front Panel Controls dE B 6 5 Recessed Panel Controls nen 7 g Paralleled nsns senten tens nennen B 8 8 Remote Control of Paralleled Converters sse B 8 5 Transporting and Storage of the Multi Weld 350 B 8 Handling tices 8 Dilecte B 9 C X B 9 Protection E
17. O 6 Insulated Gate Bipolar Transistor IGBT E 7 Pulse Width Modulation expe RE REM 8 Chopper Technology Fundamentals sss eee nennen entren nnns nnns E 9 4 E MULTI WELD 350 BLOCK LOGIC DIAGRAM i 4 INPUT LEFT AND RIGHT DIODES INPUT CHOPPER MODULES CONTACTOR CR1 gt IGBT FREEWHEELING DIODE TO ELECTRODE CHOPPER MODULE Sa oc CAFACMORS CURRENT FEEDBACK 3 NODE T inier DIODE TO WELD CONTROL BOARD 6 DC 1 Kg m CHOPPER MODULE SOUS es js POWER 5 SOURCE cate 6 EXTERNAL ANALOG SONALS 2 CONTROL REGULATED RECEPTACLE 8 POWER E SUPPLY cum 8 BOARD 2 ARC OUTPUT HOT THERMAL SO PERIPHERAL BOARD 2 WORK FIGURE E 1 MULTI WELD 350 BLOCK LOGIC DIAGRAM Y 4 2 8 z 5 A MULTI WELD 350 LINCOLN 8 THEORY OF OPERATION Return to Section TOC 9 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC CR1 INPUT CAPACITORS ON OFF MODE DC POWER SOURCE EXTERNAL lt FREEWHEELING DIODE CHOPPER MODULE pera EE CHOKE CHOPPER MODULE 15 FORCE CONTROL START LIGHT PERIPHERAL BOARD 8 9 FIGURE E 2 INPUT POWER SOURCE CONTACTOR AND DC BUSS POWER SUPPLY BOARD j ar 2 MULTI WELD 350 BLOCK LOGIC DIAGRAM 2 8 8 EJE
18. 2 17 Tigz0559 1 D2 DIODE 05 g 5 18 marsa 2 bab DIODE AXLDS 1ASDVSCHOTTKY La 5 p 19 71270544 6 D4D5D7DB8D9D10 DIODE AXLDS 1A 1000V FR BIB 20 1112702 45 i lba DIODE 1W 18V 5 2 21 111270225 2 ipz2 pz3 ZENER DIODE 5W 20 5 22 15240204 1 41 4 p 23 52402010 CONNECTOR MOLEXMNI PCB 10 PIN 724 _ 51500 _ 1 loar OPTOCOUPLERPHOTO O 70v 25 T12704 89 TRANSISTOR NMF T247 38A 250V SS 26 519400 3922 4 R1R2A27 A28 RESISTOR MF 4W 39 2K 196 6 14 RESISTOR MF 1 4W 10 0K 196 519400 1502 1 4 RESISTORMF tAW 15 0K 196 519400 5622 1 R5 BRESISTORMF 1 4W 56 2K 196 80 5194004422 3 R amp RILRI2 RESISTOR MF t MW 44 2K 196 o o UNLESS OTHERWISE SPECIFIED R7 R8 A25 RESISTOR MF 1 4W 47 5 1 CAPACITORS MFD VOLTS 32 T12300 86 1 R9 RESISTORWW 3W 0 05 1 Ele m NOTES RESISTORS 1 4W OHMS R10 RESISTOR 1 4W 150 1 EEE INDUCTANCE HENRYS RESISTOR 1 4W 1 21 1 9 e CAUTION THS DEVICE IS SUBJECT TO DAMAGE BY BUY AS 35 819400 2211 RESISTOR MF 1 4W 2 21K 1 wn STATIC ELECTRICITY LINCOLN ELECTRIC TO SEE E2454 S19400 3382 1 m8 RESISTOR MF 1 4 33 21 EJE NB PLACE CONNECTOR PLUG OVER HEADER PIN IN 19423 1 0 5194002213 1 0 221 1 B 2 LOCATION SHOWN PLUG SHOULD BE INS
19. TO ELECT 1 WORK SY 4 IN DAISY CHAIN OPERATION ELECT SOURCE TO POWER SOURCE TO ELECT N TO WORK AS O ELECT WORK q SS 2 SEPARABLE PARALLEL OPERATION ELEC Tz m 1 WORK 2 c 0 ELECT PARALLEL JUMPER ELECT mm TO ELECT 1 TO WORK TOPOWER SOURCE MULTI WELD 350 LINCOLN 8 t Retum to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION For Converters operating at rated output less than 200 ft 61 m from the power source the following min imum cable sizes are recommended for the indicated quantity of Converters supplied by the input cable run to keep cable temperature and voltage drop within acceptable limits Converters Cable Size on Cable AWG 2 1 1 0 50 2 2 0 70 3 3 0 95 4 4 0 120 5
20. n lt BUFFER LAYER p INJECTING LAYER DRAIN A PASSIVE INSULATED GATE BIPOLAR TRANSISTOR IGBT OPERATION An IGBT is a type of transistor IGBTs are semicon ductors well suited for high frequency switching and high current applications Drawing A shows an IGBT in a passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain terminal of the IGBT may be connected to a voltage supply 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 in the OFF position POSITIVE VOLTAGE GATE SOURCE BODY REGION DRAIN DRIFT REGION lt BUFFER LAYER lt INJECTING LAYER DRAIN B ACTIVE Drawing 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 circuit components coupled to the source Current will flow through the conducting IGBT to downstream components as long as the posi tive gate signal is present This is similar to turning ON a light switch MULTI WELD 350 LINCOLN 8 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC
21. 8 Return to Section Retum to Master TOC to Master TOC Retum to Master TOC F 38 F 38 TROUBLESHOOTING amp REPAIR WELD CONTROL OR PERIPHERAL PC BOARD REMOVAL AND REPLACEMENT CONTINUED 7 Carefully label and remove the 12 molex plugs from the Weld Control PC board Press and hold the keeper on each plug as you remove it Also remove plug P31 from the Peripheral PC Board as shown in This will allow the assembly to lie flat 8 Using the 3 8 nut driver remove the four 2 nuts holding the Weld Control PC Board in place 3 NOTE Verify the orientation of the Weld Con trol PC Board for replacement You may need to remove a nut on the Peripheral PC Board in order to free the Weld Control PC Board REPLACEMENT PROCEDURE 1 Set the Weld Control PC Board squarely onto the studs and press it in place Verify proper orientation Replace any nuts removed from the Peripheral PC Board at disassembly Tighten the four 3 8 nuts holding the board in place Attach the molex plugs including the plug removed from the Peripheral PC Board at disassembly See the Wiring Diagram NOTE Make sure jumper plug P3 is in place 4 Attach the rear panel with seven 5 16 9 Carefully remove the Weld Control Board Screws 5 Perform the Case Front Assembl NOTE It may be necessary to pry gently on the PC Board to remove it 6 Perform MULTI WELD 350 LINCOLN P Replacem
22. DC Trigger Internal Retum to Section TOC Retum to Master TOC MULTI WELD 350 LINCOLN 30 30 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CV MODE OUTPUT CONTROL AT MAXIMUM Retum to Section TOC Retum to Master TOC 0 volts HHEH H 0 volts 50V 5us Retum to Master TOC 5 5 9 8 This is the typical CV output voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal division represents 9g 5 us in time PE il A SCOPE SETTINGS 8 Volts Div 50V Div 5 5 Horizontal Sweep 5 us Div cic Coupling DC Trigger Internal Retum to Section TOC Retum to Master TOC MULTI WELD 350 LINCOLN 31 31 TROUBLESHOOTING amp REPAIR NORMAL WELD VOLTAGE WAVEFORM MACHINE LOADED TO 350 AMPS AT 34 VOLTS CC STICK MODE Retum to Section TOC Retum to Master TOC 0 volts 50V 50us Retum to Master TOC 5 5 9 8 This is the typical CC output voltage generated from a properly operating machine Note that each vertical divi sion represents 50 volts and that each horizontal division represen
23. E og o t gls ge E E 818 o o Return to Master TOC G 8 PC BOARD ASSEMBLY CONTROL o 87 i BHoooe 00000 EO O O 07 5 CI D39 004 pa uun nit unm 30 H s s 1 EVA D5 062 D x33 2 R380 x56 t V x24 ENED 06 01 PED jer i R85 89 R86 890 gg REB m 6766 4 l Eun e 5 x 4 008 561 X C C C C x os oop 0 1 2 C C C L C n mmn 9 a 022 xit 025 052 EN 8 E x X35 x10 US b mm
24. Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 6 F 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The Multi Weld 350 does not have output The meters turn on the input contactor activates and the Thermal light is off POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Check the welding cables for loose or faulty connections TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Check for loose or faulty con nections at the Control box the Chopper boards and the Analog Power Supply Board See the Wiring Diagram Check the heavy current carry ing leads at the choke the chopper boards the shunt and the output terminals for loose or faulty connections See the Wiring Diagram 3 Perform the Chopper Board Input Voltage and Resistance 4 Perform the Analog Control Power Supply Board Test 5 The Weld Control Board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or 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 MULTI WELD 350 LINCOLN 8 7 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROB
25. D INPUT LEFT AND RIGHT cic DIODES BOT CHOPPER MODULES CONTACTOR IGBT TO ELECTRODE CABLE FREEWHEELING DIODE 4 ON OFF VOLTS AMPS GATE SIGNALS ANALOG CONTROL POWER SUPPLY BOARD REGULATED VOLTAGES RECEPTACLE CC SLOPE STICK GOUGE or PIPE ARC OUTPUT HOT THERMAL CONTROL 1 COIL INPUT C INDICATOR LIGHT GENERAL DESCRIPTION The MULTI WELD 350 Converter uses a single DC input power source to provide up to 350 continuous amps for positive polarity stick wire processes and arc air gouging The machine converts higher volt age lower current DC input power to lower voltage higher current DC output power with over 9096 efficiency This DC output is controlled by Chopper Technology to produce DC current for multi purpose welding applications INPUT POWER SOURCE CONTACTOR AND DC BUSS POWER SUPPLY BOARD The Multi Weld 350 receives DC input power from an 80 VDC buss Multi Source recommended although other external DC sources such as the Lincoln Electric DC 1000 DC 655 or DC 600 can be used if they pro duce 50 VDC or above WORK The 50 supply voltage is applied to the input contactor via two large input diodes The input contac tor establishes the electrical connection between the Multi Weld 350 and the power source when the ON OFF MODE switch is activated in either the con stant cur
26. C14 516668 3 CAPACI TOR CEMO 100P 100 5 C11 C17 C7 C8 C9 C10 5 16668 10 516668 11 CAPACI TOR CEMO 4700P SOV 2 CAPACI TOR CEMO 0 1 SOV 10 R15 R16 R12 R13 519400 47R5 19400 1000 RESI STOR MF 1 4W 47 5 1X RESISTOR MF 1 4 100 1 L 11078 1 SHT NO R3 R4 R5 R7 R8 R14 R22 S 19400 1002 19400 1821 RESISTOR MF 1 4W 10 OK 1 RESI STOR MF 1 4W 1 82K 1 MULTI WELD 350 R23 519400 2213 RESISTOR MF 1 4W 22 IK 1 R20 R21 19400 2672 RESISTOR MF 1 4W 26 7K 1 SUP S D G R29 19400 3323 RESISTOR 1 4W 332K 1 R28 19400 4752 RESISTOR MF 1 4W 47 5K 1 R19 19400 5622 RESISTOR MF 1 4W 56 2K 1 R9 RIO R11 19400 8251 RESISTOR MF 1 4W 8 25K 1 C13 20500 2 CAPACI TOR 0 47 630V 10 BOX J46 J47 524020 4 524020 8 CONNECTOR MOLEX MI NI PCB 4 PIN TIN CONNECTOR MOLEX MINI PCB 8 PIN TIN 02 01 112199 1 112199 2 DI ODE AXLDS 1A 4007 DI ODE _05 1 10007 L1 R26 R27 122 18 16 12300 86 CHOKE GH CURRENT 100UH 104 10 LOW RESISTOR Ww 0 05 1 024 112702 25 ZENER DI ODE SW 20V 5 1N5357B 025 026 04 112702 45 112705 23 ZENER DIODE Iw 18V 5 1 4746 DI ODE AXLDS 1A 30V SCHOTTKY 1 58 18 D5 D3 112705 34 T1
27. X54 00 Ops ce x39 X00 4 V x 3 47 l we als 061 MA 037 4 b l l DAS l Vl TUTE 024 95 omn its epg wey nung 002 ui 42 ja nsum 8 DIO R359 pooo O WELD CONTROL REV CR o 23 24 ECOL i Qs IE o E e o 8 e e 5
28. 1 Disconnect input power to the Multi Weld 350 A WARNING ELECTRIC SHOCK can kill Disconnect input power before removing the case cover and performing tests or making repairs to the machine 2 Perform the Power Module Capacitor Discharge procedure 3 Locate the input contactor and coil leads 303A and 330 See Figure 4 5 MULTI WELD 350 LINCOLN P Label and disconnect leads and 330 at their in line connectors Using the external isolated 40 VDC power supply carefully apply 40 VDC to the coil leads The contactor should activate With the contactor activated check the con tinuity across the large contacts Zero ohms or very low resistance is normal See Figure F 3 If the resistance is high the input contactor is faulty Replace the input contactor When the contactor is not activated the resistance should be infinite or very high across the contacts If the resistance is low the input contactor is faulty Replace the input contactor Remove the 40 VDC external supply and reconnect the coil leads previously removed If finished testing perform the Case Cover Replacement procedure Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 20 TROUBLESHOOTING amp REPAIR ANALOG CONTROL POWER SUPPLY PC BOARD TEST WARNING
29. 525001 47855 525010 45 525010 55 525000 75005 525000 22105 525000 20005 525000 51115 525000 20025 525056 35 525000 15025 525000 68115 525000 47515 Return to Section Return to Master TOC aa afro 44 UNLESS OTHERWISE SPECIFIED RESISTANCE OHMS SCHEMATIC REFERENCE G3663 NOTES NAA CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY LINCOLN ELECTRIC TO SEE E2454 BEFORE HANDLING Ojo ojo Ele og o t gls ge E E BIZ o o PLACE CONNECTOR KEYING PLUG OVER HEADER PIN IN LOCATION SHOWN PLUG SHOULD BE INSERTED BELOW CONNECTOR TOP SURFACE SECURE PC BOARD ASSEMBLY IN PLACE WITH ITEM 4 2 PLACES IDENTIFY COMPLETE ASSEMBLY WITH A PRINTED LABEL OR OTHER PERMANENT MARKING IN AREA SHOWN BUY AS NO COMPONENTS ON BOTTOM SIDE OF PC BOARD BUY PER E3867 G3662 1B0 TEST PER E3869 P PROGRAM ITEM ITEM PART NO 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 Ten Senis T aeneo EEN p E eee pues meme ANALOG CONTROL psa ee
30. Carefully turn the machine onto its side 6 Using the 3 8 wrench remove the four 10 11 screws holding the tunnel assembly to the machine base Then carefully turn the machine back upright With the slot head screw driver carefully raise the tunnel assembly unit about one inch and block it with the piece of wood This will allow access to the bottom allen head screw on the diode module Peel away the adhesive backed rubber stripping as necessary Use care the stripping may tear Using the 7 16 wrench remove the two outer screws lock washers and flat wash ers holding the negative capacitor strap to the diode module Note fastener order for reassembly Using the 3 16 allen head wrench remove the two screws flat washers and spring washers holding the diode module to the heat sink Using the 9 64 allen wrench remove the set screw from the center of the diode module Remove the diode module from the heat sink REPLACEMENT Refer to Figure 15 A CAUTION The proper tightening sequence is required to mount the diode module to the heat sink in order to avoid warping the base plate Apply the proper torque to all fasteners 1 Be sure the heat sink mounting surface is clean dry and free of grease 2 Apply a thin even coat 1 to 25mm or 004 to 010 in of Penetrox A13 thermal joint compound to the diode module base plate only under the plastic body of the module Do not apply
31. Make sure the machine settings are correct for the process being used When stick weld ing the CC Slope Switch 52 should be in the Stick Gouge position Check the welding cables for loose or faulty connections 1 Check the CC Slope Switch S2 and the associated lead connections Check all the plug connections to the Weld Control Board for loose or faulty connections See the Wiring Diagram The Weld Control Board may be faulty Replace When using fast freeze type elec trodes such as E6010 or E7010 the welding performance is poor Make sure the machine settings are correct for the process being used When stick welding with fast freeze type elec trodes the CC Slope Switch S2 should be in the Pipe posi tion Check the welding cables for loose or faulty connections Check the CC Slope Switch S2 and the associated lead connections Check all the plug connections to the Weld Control Board for loose or faulty connections See the Wiring Diagram The Weld Control Board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or 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 MULTI WELD 350 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9
32. er uen PERIPHERAL CONTROL PCB ASSEMBLY a MATERIAL TOLERANCE t TO AGREE WITH PUBLISHED STANDARDS x NOT SCALE THis DER woes SCALE L5X ___ 2 10 99 pRwWNGN G 3662 1 Return to Section TOC Return to Master TOC 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 machine MULTI WELD 350 ELECTRICAL DIAGRAMS G 11 SCHEMATIC POWER PRINTED CIRCUIT BOARD OEEGTIA 45 120 VDC Return to Section TOC Return to Master TOC 01 1000V Work Lead Disconnect Protection Circuitry Return to Section TOC Return to Master TOC L C
33. 1K 1 525001 76815 R229 R230 R231 RESISTOR SMD 7 68K 1 4W 1206 1 TR 525020 25 C18 019 C108 C109 C110 C111 0112 113 0114 0115 C116 CAPACITOR SMD CERAMIC 0 022MF 50V 1094 S25000 51108MT R232 R233 R234 R235 R236 R237 R379 RESISTOR SMD METAL FILM 1 10W 5110HMS 525000 22125 R238 R239 R240 R242 IRESISTOR SMD METAL FILM 1 10W 22 1K 1 525000 43225 R241 R320 R321 R322 IRESISTOR SMD METAL FILM 1 10W 43 2K 1 525020 55 102 103 104 105 106 107 CAPACITOR SMD CERAMIC 2700pF 50V 596 X S25003 47R5SMT_ alfalfa ro R245 R246 R247 R248 R249 RESISTOR SMD 1W 47 5OHMS 196 8 525024 65 117 118 5 22 16 10 5 525004 24305 R250 R251 R252 R253 R254 R255 R256 R257 R258 R259 IRESISTOR SMD PREC MF 1 10W 10 0K 0 1 525020 45 C119 CAPACITOR SMD CERAMIC 820pF 50V 596 CO 525008 43215MT R260 R261 RESISTOR SMD PREC MF 1 10W 4 32K 0 596 525024 25 120 2121 6122 123 0124 125 ICAPACITOR SMD TANTALUM 1 0MF 35V 10 525010 35 R262 R263 R264 RESISTOR SMD MF 1W 20 0K 1 SURGE 525001 12115MT R265 RESISTOR SMD 1 21K 1 4W 1206 1 TR 81884 525020 85 126 127 ICAPACITOR SMD CERAMIC 0 056MF 50V 10 525000
34. 4 5 6 7 8 10 611 612 13 014 15 C16 17 20 21 C22 23 C24 25 26 027 C28 29 C30 31 32 33 C34 C35 36 37 38 39 40 41 42 43 44 45 46 47 C48 049 50 51 C52 C53 C54 C55 C56 C57 C58 C59 C60 C61 62 63 C64 C65 C66 C67 C68 C69 C70 C71 72 73 74 75 76 77 C78 C79 C80 C81 C82 C83 C84 C85 C86 C87 C88 C89 C90 C91 C92 C93 C94 C95 C96 C97 C98 C99 C100 C101 C133 C141 C142 CAPACITOR SMD CERAMIC 0 1MF 50V 1096 X 8 828 525000 15005 R190 R191 R192 R193 R194 FR195 R372 RESISTOR SMD METAL FILM 1 10W 1500HMS S25000 30118MT R196 R197 R198 R199 R200 R201 R202 R203 R204 R205 R206 R207 IRESISTOR SMD METAL FILM 1 10W 3 01K 1 525000 18225 R208 R209 IRESISTOR SMD METAL FILM 1 10W 18 2K 1 525000 26705 R211 RESISTOR SMD METAL FILM 1 10W 2670HMS 525000 33225MT R213 R214 IRESISTOR SMD METAL FILM 1 10W 33 2K 1 525000 22135 R215 R216 R217 R218 R369 RESISTOR SMD METAL FILM 1 10W 221K 1 525000 15035 R219 IRESISTOR SMD METAL FILM 1 10W 150K 1 525000 39225 R220 R221R222 R223 R371 RESISTOR SMD METAL FILM 1 10W 39 2K 1 525000 33235 IR224 R225 RESISTOR SMD METAL FILM 1 10W 332K 1 525000 68135 R226 RESISTOR SMD METAL FILM 1 10W 681K 1 22 525000 68125 R227 R228 IRESISTOR SMD METAL FILM 1 10W 68
35. 6 Disconnect input power before removing the case cover and performing tests or making repairs to the machine MULTI WELD 350 LINCOLN P Perform the Case Cover Assembl Removal procedure Perform the Power Capacitor Discharge procedure Perform the Case Front Assembl Removal procedure Label and disconnect leads 330 and at their in line connectors Cut any necessary cable ties Retum to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 8 E 5 rA Retum to Master TOC F 44 TROUBLESHOOTING amp REPAIR 7 Using the 17 mm wrench remove the nuts from the input contactor terminal closest to the machine front Label the leads and note their placement bottom nut not removed lead X1A Lead X1 lead BP5 NOTE The top nut has grooves on the side that faces up 8 Using the 17 mm wrench remove the nuts from the other input contactor terminal Bottom nut not removed copper contac tor strap center nut lead 331 top nut NOTE The top nut has grooves on the side that faces up 9 With the 3 8 socket wrench remove the two bolts and nylon insulators holding the input contactor to the input diode heat sink NOTE The mylar insulation sheet fits between the nylon insulators at replacement 10 Using the 3 8 socket wrench remove the two screws holding the input contactor to
36. L 410 91 11 5 PERIPHERAL PCB r L ANALOG CONTROL POWER SUPPLY PCB Return to Section TOC Return to Master TOC m im INPUT CAPACITOR LEFT INPUT CAPACITOR RIGHT pe D4 PPAR 31 REMOTE RECEPTACLE Ape HOT START CHOPPER PCB RIGHT FREE WHEELING DIODES RIGHT FREE WHEELING DIODES LEFT quc WELD CONTROL PCB HOT START ARC FORCE 8 J9 HEATSINK CONNECTION LEFT OUTPUT CHOKE LEFT OUTPUT CHOKE RIGHT xi I 330 B 5 INPUT CONTACTOR CR CR1 5 00000000 00000000 Ojo ojo E 56 o t gls 218 E E BIZ o o 303A 307 THERMOSTAT 50 mV 400A 326 9 INPUT aa INPUT DIODES PCB CONNECTOR CAVITY NUMBERING SEQUENCE PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE NOTES THIS JUMPER TO ENABLE ON OFF L VIEWED FROM COMPONENT SIDE OF P C BOARD VIEWED FROM LEAD SIDE OF RECEPTACLE l3 1 94 1 5 1 8 0000 00000 00000000 45 5 8 0 5 16 6 PIN 8 10 PIN 16 PIN J7 J8 J9 J10 J11 J45 J2 J3 J4 J5 J42 J12 J31 J1 OUTPUT SWITCHING FROM REMOTE RECEPTACLE SEE INST
37. NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LIN LN 3 MULTI WELD 350 Return to Section TOC Return to Master TOC G 18 ELECTRICAL DIAGRAMS G 18 PC BOARD ASSEMBLY CHOPPER _ ___6__________ DRA CHOPPER ENGINE WELDERS CHOPPER P C BOARD AS BLY L 11038 1 Return to Section TOC Return to Master TOC COMPONENT SIDE OPPOSITE SIDE CIRCUITRY MULTIPLE BLANK PART NO L11038 D CIRCUITRY MULTIPLE MAKE FROM S19399 MAKES 8 BOARDS NOTE FOR BLANK SHEARING TOLERANCE SEE P C BOARD ASSEMBLY EQUIP SUBJECT ge 7 B119 Bli2 P pam 12 98 DE REF P4 N J ITEM B Ci C8 C7 C2 C5 490 005 ae 25 CUELECUEGE D1 D2 D3 04 D5 06 1 4004 a ee T12705 23 1NS8 18 4 1 1 1 6 2 a 2 T12702 11 1N4745A 1 1 1 1 e THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A 513490 173 TOR MPF 1 0 uF 63VDC Return to Section TOC Return to Master TOC Luosed 515000 28 OPT COUPLER TTL OUT CHOPPER _ T12704 41 H S S20590 177 51838025 THERMI STOR PTC 0 5 1 17 OHMS 0 5A 152 1 17 519400 5620 562 1 4W ENCAPSULATE WITH E1844 m x ME hee M 1 519400 1001 174W FRO
38. REMOVAL PROCEDURE Refer to Figure F 11 5 Perform the Case Front Assembl 1 Set the CC CV power switch to OFF Removallprocedure 6 Perform the Contactor Removal 2 Remove input power to the machine procedure 7 Using the 3 8 socket wrench remove the WARNING bolt nylon insulators and mylar insulation ELECTRIC SHOCK can kill sheet where the diode heat sink attaches to the choke Note order for replacement Disconnect input power before removing the case cover and performing tests or making repairs to the machine Using the 1 2 socket wrench and exten sion remove the nut lock washer flat washer and bolt holding the heat sink to the input terminal strap Note the flat washer 3 Perform the Removal procedure 9 Using the 1 2 wrench remove the bolt and 4 Perform the Power Capacitor Discharge waehere connecting tie diode pigtails 10 recede the contactor strap if this was not done dur ing input contactor removal MULTI WELD 350 LINCOLN P Retum to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC to Master TOC Retum to Master TOC Retum to Master TOC F 47 TROUBLESHOOTING amp REPAIR 10 Disconnect thermostat leads 306 and 307 11 Carefully remove the input diode assembly 12 Using the 17 wrench loosen the appropri ate diode and remove the diode that is to be replaced 13 Clean th
39. REPAIR AMPS VOLTS DIGITAL METER AND POTENTIOMETER REMOVAL AND REPLACEMENT CONTINUED FIGURE F 9 DIGITAL METER AND POTENTIOMETER DETAILS Retum to Section TOC Retum to Master TOC DIGITAL METER N OUTPUT CONTROL POTENTIOMETER B 5 9 8 to Master SEAL 2 gig PP 5 5 812 5 5 DIGITAL METER REMOVAL cuoc PROCEDURE 3 Perform the Case Cover Assembl Refer to Figure F 9 Removal procedure 1 Set the CC CV power switch to OFF 4 Perform the Power Capacitor Discharge procedure 2 Remove input power to the machine 5 Perform the Case Front Assembl A WARNING Removallprocedure 6 Using the 5 16 nut driver remove the ELECTRIC SHOCK can kill seven screws from the control box rear panel Disconnect input power before removing the case cover and performing tests or making repairs to the machine Retum to Section TOC Retum to Master TOC MULTI WELD 350 LINCOLN P Retum to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 41 F 41 TROUBLESHOOTING amp REPAIR AMPS VOLTS DIGITAL METER AND POTENTIOMETER REMOVAL AND REPLACEMENT CONTINUED 10 Carefully remove the Amps or Volts Digital Meter molex plug from the Weld Control PC Board Press and hold
40. TO AGREE ENGINEER APM TLD WITH PUBLISHED STANDARDS REVISED OV Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual E MULTI WELD 350 G 16 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY BY PASS 7 DESCRIPTION COMPONENT SIDE OPPOSITE COMPONENT SIDE cicacacacs s T5748 CAPACITOR CD 5 600V BU AUR Pu 1 1 2 3 5 6 112640 22 MOV 175VRMS 120J 20MM 2 Return to Section Return to Master TOC 55 4 0 I BLANK PART NO M19510 A Em MAKE FROM 519399 MAKES 32 BOARDS olov HE ax 1 visio __ __ 1 28 2 273 wie errizePi 0 EE G 16 5 5 167 BP2 1 BE 4 1012715 5 1012716 5 00277 111 2527 a o e 6 oe 0 olg 2e a NOTES THESE HOLES TO BE KEPT FREE POTTING HIE b MATERIAL BOTH SIDES 38 DIA MIN 5 MAKE PER E1911 gle POT PER E1911 E 3829 2 5 MANUFACTURED AS M19510 1A0 57564 IDENTIFICATION CODE THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND 15 NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE L
41. contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 MULTI WELD 350 LINCOLN 8 Return to Section Retum to Section TOC 5 8 9 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Y 4 2 8 5 rA Retum to Master TOC TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES A WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the machine OFF before working on equipment Do not touch electrically hot parts Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections 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 elec trical damage and electrical shock Read the warn ing inside the static resistant bag and perform the following procedures Do Not Destroy PC Board can be damaged by static electricity Remove your body s static charge before opening the static shi
42. er and flat washer See the Wiring Diagram Using the 7 16 wrench remove the two bolts holding the negative strap to the diode module Note the fasteners for reassembly bolt lock washer two flat washers Using the 7 16 wrench remove the two nuts holding the positive strap to the Chopper PC board Hold the bolt head behind the board to remove each nut Note the fasteners for reassembly flat washer lock washer nut Note the place ment of the reverse diode lead on the bot tom bolt Push the capacitor from the inside out of the heat sink Note that the bracket stays in the heat sink MULTI WELD 350 LINCOLN P REASSEMBLY 1 Slide the capacitor into the heat sink Position the positive terminal next to the Chopper PC board Tighten the bracket clamp Replace the leads and straps as labeled 3 _ 13 and tighten the fasteners Use the 7 16 socket and torque wrench to tighten the capacitor terminal bolt to 50 60 in lbs Tighten the nuts holding the positive strap to the Chopper PC board to 50 60 in Ibs Tighten the two 7 16 screws that hold the negative strap to the diode module to 30 40 in Ibs Replace any adhesive backed rubber strip ping if present that was damaged during disassembly Replace the Analog Control Power Supply PC Board Replace the tunnel assembly top cover Connect the wire harness plug assemblies above each Chopper PC Board and above the tunnel asse
43. i 4 B 4 2 8 i 4 8 4 2 8 i ux MULTI WELD 350 LINCOLN 8 Retum to Section TOC Return to Section TOC 5 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC A 2 INSTALLATION TECHNICAL SPECIFICATIONS MULTI WELD 350 K1735 1 ELECTRICAL SPECIFICATIONS Amps DC Volts DC Output Rating 50 122 350 34 Input Rating 50 C 122 F 165 80 Max Input Range 50 113 Peak Max O C V 78 Output Preset Range 15 40 PHYSICAL DIMENSIONS Net Weight 59 5 Ibs 27 0 kg TEMPERATURE RANGES Storage Temperature Range Operating Temperature Range 40 to 122 F 40 to 185 F 20 to 50 C 40 to 85 C MULTI WELD 350 LINCOLN 8 A 2 Retum to Section Retum to Section TOC 5 8 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet clothing e Insulate yourself from the work and ground Always wear dry insulating gloves Only qualified personnel should install use or ser vice this equipment QUICK CONNECT PIG TAILS The Multi Weld 350 is fact
44. j 8 Return to Section Retum to Master TOC Retum to Master TOC 2 8 E Retum to Master TOC B 3 B 3 OPERATION PRODUCT DESCRIPTION The Multi Weld 350 Arc Converter K1735 1 is part of a Multi Weld system ideally suited for construction site welding It uses a single DC power source as the only input supply and provides independent full range control of up to 350A continuous with each Converter arc for polarity stick and wire processes as well as for arc air gouging See Figure B 1 FIGURE B 1 MULTI WELD SYSTEM MULTI WELD SYSTEM gt MULTISQURCE CONVERTERS The Multi Weld 350 is a DC to DC Converter that con verts higher voltage lower current input power to lower voltage higher current output power with over 90 effi ciency For example a single 600A continuous rated 70 80V power source could supply up to five Multi Weld 350 converters each wire welding at 300 amps or about ten converters for stick welding at 150 amps with 26 29V at the arcs The Multi Weld 350 Arc Converter is a single world model built to IEC and CSA standards and meeting the specific needs inherent to construction site welding Versatile Constant Current CC mode for stick and gouging Includes Hot Start and Arc Force controls to optimize CC performance and can be paralleled for higher capacity welding and arc gouging pxsrRIBLITION BOE CONVERTER
45. the coil resistance is abnormally high or low the contactor may be faulty Replace the contactor 8 Reconnect leads 303A and 330 to the coil leads 3 Perform the Case Cover Removal dure Return to Section TOC Retum to Master TOC MULTI WELD 350 LINCOLN P Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC to Master TOC Retum to Master TOC Retum to Master TOC F 19 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR COIL RESISTANCE AND SUPPLY VOLTAGE TEST CONTINUED A WARNING ELECTRIC SHOCK can kill With the input power ON there are high volt ages inside the machine Do not reach into the machine or touch any internal part of the machine while power is on 9 Carefully apply the correct input power to the Multi Weld 350 50 113 VDC 10 Set the Multi Weld 350 to either CC or CV mode The contactor should activate If it does not increase the input voltage but do not exceed 113 VDC 11 Carefully check for approximately 40 VDC at leads 303A to 330 If the 40 is applied to the coil leads the contactor should activate 12 If the reading is less than 40 VDC or not present perform the DC Buss Power Supply PC Board Test 13 Also check leads 3034 330 303 403 230 and their associated plugs for loose or faulty connections See the Wiring Diagram TEST FOR CONTACT CONTINUITY
46. 023 024 D25 D26 D27 D28 D29 D30 031 032 DIODE SMD 1A 400V DO 214BA AC 88488 2 8 83 525007 60405MT R298 RESISTOR SMD PREC MF 1 10W 6040HMS 0 525001 47515 R209 RESISTOR SMD 4 75K 1 4W 1206 196 TR 525040 55 D33 D34 D35 D36 D37 D38 D39 D40 D41 D42 D43 D44 045 046 047 048 DIODE SMD DUAL 0 200A 70V UFR 525000 20015 525000 28015 R300 R305 RESISTOR SMD METAL FILM 1 10W 2 00K 1 RESISTOR SMD METAL FILM 1 10W 2 80K 1 525000 22105 R306 R307 RESISTOR SMD METAL FILM 1 10W 2210HMS 525001 15015 R308 R309 R310 R311 R312 RESISTOR SMD 1 5K 1 4W 1206 1 TR 525049 15 D49 D50 D51 D52 D54 D55 061 063 064 DIODE SMD 0 5A 30V SOD 123 SCHOTTKY 525000 15035 R316 R317 IRESISTOR SMD METAL FILM 1 10W 1 82K 1 25000 1003SMT R318 R319 IRESISTOR SMD METAL FILM 1 10W 100K 1 525040 45 056 057 062 DIODE SMD DUAL 0 200A 70V UFR 25001 1001SMT R323 R324 RESISTOR SMD 1K 1 4W 1206 1 TR 525049 25 058 059 DIODE SMD 1A 30V SMA SCHOTTKY 25000 39R2SMT_ R325 IRESISTOR SMD METAL FILM 1 10W 39 20HM 525040 35 D60 DIODE SMD DUAL 6A 200V DPAK CC ULTRA 525000 47535 R326 R370 IRESISTOR SMD METAL FILM 1 10W 475K 1 525044 55 021 022 ZENER DIODE SMD 3W 16V 5 SMB 525044 35 23 024 0214 ZENER DIODE
47. 40040 400 00 nnne dass dns C 3 Retum to Master TOC Y 4 2 8 5 A Retum to Master TOC MULTI WELD 350 LINCOLN 8 Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC ACCESSORIES OPTIONS ACCESSORIES SEMIAUTOMATIC WELDING ACCESSORIES The following options accessories are available for your Multi Weld 350 from your local Lincoln Distributor FIELD INSTALLED OPTIONS K1736 1 DISTRIBUTION BOX Makes connecting up to 10 Multi Weld 350s quick and easy Contains cop per bus bar for connecting multiple pig tails Four pig tails included K857 25 ft 7 5 m or K857 1 100 ft 30 4 m REMOTE CONTROL Provides 25 ft or 100 ft 7 5 m or 30 m of remote output control Connects to 6 pin receptacle on front of Multi Weld 350 WELDING CABLE CONNECTORS Twist Mate M plug for fast connection of additional Multi Weld 350s K852 70 Twist Mate male plug for 1 0 2 0 500 70 cable K852 90 Twist Mate male plug for 2 0 3 0 70 95 mm cable K1759 70 Twist Mate female plug for 1 0 2 0 50 70 cable K1759 90 Twist Mate female plug for 2 0 3 0 70 95 mm cable K449 LN 25 WIRE FEEDER The LN 25 is perfect for use with the Multi Weld 350 It is designed to run across the arc with no control cables This portabl
48. 61915MT ny 4 03 9 R266 R267 IRESISTOR SMD METAL FILM 1 10W 6 19K 1 525020 165 C128 ICAPACITOR SMD CERAMIC 0 018MF 50V 196 525024 15 C129 ICAPACITOR SMD TANTALUM 0 47MF 50V 10 25024 5SMT 130 131 0132 CAPACITOR SMD TANTALUM 4 7MF 35V 109 525024 35 C134 CAPACITOR SMD TANTALUM 2 2MF 20V 10 525008 10025 R269 R270 R271 R272 R273 R274 R275 R276 R277 R278 R279 R280 R281 R282 R283 R284 IRESISTOR SMD PREC MF 1 10W 10 0K 0 5 S25020 108MT C135 C136 ICAPACITOR SMD CERAMIC 4700pF 50V 10 S25000 4R70SMT R285 R286 R287 IRESISTOR SMD METAL FILM 1 10W 4 700HM 525020 15 C137 CAPACITOR SMD CERAMIC 0 022MF 50V 1 6 525000 56218MT R288 IRESISTOR SMD METAL FILM 1 10W 5 62K 1 525024 75 138 139 5 47 20 10 5 525008 90915 R289 R290 R291 IRESISTOR SMD PREC MF 1 10W 9 09K 0 5 25020 17SMT C140 ICAPACITOR SMD CERAMIC 27MF 50V 10 6 518380 14 R292 R293 R294 R295 THERMISTOR PTC 5000HMS 28mA 525040 65 D1 D2 D3 D4 D5 D6 D7 D8 D9 010 011 012 DIODE SMD DUAL 0 200A 70V UDR CC SOT 525008 47515 R296 RESISTOR SMD PREC MF 1 10W 4 75K 0 5 525007 21505 R297 RESISTOR SMD PREC MF 1 10W 2150HMS 0 525040 25 D13 D14 D15 D16 D17 D18 019 020 021 022
49. 9 09K 1 524020 16 12 CONNECTOR MOLEXMINL PCB 16 PIN TIN 525007 68125 R349 R350 IRESISTOR SMD PREC MF 1 10W 68 1K 0 1 515000 225 OPTOCOUPLER SMD PHOTO TRANSISTOR7UV 525007 90915 R351 RESISTOR SMD PREC MF 1 10W 9 09K 0 1 525050 15 01 02 03 04 05 06 07 08 09 1010 011 012 014 TRANSISTOR SMD NPN 0 5A 40V SOT 23 MM 25000 1330SMT R352 IRESISTOR SMD METAL FILM 1 10W 1330HMS 525008 15025 R353 IRESISTOR SMD PREC MF 1 10W 15 0K 0 5 525050 25 015 016 017 018 019 020 021 022 ITRANSISTOR SMS PNP SOT23 0 5A 40V MM 525007 90925 R354 R355 RESISTOR SMD PREC MF 1 10W 90 9K 0 1 25000 22R1SMT_ R356 IRESISTOR SMD METAL FILM 1 10W 22 1OHM 525051 15 023 ITRANSISTOR SMD NMF SOT 223 1 5A 100V S25010 15MT R357 IRESISTOR SMD MF 2 21K 1 4W 1 SURGE 525051 25 024 TRANSISTOR SMD NMF D2PAK 18A 200V IRF 25000 3320SMT R358 IRESISTOR SMD METAL FILM 1 10W 3320HMS S25000 4751SMT R1 R24 R25 R26 R27 R28 R29 R30 R31 R32 R34 R35 R36 R37 R38 R39 R41 R42 R43 R44 R45 R46 R47 R48 R49 R382 RESISTOR SMD METAL FILM 1 10W 4 75K 1 525003 08155 R359 RESISTOR SMD 1W 0 150HMS 1 525001 20018 R360 R361 R362 R363 R364 R365 R366 R367 R383 RESISTOR SMD 2K 1 4W 1206 1 TR 525007 33215 R368 RESISTOR SMD PR
50. A pin 1 to 45 pin 3 This is the 20 VDC supply from the Analog Control Power Supply PC Board to the Chopper PC Board NOTE Be careful not to touch the capacitor terminals 4 Also carefully check for 11 0 14 0 VDC at 45 pin 7 to P45 A pin 9 This is the Pulse Width Modulation Signal from the Weld Control Board to the Chopper PC board 5 If any of the voltages are not present check associated leads and plugs for loose or faulty connections See the Wiring Diagram 6 Remove the input power and perform the Power Module Capacitor Discharge Procedure 7 Reconnect the plugs previously discon nected 8 If finished testing perform the Case Cover Replacement procedure MULTI WELD 350 LINCOLN P 29 29 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CC MODE INPUT VOLTAGE APPLIED 75 VDC Retum to Section TOC Retum to Master TOC 0 volts pee ay HH 0 volts 50V 5us Retum to Master TOC 5 5 9 8 This is the typical CC open circuit out put voltage generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal division rep resents 5 in time gig 2 5 8 E SCOPE SETTINGS 5 Volts Div ees 50V Div a Horizontal Sweep 5 us Div Coupling
51. AND ALL AROUND EYELET ON OPPOSITE COMPONENT SIDE ONLY NO ICICLES OR S SOLDER BLOBS PERMITTED Set IDENTIFICATION CODE BAR MUST BE FREE OF ENCAPSULATION MATERIAL ON BOTH SURFACES AROUND MOUNTING HOLES AND ENTIRE LENGTH OF MOUNTING SURFACE ENCAPSULATION MATERIAL MUST NOT MAX n 105 CRIMP HEIGHT EXTEND BEYOND THE MOUNTING SURFACE PLANE FOR PARTS ORDERS INCLUDE DO NOT COVER OVER COMPONENT C5 WITH SEALANT x ONE D PRINT OF 111121 PLACE SEALANT ALONG SIDE AND UNDER COMPONENTS OPPOSITE COMPONENT SIDE ONE 1 PRINT OF 111080 THIS SHEET CONTAINS PROPRIETARY INFORMATION OwwED mv THE LINCOLN ELECTRIC CO AND i5 NOT TO BE REPRODUCED DISCLOSED OR USED THE LINCOLN ELECTRIC CO WITHOUT THE EXPRESS PERMISSION OF THIS DIMENSION APPLIES TO TWO OF THE FOUR EYELETS ONE D PRINT OF 111081 AS SHOWN 1 ONE 1 TUBE OF 12837 1 ELECTRONIC MODULE TO BE ASSEMBLED SOLDERED AND SEALED TO P C BOARD PER E3875 PRINTS MAY BE MADE ON 11 X 17 PAPER Return to Section TOC Return to Master TOC 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
52. Multi Weld 350 is provided with a 6 pin remote receptacle to permit use with the 25 ft 7 6 m K857 or 100 ft 30 4 m K857 1 Remote Output Control options The remote receptacle can also be used with the LN 25 equipped with the K444 1 Remote Control option These remotes have single turn resolution on a Minimum to Maximum numbered dialplate CV MODE WIRE WELDING The Converter in CV mode was designed for use with an arc powered wire feeder like the LN 25 The Converter output is always hot when the mode switch is not OFF Therefore it is recommended that the LN 25 model be equipped with the internal contactor in order to have a cold electrode when the gun trigger is released The CV mode recommended processes are positive polarity wire welding within the output capacity of the Converter including Flux Cored Arc Welding FCAW Innershield _ NS3M 5 64 3 32 NR305 068 Outershield 5 70 1 16 5 64 OS 71 045 1 16 MC 710 045 5 64 Gas Metal Arc Welding GMAW Carbon Steel L50 56 030 1 16 CC MODE STICK WELDING AND GOUGING The CC mode recommended processes are positive polarity stick and arc gouging within the output capacity of single or paralleled Converters including Shielded Metal Arc Welding SMAW E6010 6011 FW5P 180 3 32 1 4 fast freeze E6013 FW37 3 32 3 16 fill freeze E7010 8010 SA85 70 3 32 7 32 fast freeze HT pipe E7018 7028 JW LH70 3800 3 32 5 32 low
53. OF THE LINCOLN ELECTRIC rec GROUND CONNECTIN UNLESS OTHERWISE SPECIFIED TOLERANCE Shea X info THE LINCOLN ELECTRIC CO Es COMMON ANALOG CONTROL NOTES HOLES SIZES PER E 2066 Tae 2 PLACE DECIMALS 15 02 CLEVELAND OHIO U S A PERIPHERAL BOARD NA SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE ON 5 PLACE DECIMALS 13 002 01 WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY ON ALL ANGLES IS 5 OF A DEGREE SCALE _NONE NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE MATERIAL TOLERANCE 149 TO AGREE op __ __ pare 03715700 3663 NUMBER WITH PUBLISHED STANDARDS Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LIN LN 3 INCOLN S MULTI WELD 350 ale ELECTRICAL DIAGRAMS G 10 PC BOARD ASSEMBLY PERIPHERAL PC BOARD REFERENCE PART NO QTY DESIGNATORS DESCRIPTION G3662 B 1 PCB BLANK 524671 1 PLUG KEYING PLUG M19436 4 1 POTTING TRAY 58025 80 2 SELF TAPPING SCREW E2527 65g EPOXY ENCAPSULATING RESIN E3539 AS REQ ELECTRICAL INSULATING COMPOUND 524764 2 1 SOFTWARE FOR ITEMS LISTED BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS 525020 35 15 C15 C17 019 C20 C21 C22 SCAP 0 1uF 0805 50V X7R 1096 TR NP C28 C29 C30 C31 C32 C3
54. Resistor 25 1000 ohms 25 watts minimum Small block of wood approximately 1 x 3 This procedure should take approximately 1 hour to perform MULTI WELD 350 LINCOLN Retum to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 5 rA Retum to Master TOC F 55 F 55 TROUBLESHOOTING amp REPAIR CHOPPER PC BOARD REMOVAL AND REPLACEMENT CONTINUED FIGURE F 14 CHOPPER PC BOARD AND DIODE MODULE CONNECTIONS ALLEN HEAD SCREWS 2 CHOPPER PC BOARD CAPACITOR POSITIVE STRAP REVERSE DIODE LEAD CONNECTION HEX HEAD BOLTS 2 4 SCREWS ACCESSED FROM BOTTOM REMOVAL A WARNING Refer to Figure F 14 1 Set the CC CV power switch to OFF ELECTRIC SHOCK can kill 2 Remove input power to the machine Disconnect input power before removing the case cover and performing tests or making repairs to the machine MULTI WELD 350 LINCOLN P Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 5 rA Retum to Master TOC F 56 F 56 TROUBLESHOOTING amp REPAIR CHOPPER PC BOARD REMOVAL AND REPLACEMENT CONTINUED Perform the Case Cover Removal proce dure Perform the Power Capacitor Discharge proc
55. SMD 3W 12V 5 6 SMB 525002 20005 R327 R328 R329 R330 R331 R332 R333 R334 IRESISTOR SMD 2000HMS 1 3W MF 1 S1210 525045 15 25 026 027 028 029 0210 0211 ZENER_DIODE SMD 225mW 12V 5 SOT 23 525000 10805 R335 R336 R337 R338 IRESISTOR SMD METAL FILM 1 10W 10 00HM 525007 24315 R339 RESISTOR SMD PREC MF 1 10W 2 43K 0 1 525044 45 DZ12 DZ13 ZENER DIODE SMD 3W 15V 5 SMB 525007 13015 R340 RESISTOR SMD PREC MF 1 10W 1 30K 0 1 525044 15 0215 ZENER DIODE SMD 3W 5 1V 5 SMB 525007 10235 R341 IRESISTOR SMD PREC MF 1 10W 102K 0 1 518248 12 t CONNECTOR MOLEX MINI PCB 12 PIN 525000 51115 R342 RESISTOR SMD METAL FILM 1 10W 5 11K 1 524020 8 32 313 CONNECTOR MOLEX MINI PCB 8 PIN TIN 825001 23708MT R343 R344 RESISTOR SMD 2370HMS 1 4W 1206 196 TR 524020 6 231011 CONNECTOR MOLEXMINI PCB 6 PIN TIN 525008 68125 R345 IRESISTOR SMD PREC MF 1 10W 68 1K 0 5 524020 10 445 CONNECTOR MOLEX MINI PCB 10 PIN TIN 525008 15035 R346 IRESISTOR SMD PREC MF 1 10W 150K 0 5 524020 26 524020 4 6 7 8 9 CONNECTOR MOLEX MINI PCB 2 PIN GOLD CONNECTOR MOLEX MINI PCB 4 PIN TIN 525008 12125 347 IRESISTOR SMD PREC MF 1 10W 12 1K 0 5 525000 90915 R348 IRESISTOR SMD METAL FILM 1 10W
56. 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the Analog Control Power Supply PC Board is receiving and passing the proper signal voltages MATERIALS NEEDED 3 8 Nut driver Analog Volt Ohmmeter Wiring Diagram This procedure should take approximately 30 minutes to perform MULTI WELD 350 LINCOLN F 20 Retum to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 8 E 5 rA Retum to Master TOC F 21 F 21 TROUBLESHOOTING amp REPAIR ANALOG CONTROL POWER SUPPLY PC BOARD TEST CONTINUED FIGURE F 4 ANALOG CONTROL POWER SUPPLY PC BOARD P41 P42 TEST PROCEDURE 1 Set the CC CV power switch to OFF 5 2 Remove i
57. Set the CC CV power switch to OFF 4 2 Remove input power to the machine 5 A WARNING ELECTRIC SHOCK can kill 6 Disconnect input power before removing the case cover and performing tests or making 7 repairs to the machine 3 Perform the Cover Removal proce dure MULTI WELD 350 LINCOLN P DC BUSS POWER SUPPLY PC BOARD Perform the Power Module Capacitor Discharge procedure Locate the DC Buss Power Supply PC Board and plugs P46 and P47 See Figure F 5 Carefully apply the correct input power to the Multi Weld 350 50 113 VDC Set the Multi Weld 350 to either CC or CV mode Make sure the input contactor acti vates If it does not increase the input volt age but do not exceed 113 VDC The LED on the DC Buss Power Supply PC Board should light 25 25 TROUBLESHOOTING amp REPAIR Q o8 DC BUSS POWER SUPPLY PC BOARD TEST CONTINUED 0 r g 8 Check the DC Buss Power Supply PC 11 If the input voltage is not correct check 2 8 Board input and output voltages according leads 401A 402 802 202 231 and E E to Table F2 See and the the On Off mode switch SW1 See the 8 8 Wiring Diagram Wiring Diagram cic 9 If all the voltages are correct the DC Buss NOTE The input voltage to the DC Buss Power Power Supply PC Board is operating prop Supply PC Board should be the same as the erly input voltage applied to the Multi Weld 350 10 Ifany of the
58. Voltage 74 78 VDC Volts In 4 VDC 73 78 VDC 17 20 VDC 50 54 VDC Output Amps and Volts CC Stick Gouge CC Stick Gouge CC Stick Gouge 60 113 VDC 60 113 VDC 60 113 VDC FAN AS NEEDED F A N 100 Amps 24 VDC 200 Amps 28 VDC 350 Amps 34 VDC The fan should turn on when the machine is loaded and stay on for 50 70 seconds after the output load is removed MULTI WELD 350 LINCOLN P Retum to Master Retum to Master TOC Y 4 2 8 5 A Retum to Master TOC G 1 ELECTRICAL DIAGRAMS G 1 TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION ELECTRICAL DIAGRAMS MT SECTION G WIRING DIAGRAM ECT G 2 CONTROL PC BOARD SCHEMATIC 1 3 2 Deci s ik test G 3 CONTROL PC BOARD SCHEMATIC 2 5 atia t aa ROC EE Le dea Ran e ds G 4 CONTROL PG BOARD SCHEMATIC 3 3429 66m reta Pre dx CIA e A G 5 CONTROL PC BOARD SCHEMATIC ovt untra OE weeks drew ar t G 6 CONTROL PG BOARD SCHEMATIC d Sus sudes ges G 7 CONTROL PC BOARD ASSEMBLDY Lara oe ede od dede puc ds G 8 PERIPHERAL PC BOARD SCHEMATIC e E CREE S G 9 PERIPHERAL BOARD ASSEMBLY L ees uir nci rtr RD EUER E panes Apa G 10 POWER BOARD SCHEMATIC belly G 11 POWER PC BOARD ASSEMBLY s adea 4 at UR dard ol G 12 ANALO
59. all be simultaneously welding or gouging Power Source Volts x Amps capacity gt 1 1 x Sum of Converters Volts x Amps arcs DISTRIBUTION BOX The Multi Weld Distribution Box K1736 1 is available for interconnection of the Multi System using the same pig tail connection method provided with the Multi Weld 350 converter Six cable strain relief ports are provided for connection of up to 12 cables for distrib ution or daisy chain inter connection to other boxes Four pig tail leads see below are included with the Box PIG TAIL LEADS AND CONNECTORS Accessory pig tail leads and Twist Mate connectors are available from Lincoln for extra connections to the Multi Weld 350 or the Distribution Box Order Description CLO12705 22 56 cm long 2 0 70 mm cable with 0 5 in 13 mm hole lug and cut off ends K852 70 Twist Mate male insulated plug for 1 0 2 0 50 70 cable K852 95 Twist Mate male insulated plug for 2 0 3 0 70 95 mm cable K1759 70 Twist Mate female insulated receptacle for 1 0 2 0 50 70 mm cable K1759 95 Twist Mate female insulated receptacle for 2 0 3 0 70 95 mm cable MULTI WELD 350 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 8 E 5 rA Retum to Master TOC B 5 B 5 OPERATION REMOTE OUTPUT CONTROL OPTIONS The
60. ble PC boards and interchangeable plug n play panel instruments Robust Capacity is rated for continuous operation at 350 amps in 50 122 F ambient temperature and can be paralleled to multiply CC mode output rating Overload protection is provided with electronic limit ing of output current and with thermostat and over voltage shutdown protection that automatically reset Outdoor operation protected with sealed control and power electronics compartments with sealed inter connections housing potted circuit boards and using Central Air cooling with Fan As Needed for less dirt intake Handling and mishandling protection is enhanced with light but durably designed aluminum construc tion with front to back top and bottom handles also serving as roll bar and skid and a sheetmetal shell attached with 1 4 steel threaded fasteners RECOMMENDED EQUIPMENT AND PROCESSES MULTI SYSTEM POWER SOURCE The Multi Source 40KW 80VDC buss power source K1752 1 is recommended for use in the Multi Weld system However other DC power sources capable of supplying the required system buss current at above 60 volts may be used It is recommended that this power source have lower output inductance choke such as the Lincoln Electric DC 1000 DC 655 or DC 600 set for maximum output in CC mode The power source output VA capacity should be 10 greater than the sum of the maximum VA of the converter arcs which may
61. compound to the area under the mounting holes 3 Press the module firmly against the heat sink aligning the mounting holes MULTI WELD 350 LINCOLN P Retum to Section Return to Section TOC Retum to Master TOC 5 8 9 8 Return to Section Retum to Master TOC Y 4 2 5 rA Retum to Master TOC F 59 F 59 TROUBLESHOOTING amp REPAIR DIODE MODULE REMOVAL AND REPLACEMENT CONTINUED FIGURE F 16 DIODE MODULE TIGHTENING SEQUENCE SPRING WASHER 12 18 IN LBS FINGER TIGHT 2 TO 3 TURNS Ang Refer to Figure F 16 4 Place a spring washer then a flat washer over each outer mounting screw and insert them into the holes Insert the allen head screw into the center hole Tighten all three screws 2 3 turns each finger tight only 1 Using the torque wrench and 7 16 socket tighten the outer screws to between 5 0 and 10 in Ibs 2 Using the torque wrench and 9 64 allen head socket tighten the center screw between 12 and 18 3 Now tighten the two outer screws between 30 and 40 in lbs 4 Place the negative capacitor strap over the diode module and align the mounting holes Place a lock washer and two flat washers 5 0 10 IN LBS 10 11 12 MULTI WELD 350 LINCOLN P 5 0 10 IN LBS 30 40 IN LBS boaa over each 7 16 s
62. danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN amp hine LINCOLN Y machine MULTI WELD 350 Retum to Master Retum to Master TOC Y 4 2 8 E 5 A Retum to Master TOC 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 5
63. faulty Reverse the meter leads The resistance should be low approximately 100 ohms If the resistance is high the diode D5 may be open Using the analog ohmmeter check diode module Connect the negative meter probe to the negative copper strap connect ed to the diode module and the positive probe to the heat sink See Figure the test point locations The resistance should be very high over 20 000 ohms If the resistance is low the diode module D3 may be shorted Reverse the meter leads The resistance should be low approximately 100 ohms If the resistance is high the diode module D3 may be open Repeat Steps 1 through 5 for the Right Side Power Module See the Wiring Diagram Replace all leads previously removed See Figure the Wiring Diagram Torque the capacitor bolts to 50 to 60 inch pounds CHOPPER PC BOARD VOLTAGE TESTS FOR BOTH LEFT AND RIGHT SIDES 1 Locate Plug P45 A and disconnect it from J45 A See Figure F 6 A WARNING ELECTRIC SHOCK can kill With the input power ON there are high volt ages inside the machine Do not reach into the machine or touch any internal part of the machine while power is on 2 Carefully apply the correct input voltage to the Multi Weld 350 50 113 VDC The machine should be in the CC mode and the CC Slope switch should be in the Stick Gouge position 3 Turn the machine on and carefully check for 18 0 21 0 VDC at P45
64. hydrogen E7024 6027 JW1 3 2 1 8 5 16 fast fill Arc Air Carbon AAC Gouging Carbons 5 32 3 8 MULTI WELD 350 LINCOLN 8 OPERATION FIGURE B 2 FRONT PANEL CONTROLS Retum to Section TOC Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 8 E 5 rA Retum to Master TOC IDN q ia N N 1 T 9 i D s zw e amp e amp N L j 2 L SEL 9 AY 2209 4 _ a 9 WORK INPUT ELECTROD FRONT PANEL CONTROLS The numbered items of Figure B 2 match the num bered items described below These few instruments and controls are basic to the operation and monitoring of the Converter They are intuitively laid out so that the panel left side is weld cur rent related and the right side is weld voltage related 1 Input Power Mode Switch has three positions Center is OFF which shuts off input power to the Converter Neither displays nor output is on if in OFF position Left is on for CC constant current welding mode Only AMPS digital meter is lit displaying the preset current setting Output will be on at o c v open circuit voltage Right is on
65. output voltages are not correct and the input voltage is correct the DC Buss Supply Board may be faulty 5 TABLE F 2 BUSS POWER SUPPLY PC BOARD VOLTAGE TABLE D 2 Positive Meter Probe Negative Meter Probe Acceptable Voltage T Test Point Test Point Reading 5 Plug 46 Pin 1 Plug P46 Pin 3 50 113 VDC voltage supplied to Multi Weld 350 ET E _ Supply to Analog Control Plug P47 Pin 7 Plug P47 Pin 1 38 0 42 0 VDC Power Supply PC Board Plug P47 Pin 8 Plug P47 Pin 6 38 0 42 0 VDC rs Irene ontactor Plug P47 Pin 4 Plug P47 Pin 6 38 0 42 0 VDC 2 12 If finished testing perform the Case Replacement procedure Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC MULTI WELD 350 LINCOLN P 26 26 TROUBLESHOOTING amp REPAIR CHOPPER PC BOARD INPUT VOLTAGES AND RESISTANCE 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 Retum to Section TOC Retum to Master TOC If for an
66. the ON OFF Mode Selector switch is turned on The Multi Weld 350 does not have output Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Make sure the input voltage applied to the Multi Weld 350 is not greater than 113VDC RECOMMENDED COURSE OF ACTION 1 Check leads 330 and 303A for loose or faulty connections See the Wiring Diagram 2 Perform the Input Contactor Coil Resistance and Suppl Voltage Test 3 The Peripheral Board may be faulty 4 The Weld Control Board may be faulty The Thermal Light is on The Multi Weld 350 does not have output The fan operates normally The output rating of the machine may be exceeded See the Wait until the machine cools and the Thermal Light goes out The machine s output should be restored 1 The Thermostat located on the input diode heat sink may be faulty Check leads 306 307 206 207 and plugs J22 and J11 for loose or faulty connections See the Wiring Diagram CAUTION If for any reason you do not understand the test procedures or 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 MULTI WELD 350 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Retum to Section
67. the harness plug above the Chopper PC board Slip the wires into the cord clip See the procedures following for removal and replacement of the diode module When proce dures are complete perform the Assembly MULTI WELD 350 LINCOLN P Retum to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 5 rA Retum to Master TOC F 57 F 57 TROUBLESHOOTING amp REPAIR DIODE MODULE REMOVAL AND REPLACEMENT FIGURE F 15 DIODE MODULE MOUNTING DETAILS 3 16 ALLEN HEAD SCREWS 2 CAPACITOR NEGATIVE STRAP lt c MOUNTING 9 64 BOLTS 2 ALLEN HEAD SCREW 1 REMOVAL A WARNING Refer to Figure F 15 1 Set the CC CV power switch to OFF ELECTRIC SHOCK can kill 2 Remove input power to the machine Disconnect input power before removing the case cover and performing tests or making repairs to the machine MULTI WELD 350 LINCOLN P Return to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 58 F 58 TROUBLESHOOTING amp REPAIR DIODE MODULE REMOVAL AND REPLACEMENT CONTINUED Perform the Case Cover Removal proce dure Perform the Power Capacitor Discharge procedure
68. the keeper on the plug as you remove it Using the 5 16 nut driver remove the two nuts and flat washers holding the Amps or Volts Digital Meter in place Using the phillips screw driver remove the two screws holding the bezel and lens and the meter to the front panel Carefully remove the Amps or Volts Digital Meter Do not damage the gasket REPLACEMENT PROCEDURE 1 7 Perform the Case Cover Assembl Fit the meter into position adjustable slot side down Verify that the gasket is in place Insert the two phillips screws through the bezel and with the lens in place tighten the screws into the meter Install the flat washers and 5 16 nuts onto the screws and tighten them Attach the molex plug to the Weld Control PC Board See the Wiring Diagram Attach the rear panel with seven 5 16 Screws Perform the Case Front Assembl procedure procedure OUTPUT CONTROL POTENTIOMETER REMOVAL PROCEDURE Refer to 1 2 Set the CC CV power switch to OFF Remove input power to the machine A WARNING ELECTRIC SHOCK can kill Disconnect input power before removing the case cover and performing tests or making repairs to the machine MULTI WELD 350 LINCOLN P 3 4 10 Perform the Case Cover Assembl Removal procedure Perform the Power Capacitor Discharge procedure Perform the Case Front Assembly Removal procedure Using the 5 16 nut driver remove the seven scre
69. the machine base 11 Carefully remove the input contactor INPUT CONTACTOR REMOVAL AND REPLACEMENT CONTINUED REPLACEMENT PROCEDURE 1 Set the input contactor onto the machine base and install two 3 8 screws in the base mounting holes 2 Install the two sets of 3 8 bolts and nylon insulators along with the mylar insulation sheet to the input diode heat sink The mylar sheet fits between the nylon insula tors under the mounting bracket 3 Install the copper contactor strap and lead 331 to the input contactor rear terminal See Figure F 10 4 Install leads X1A X1 and BP5 to the input contactor front terminal See Figure Be sure the top nut on each terminal is the grooved nut with the grooves facing up 5 Connect leads 330 and 303A at their in line connectors Replace any cable ties cut at disassembly 7 Perform the Case Front Assembl Replacement procedure 8 Perform the Case Cover Assembly Replacement procedure MULTI WELD 350 LINCOLN P Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 45 TROUBLESHOOTING amp REPAIR INPUT DIODE REMOVAL AND REPLACEMENT A 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 te
70. the two 0 25 6 3 mm screws secur ing each cover and fold out the cover insulation 2 Route the appropriate pig tail cable lug ends under the skid rail for strain relief through the desired front and or rear corner channels to the exposed 0 5 13 mm stud Remove the flange nut with a 75 19 mm wrench NOTE Input supply cable s must connect through INPUT labeled channels and output weld cable s must connect through ELECTRODE labeled channels 3 Slip the pig tail cable lug s over the stud and re secure the flange nut Make sure that the lug s do not touch any sheetmetal of the stud housing Fold back the cover insulation and replace the stud cover MULTI WELD 350 LINCOLN 8 Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC INSTALLATION WARNING Be sure to follow the safety practice to use the female connector on the cable which would normally be electrically hot supply lead if disconnected when the system is energized and the male on the normally cold load lead side If practical shut off power before connecting or disconnecting terminals WORK CONNECTION Each Converter in the Multi Weld system must have its individual Work lead connected clipped to the work The 3 AWG 27 mm Work clip lead must have clean metal connecti
71. to Master TOC MATERIALS NEEDED 3 8 Nut driver wrench or socket wrench 17 mm socket wrench and extension Phillips head screw driver Diagonal cutters This procedure should take approximately 45 minutes to perform Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC MULTI WELD 350 LINCOLN 49 49 TROUBLESHOOTING amp REPAIR FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT CONTINUED FIGURE F 12 FAN MOTOR ASSEMBLY DETAILS Retum to Section TOC Retum to Master TOC Return to Section TOC Retum to Master TOC 1r SB HE 8 8 E cic REMOVAL PROCEDURE A WARNING Refer to Figure F 12 1 Set the CC CV power switch to OFF ELECTRIC SHOCK can kill 2 Remove input power to the machine Disconnect input power before removing the case cover and performing tests or making repairs to the machine Return to Section TOC Retum to Master TOC MULTI WELD 350 LINCOLN P Retum to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 50 TROUBLESHOOTING amp REPAIR Perform Input Diode Removal proce dure Disconnect the red motor lead from leads 303 and and the blue motor lead from lead 300 at their in line connectors Cut any necessary cable ties Disconnect the two plug harness co
72. 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 5 5 5 be dangerous 5 a Welding may produce fumes 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 insu
73. 2705 59 DI ODE AXLDS 1A 400 FR 1 4936 DI ODE AXLDS 3A 600V UFR MOVI MOV2 113640 15 T13640 24 MOV 5OVRMS 15J 14MM MOV 175VRMS 120J 20MM LEO R25 T13657 2 T14648 17 LED T 1 3 4 RED HLMP 3003 RESISTOR Ww 5w 270 5 SO 40V DC BUS P C BOARD ASSEMBLY SUBJECT CHK AT DATE _3 26 99 THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A CAPACITORS MFD VOL IS RESISTORS OHMS 1 4 WATT UNLESS OTHERWISE SPECIFIED ITEM REQ D PART NO DESCRIPTION 1 1 G3699 B P C BOARD BLANK 1 M16100 43 ELECTRONIC MODULE 3 100g E2527 EPOXY ENCAPSULATING RESIN CAUTION ruis DEVICE 15 SUBJECT TO DAMAGE BY STATIC ELECTRICITY SEE E2454 BEFORE HANDLING N B THESE HOLES TO BE KEPT FREE OF POTTING MATERIAL 50 DIA MIN N C COVER EXPOSED BOTTOM SURFACE OF ELECTRONIC MODULE TO AVOID POTTING MATERIAL BUILD UP WITH PUBLISHED STANDARDS PLACE DECIMALSIS 002 ONALLANGLESIS 5 A DEGREE MATERIAL TOLERANCE TO AGREE UNLESS OTHERWISE SPECIFIED TOLERANCE HOLE SIZES PER E2056 2 PLACE DECIMALS IS 02 THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO MANUFACTURED AS L11078 1B0 m IDENTIFICATION CODE SCHEMATIC REFERENCE M19330 Return to Section TOC Re
74. 2x3 0 2x95 The output Electrode cable should be 2 0 AWG 70 mm if sized for rated output up to 200 ft 61 m from the Converter If paralleled the output cable to the arc should be 4 0 120 mm A WARNING Do not disconnect the Work clip lead without first switching OFF the Converter panel switch Failure to do so will allow the Work lead clip to be electrically hot to work and hot to the electrode through the circuit of the Converter for about 5 seconds until the input con tactor opens POWER SOURCE SETUP Refer to the Instruction Manual provided with the Multi Source power source or other DC power source being used for input power supply connections output con nections and controls setup In general 1 Connectthe positive output connection terminal to the input supplying the Multi Weld system and the negative output connection terminal to the work See Figure A 1 2 If not using a Multi Source power source a If an inductance control or tap is selectable use lowest inductance b Use CC Constant Current mode for maximum supply voltage c Set panel output control to maximum for maxi mum current capacity d Activate output with the output terminals on switch or jumper 2 4 on Lincoln Electric termi nal strips MULTI WELD 350 LINCOLN 8 Section 1 Section 1 TABLE OF CONTENTS OPERATION SECTION 8 je rri mM
75. 4 ANALOG CONTROL POWER SUPPLY BOARD AND WELD CONTROL BOARD MULTI WELD 350 BLOCK LOGIC DIAGRAM INPUT DIODES INPUT CONTACTOR CR1 LEFT AND RIGHT CHOPPER MODULES K IGBT FREEWHEELING DIODE INPUT CAPACITORS T ON OFF MODE TO ELECTRODE CHOPPER MODULE E CURRENT FEEDBACK TO WELD CONTROL BOARD DC sa POWER SOURCE EXTERNAL ANALOG CONTROL POWER SUPPLY BOARD AND WELD CONTROL BOARD The Analog Control Power Supply Board which is pow ered by 40 VDC delivered from the DC Buss Power Supply Board supplies various regulated DC voltages to operate the Weld Control Board circuitry It also pro vides two regulated 20 VDC supplies to operate the electronics on the Chopper Module Boards and applies a 15 VDC supply to the Peripheral Board The Weld Control Board monitors the operator controls arc control output control hot start control mode selector switch CC Slope switch and the remote con trol receptacle It compares these commands to the CHOPPER MODULE PERIPHERAL ON OFF VOLTS AMPS ANALOG CONTROL POWER SUPPLY BOARD REGULATED VOLTAGES RECEPTACLE CC SLOPE STICK GOUGE or PIPE ARC OUTPUT HOT THERMAL 15 VDC FORCE CONTROL START LIGHT CONTROL CR1 COIL BOARD gt O LIGHT WORK current and voltage feedback information it receives from the shunt and output terminal circu
76. 662 5 T 173V 50 45V GND C35 39 47uf 20 20 SMT UNDER_VOLTS 1 35 1HZ oscillator 5V_BATT COM INPUT VOLTS LAMP A i 5 e 15621 RISS 1 14 1 4 LAMP DRIVER CIRCUIT 332K MULTIWELD VOLTAGE SENSE 5V SUPPLY AND REF VOLTAGE 01 4 50 COM TO PULL COIL FUEL CONTACTOR AND PUMP PC BOARD FUEL CONT SOL 40 gig 1 0182 MOTOR CIRCUIT OIL TEMPACOOLER ON SWITCH SENSE CIRCUIT OIL PRES LAMP 41 1 1 0282 OL TEMP LAMP 42 1 0482 10V_ 15V gt C FUEL LEVEL LAMP 1 0681 1 0782 410v 15V ENG ALT VULT LAMP LOW TURNS FUEL OR CONTACTOR ON 2 COIL POS 3 1 0881 0882 INPUT VOLTS LAMP 5 1 1 0982 6 7 8 022 v GW SMT AT FUEL_CONT_SOL TURNS LINE ORE 7 MV 1 00K 4 55 TO FUEL Am 0 CONTACTOR CONTROL 6 1 01082 BLOCK 1 BLOCK 2 ENG ALT NOLTS EW vous 1 01182 HOLD COIL 10 FUEL LEVEL SWITCH elos x 01282 OLL TEMP SWITCH 111001381 101382 CONTACTOR 05 200V 10 SOR 2
77. 7 C40 C41 C42 2 36 43 44 45 46 SCAP 0 022uF CER 0805 50V X7R 1096 TR C23 CAP 0 0047 3000V 2096 CERAMIC DISC 24 27 SCAP 4 7UF TANT 7343 35V 1096 TR NP 34 5 100 7343 20 20 C35 C38 SCAP 47uF TAN 7343 20V 10 C39 SCAP 22uF TAN 7343 25V 10 POLAR TR D1 SDIO MURD620CT 6A 200V ULTRA FAST TR NP D6 D7 D10 D11 D12 D15 SDIO 1A 400V DO 214BA GLS NP D17 D18 D19 D20 D22 DZ2 DZ3 SDIO 1SMB5929BT3 3W 15V 5 024 SDIO 1SMB5935BT3 3W 27V 5 TR NP_ 025 SDIO 1SMB5943BT3 3W 56V 5 DZ6 SDIO 1SMB5932BT3 3W 20V 5 J30 CON MOLEX 39 28 1063 PCB 6 PIN TIN J31 CON MOLEX 15 97 7162 MINI PCB 16 PIN TIN J32 CON MOLEX 15 97 7122 MINI PCB 12 PIN TIN Q1 STRA IRF640S 200V D2 PAK Q2 03 04 STRA 2N4401 SOT 23 NPN TR Q5 STRA 2N4403L PNP SOT 23 NP IR102 R156 R157 R158 SRES 511 TKF 0805 1 1 10W TR R159 R160 R103 SRES 47 5 0805 1 1 10W R127 SRES 475 TKF 0805 1 1 10W TR R129 R130 R144 SRES 1 21K 0805 1 1 10W TR NP R131 R132 R141 R142 R173 SRES 1 5K TKF 0805 196 1 10W TR R133 R150 SRESA7 5 TKF 1206 195 1 4W R134 5 5 4 32 2512 1 1 R135 R143 5 5 3 92 2512 1 1 R136 5 5 750 0805 1 1 10 IR145 R146 SRES 221 TKF 0805 196 1 10W TR R162 SRES 200 TKF 0805 1 1 10W R163 SRES 5 11K TKF 0805 1 1 10W R168 SRES 20K TKF 0805 196 1 10W R169 SRES 50K 5 TURN 1 4W 10 R170 SRES 15K TKF 0805 196 1 10W R171 R172 SRES 6 81K TKF 0805 196 1 10W R20 R21 R23 R25 R27
78. 7 20V SW HIN 7 073 121K e 2 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD UNLESS OTHERWISE SPECIFIED RESISTORS Ohms UNLESS OTHERWISE SPECIFIED NOTES DIODES UNLESS OTHERWISE SPECIFIED Ojo ojo Ele og o t gls 2 BIZ o o SUPPLY VOLTAGE N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 2 WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY Power SUPPLY SOURCE POINT NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING amp COMMON CODE 57 COMMON CONNECTION NUMBER M19422_1BA 17 FRAME CONNECTION THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO EARTH GROUND CONNECTION AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO UNLESS OTHERWISE SPECIFIED TOLERANCE _ EQUIP ON HOLES SIZES PER 2056 COI ELECTRIC CO TYPE Multi System ON 2 PLACE DECIMALS 15 02 ON 3 PLACE DECIMALS 15 002 ELAND OHIO U S A suggect Analog Control Power Su ON ALL ANGLES IS 5 OF DEGREE NONE MATERIAL TOLERANCE TO AGREE T mn SCALE SHT WITH PUBLISHED STANDARDS 7 DATE 99 02 99 SUP S D G NO M 17522
79. 8 Retum to Section Retum to Master TOC to Master TOC Retum to Master TOC Retum to Master TOC F 12 F 12 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The arc starting is not satisfactory POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS The Hot Start Control may not be set correctly for the process being used Make sure the Output Control is adjusted correctly for the process being used TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check the Hot Start Control R2 and associated leads and connections Note The Arc Force Control and Hot Start Control are interchangeable and may be switched to aid in trou bleshooting See the Wiring Diagram 2 The Weld Control Board may be faulty When stick welding the electrode stubs The Arc Force Control may not be set correctly for the process being used Increase the Arc Force Make sure the Output Control is adjusted correctly for the process being used Check the welding cables for loose or faulty connections Check the Arc Force Control R3 and associated leads and connections Note The Arc Force Control and Hot Start Control are interchangeable and may be switched to aid in trou bleshooting See the Wiring Diagram 2 The Weld Control Board may be faulty CAUTION If for any reason you do not
80. DETECT AMETER_PSET MODE ARC_FORCE_SENSE x x 05 gt NAB GL F I SETPOINTS i MAX PRESET ENABLE E HLIDLE SENSE 5_1_SCALE 7 SIGNA MIN OUT Y 0560 EXPANSION REMOTE SENSE A mE START ENABLE ARC_FORCE_ENABLE KL ARC FRC Return to Section TOC Return to Master TOC 5 MACHINE SPECIFIC E o o 8 8 B L4 o o 2 o wn 8 B
81. E ARC CONNECTION DIAGRAM 6 PIN AMPHENOL ELECTRODE TO WORK OPTIONAL K444 REMOTE CONTROL LN 25 WIRE FEEDER WORK CLIP LEAD TO WORK TO WORK MULTI WELD 350 LINCOLN 8 C 4 NOTES MULTI WELD 350 LINCOLN 9 C 4 DOL WINDY DOL UNY DOL OF DOL OF DOL DOL DOL UMY DOL UMY Section D 1 Section D 1 TABLE OF CONTENTS MAINTENANCE SECTION Maintenance Section D 0 2 Maintenance D 2 Digital Meter Calibration riri eet tete eet x e eles D 2 cm D 3 Retum to Master TOC Retum to Master TOC Y 4 2 8 5 A Retum to Master TOC MULTI WELD 350 LINCOLN 8 Return to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 8 E 5 rA Retum to Master TOC MAINTENANCE SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves Have
82. EC MF 1 10W 3 32K 0 1 S25056 25MT R380 R561 R619 R766 TRIMMER SMD MT 1 4W 2K 10 LINEAR S25000 1501SMT R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R17 R63 RESISTOR SMD METAL FILM 1 10W 1 50K 1 515128 275 IC OP AMP SINGLE PRECISION LT1097S8 515128 45 X2 X3 X39 X40 X41 X42 X51 x55 OP AMP SMD QUAD GEN PURPOSE 224D 525000 47505 R18 R19 R20 R21 R22 R23 RESISTOR SMD METAL FILM 1 10W 4750HMS 525000 10005 R50 R51 R52 R53 R54 R55 R56 R57 R58 R59 R60 R61 R64 R65 R66 R67 R68 R69 R70 R71 R72 R73 RESISTOR SMD METAL FILM 1 10W 1000HMS 515128 185 X4 X5 X6 X7 X16 X22 X46 X47 X52 X56 IC OP AMP SMT QUAD HIGH PERF 33074D M15458 6SMT IC SMD PWM CONTROL 515018 65 9 10 11 14 17 24 34 X35 X36 IC SMD CMOS SWITCH ANALOG QUAD 4066B 525000 82515 R62 R243 R24 R268 R381 RESISTOR SMD METAL FILM 1 10W 8 25K 1 515128 115 15 43 1C 5MT COMPARATOR QUAD 2901D 525001 13015 R74R75 R76 R77 RESISTOR SMD 1 3K 1 4W 1206 196 TR 525065 15 X20 IC SMD MULTIPLEXER 2 TO 1 LINE 525001 47505 R78 R79 R80 R81 R82 R83 R84 R85 R86 R87 R88 R89 R90 R91 RESISTOR SMD 4750HMS 1 4W 1206 1 TR 525057 35 X27 53 57 POT DIGITAL SMD 10K QUAD TSSOP 24 525069 25 x30 IC SMD CMOS EEPROM
83. ERTED BELOW 519400 1003 RESISTOR 1 4W t O0K 194 CONNECTOR TOP SURFACE i 40 15194001580 1 022 RESISTORMF 1 4 W 15 0 1 PART NO IDENTIFICATION CODE 41 519400 2490 1 R24 RESISTOR 1 4W 249 196 SECURE PC BOARD ASSEMBLY IN PLACE WITH ITEM 4 mE RM TRANSFORMER P Ca PV EWEEK 2 PLACES 1 BUY PER E3867 43 75 8 622 14 ND IDENTIFY COMPLETE ASSEMBLY WITH A PRINTED LABEL n 44 4 3 xt OPWM CONTROLLER IMODE 2842A OTHER PERMANENT MARKING IN AREA SHOWN TEST PER E3861 sisas 1 bo REF ADJ PECISION A311 NE NO COMPONENTS ON BOTTOM SIDE OF PC BOARD SCHEMATIC REFERENCE 9122 BMC MMOL PUES MATION 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 USA THIS SHEET CONTAINS PROPRIETARY INFORI price RR EQUIPMENT TYPE COMMON ANALOG CONTROL pa mer LL peer ee fuet ANALOG POWER SUPPLY PCB ASSEMBLY PUSHED STANDARDS XC UF i 4 RAN NNI EY DATE2 23 99 DRAWNGNO Olio ojo Ele 5 o 25 215 2 cite m Bla o o 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 Componen
84. G PC BOARD SCHEMATIC daos quet Fame G 13 ANALOG PC BOARD ASSEMBLY beides ow os e aH Ru G 14 BY PASS BOARD SCHEMATIC is races eat e er dada do bh paste ins G 15 BY PASS PC BOARD ASSEMBLY oobis patent arae ca Ce ed dd oae ciat de G 16 CHOPPER PC BOARD SCHEMATIC vita Ia ne i EE edd G 17 CHOPPER BOARD ASSEMBLY 4632 en cnt tetro era EN eran G 18 MULTI WELD 350 LINCOLN 5 ELECTRICAL DIAGRAMS WIRING DIAGRAM MULTI WELD 350 MULTI WELD 350 WIRING DIAGRAM CONTROL BOX A TUNNEL ASSEMBLY BACK PANEL VIEWED FROM PCB SIDE VIEWED FROM SIDE Return to Section TOC Return to Master TOC 2004 R313 314 KEY PIN R315 316 J 309 4Q 310 4 R313 PANEL PLUGS ON OFF amp MODE SELECT P21 1 J21 Ee PANEL RECEPTACLES KEY PIN 311 303 304 PANEL PLUGS P20 n 326 2 302 330 1304 t 06 5 307 gt 308 227 327 fi 4 gt gt gt gt J20 PANEL RECEPTACLES E J od 200 gt q 300 j gt 210 3 p 211 Slog N gt d R213 gt 214 gt 2151 5 216 209 gt 402 302 408 co 226 207 208 416 404 gt R413 A 414 3 pe amp o 8 lap gt 412 7 01 0 08
85. GREE rmon MATERIAL TOLERANCE TO AGREE 910 SCALE m WITH PUBLISHED STANDARDS Date 09 01 99 CHK SUP S D G NO 19330 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual E MULTI WELD 350 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Ojo ojo Ele og o t gls 2 BIZ o o G 12 ELECTRICAL DIAGRAMS G 12 PC BOARD ASSEMBLY POWER BUSS L11078 1 MAKE PER E1911 POT PER E1911 E TEST PER E3862 REQ D PART NO IDENTIFICATION 15458 4 I C PwM CONTROLLER I MODE 2842A C2 C3 C5 C16 513490 25 513490 42 CAPACI TOR TAEL 4 7 35 10 CAPACI TOR TAEL 1 O 35V 10 C6 5 13490 66 5 13490 93 CAPACI TAEL 47 35 10 CAPACI TAEL 27 35V 10 C15 x2 513490 174 5 150 18 16 CAPACI TOR ALEL 470 1007 50 10 I C CMOS ORI VER MOSFET 2110t SS
86. INCOLN ELECTRIC COMPANY CLEVELAND OHIO USA Chg Sheet No DESIGNINFORMATION RereRENCE EQUIPMENT E ON ALL ANGLES IS l E SUBJECT BY PASS PC BOARD ASSEMBLY 5 MATERIAL TOLERANCE XD UF ENGINEER SUPERSEDING APPROVED LO SCALE DATE 4 22 99 DRAWNGN 19510 1 E 9166 9 L DO NDT SCALE THIS DRAWING Olio Fle 5 o 25 215 wn 81 8 cit m o o 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 machine MULTI WELD 350 E ELECTRICAL DIAGRAMS e SCHEMATIC CHOPPER PRINTED CIRCUIT BOARD 066 N Return to Section TOC Return to Master TOC 2 5 8 114 C1 C2 C8 C4 C5 Gt MIC4451BN Ga G3 G4 16100 39 i Ej E2 E 1 4 10 to heatsink O Retu
87. IPTION The following procedure will aid the technician in removing and replacing the Weld Control or Peripheral PC Board on the Multi Weld 350 MATERIALS NEEDED 3 8 Nut driver wrench or socket wrench 5 16 Nut driver Wiring Diagram This procedure should take approximately 30 minutes to perform MULTI WELD 350 LINCOLN F 36 37 37 TROUBLESHOOTING amp REPAIR WELD CONTROL OR PERIPHERAL PC BOARD REMOVAL AND REPLACEMENT CONTINUED FIGURE F 8 CASE FRONT ASSEMBLY DETAILS Retum to Section TOC Retum to Master TOC PLUG P31 PERIPHERAL PC BOARD JUMPER PLUG P3 WELD CONTROL PC BOARD SCREWS Fa Retum to Master TOC 5 9 8 eig 9 9 5 8 nile 8 8 JE cic REMOVAL PROCEDURE Refer to Figure F 8 3 Perform the Case Cover Assembl 1 Set the CC CV power switch to OFF Removal procedure 4 Remove input power machine 4 Perform the Power Capacitor Discharge PUER procedure 5 Perform the Case Front Assembl WARNING Removal procedure ELECTRIC SHOCK can kill 6 Using the 5 16 nut driver remove the Disconnect input power before removing the REINO DONE Mea case cover and performing tests or making repairs to the machine Return to Section TOC Retum to Master TOC MULTI WELD 350 LINCOLN P Retum to Section to Master TOC Retum to Section TOC 5 8 9
88. K can kill Disconnect input power before removing the case cover and performing tests or making repairs to the machine 2 Remove input power to the machine Return to Section TOC Retum to Master TOC MULTI WELD 350 LINCOLN P Retum to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 28 F 28 TROUBLESHOOTING amp REPAIR CHOPPER PC BOARD INPUT VOLTAGES AND RESISTANCE TEST CONTINUED Test Procedure for the Left Side Power Module 1 8 Locate the Power Module Capacitor termi nals Using the 7 16 wrench disconnect leads X1 X4 401 401 and the cop per straps Carefully electrically isolate these leads and straps from the capacitor terminals and heat sink assembly See Using the 3 8 nut driver remove the four screws holding the case back to the tunnel assembly This will provide access to the IGBT heat sinks Using the analog ohmmeter connect the positive meter probe to the positive copper strap and the negative meter probe to the IGBT heat sink This is the inner heat sink See Figure test point loca tions The resistance should be very high over 20 000 ohms If the resistance is low then either the IGBT is shorted or the diode D5 is shorted Disconnect the small D5 cathode lead to isolate the problem It is possible that both devices may be
89. LEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS The preset amps CC mode or 1 The panel Output Control is dis 1 The Output Control R1 may be volts CV mode are not adjustable abled when a remote control faulty Check or replace Also device is plugged into the 6 pin check associated leads for remote receptacle loose or faulty connections Retum to Section TOC Retum to Master TOC Check all the plug connections to the Weld Control Board for loose or faulty connections See the Wiring Diagram The Weld Control Board may be faulty Replace The preset range is not correct The panel Output Control is dis Make sure plug P3 is connected abled when a remote control securely to receptacle J3 on the device is plugged into the 6 pin Weld Control Board See the Return to Section TOC Retum to Master TOC remote receptacle Wiring Diagram Make certain all the jumper leads are in place Check all the plug connections to the Weld Control Board for loose or faulty connections See the Wiring Diagram The Weld Control Board may be faulty Replace Retum to Master TOC 5 8 9 8 CAUTION If for any reason you do not understand the test procedures or 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
90. M MODULE UP EN c ri R6 R14 R16 R18 R20 5 19400 4751 4 75K per NG 17 19400 4750 475 l 4W R10 R11 R13 RIS R17 5 519400 1080 10 1 4W N D 5 PLACES N A IX2 1 515018 21 IC DRIVER 9A LOW SIDE MOSFET 55 IDENTIFICATION L11038 D BOARD BLANK M16100 39 ELECTRONIC MODULE A 1 T9147 15 EYELETS MALE 84 85 8 112 B119 FEMALE ANGUS TERIAL TOLERANCE AGREE WITH PUBLISHED STANDARDS NOTES E2861 SEALANT CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC 520590 1 HEAT SINK ELECTRICITY SEE E2454 BEFORE HANDLING S18250 542 PLUG amp LEAD ASSEMBLY N B DO NOT COAT WITH ENCAPSULATION MATERIAL o o g B L4 o o 8 B THESE AREAS TO BE COVERED ON BOTH SIDES OF BOARD WITH SEALANT PRIOR TO ENCAPSULATION MAKE PER E1911 N D INJECT SEALANT THROUGH THE PC BOARD TO SEAL MODULE LEADS ENCAPSULATE WITH E1844 MANUFACTURED AS AND TO COVER ALL MODULE LEAD PINS ON TOP OF BOARD TEST PER 827 N E FEMALE EYELET TO BE AGAINST THE OPPOSITE COMPONENT SIDE AS PRU SUR SHOWN EYELET MUST NOT SPIN AFTER CLINCHING L 1 1 3 8 1 D N F SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET
91. N AREA SHOWN PROGRAM ITEM 140 WITH ITEM 7 PROGRAM ITEM 142 WITH ITEM 8 IR147 R301 R302 R303 R304 IRESISTOR SMD METAL FILM 1 10W 47 5K 1 525057 25 NOTE G3990 2 MUST BE REVIEWED WHEN MODIFYING THIS BOARD BUY AS 3660 2C PART NO IDENTIFICATION CODE x54 POT SMD DIGITAL 10K 1 CHNL SOIC 8 UNLESS OTHERWISE SPECIFIED RESISTANCE 5 SCHEMATIC REFERENCE G3661 2 0 BUY PER E3867 TEST PER 869 PARTS SHOWN MUST BE COMPLETELY COVERED WITH ENCAPSULATION 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 E EQUIPMENT TYPE COMMON ANALOG CONTROL 5075 owe WELD CONTROL PCB ASSEMBLY Lu TEM s a SET XB RW SCALE 5X DATE 1 27 2000 DRAWNGNo G 3660 2 MANUFACTURING TOLERANCE PER E2066 ON 2 PLACE DECIMALS IS 102 ON 3 PLACE DECIMALS IS 5 002 ONALL ANGLES IS OF A DEGREE MATERIAL TOLERANCE AGREE WITH PUBLISHED STANDARDS NOTSCALE THIS DRAWING Return to Section TOC Return to Master TOC 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 i
92. OOTING amp REPAIR CASE COVER ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE COVER REMOVAL DETAILS Retum to Section TOC Retum to Master TOC CASE COVER Retum to Master TOC B 5 9 8 2 8 REMOVAL PROCEDURE REPLACEMENT PROCEDURE 5 5 1 Set the CC CV power switch to OFF 1 Be sure that the toroid rings on the top of cic the tunnel assembly are lying flat and will not restrict placement of the machine cover See Figure F 1 A WARNING 2 The cover fits on in one direction only ELECTRIC SHOCK can kill Verify front back orientation then carefully lower the cover into place Disconnect input power before removing the case cover and performing tests or making repairs to the machine 2 Remove input power to the machine 3 Install the 13 sheet metal screws that hold the case cover in place 3 Using the 3 8 nut driver remove the 13 sheet metal screws holding the case cover assembly in place 4 Carefully lift the cover off the machine Return to Section TOC Retum to Master TOC MULTI WELD 350 LINCOLN P Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 15 TROUBLESHOOTING amp REPAIR POWER MODULE CAPACITOR DISCHARGE PROCEDURE WARNING Service and repair should be performed by only Lincoln El
93. P22 and P31 See the Wiring Diagram Check the Output Control R1 and the associated leads See the Wiring Diagram The Weld Control Board may be Faulty No control of welding output 1 800 833 9353 The panel Output Control is dis abled when a remote control device is plugged into the 6 pin remote receptacle Check the welding cables for loose or faulty connections Check the Output Control R1 and the associated leads for loose or faulty connections Check all the plug connections to the Weld Control Board for loose or faulty connections See the Wiring Diagram The Weld Control Board may be faulty Replace 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 MULTI WELD 350 LINCOLN 8 11 11 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION Retum to Section TOC Return to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC When welding in the Stick Mode the current changes with arc length WELDING PROBLEMS
94. R30 5 5 4 75 0805 1 R32 R33 R34 R109 R113 R114 R115 R116 R138 R151 R152 R153 R154 R166 525000 68125 R35 R111 5 5 68 1 0805 1 1 10 525000 33215 R37 R118 R119 R139 R140 5 5 3 32 0805 1 1 10 80042 71 R155 525000 10015 R40 R46 R167 SRES 1K 0805 1 1 10W TR NP 525056 45 R47 SRES 5K 5 TURN POT 1 4W 10 525000 22125 R51 SRES 22 1K TKF 0805 1 1 10W 525000 10005 IR55 R124 R125 R126 ISRES 100 TKF 0805 1 1 10W 525001 26705 R57 R58 R59 R60 R62 R63 SRES 267 1206 196 1 AW TR NP R64 R65 525000 10025 R7 R110 R164 R165 ISRES 10K 0805 1 1 10W TR NP 515128 115 1 2 SICS 2901 NP M15102 4SMT SICS MC1413BD ARRAY DRIVER SO16 525068 15 SICS 5V REG 0 5A 2 DPAK 525070 35 ISICS XC9536 44 PIN VQ44 517900 85 5 5 74 14 525020 25 T11577 58 525024 55 525024 95 525024 75 525024 85 525040 35 525040 25 Return to Section Return to Master TOC SI o 525044 45 m 525044 65 BN 3525044 75 525044 85 518248 6 524020 16 524020 12 525051 2507 525050 15 525050 25 525000 51105 TE a a 5 525000 47 55 525000 47505 525000 12115 525000 15015
95. RUCTION MANUAL N B R XXX DENOTES A RED LEAD NUMBERED XXX R1 10K MULTI TURN R2 R3 10K ONE TURN E L GENERAL INFORMATION CASE ELECTRICAL SYMBOLS PER E1537 GROUNDING RESISTORS OHMS WATT UNLESS OTHERWISE SPECIFIED ALL SWITCH WIRING VIEWED FROM REAR OF SWITCH INPUT WORK NOTE SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD 4 MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER 4PI 9 PIN J20 J22 23 P20 P22 P23 J24 J45 J45A P24 P45 P45A G3676 Return to Section TOC Return to Master TOC 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 LINCOLN MULTI WELD 350 ELECTRICAL DIAGRAMS b SCHEMATIC CONTROL PC BOARD 1 MACHINE SELEC HERMAL SENSE Return to Section TOC Return to Master TOC MACH_SEL_1 2 V SET MODE 2 MACH 1 2_ON 012 4 0141 REMOTE_
96. Retum to Section TOC Retum to Master TOC MULTI WELD 350 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 8 F 8 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The meters do not light in either CV or CC modes POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS 1 In the CC mode only the AMPS meter will light In the CV mode only the VOLTS meter will light TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION Check all the plug connections to the Weld Control Board for loose or faulty connections See the Wiring Diagram Check the leads and connec tions between the meters and the Weld Control Board See the Wiring Diagram 3 Perform the Analog Control Power Supply Board Test 4 The meters may be faulty 5 The Weld Control Board may be faulty Replace One or both of the meter s readings are not accurate 1 Make sure the test or external meter is reliable and accurate Check shunt feedback leads R326 327 R226 227 plugs P21 and P6 for loose or faulty connections See the Wiring Diagram Check the integrity of lead 237 at plug P12 on the Weld Control Board and also at plug P31 on the Peripheral Board 3 See the Digital Meter Cal
97. SERIAL SPI 64Kx8 S S25070 5SMT bot IC SMD FPGA XCS20 TOFP 144PIN 525069 55 beg IC SMD EEPROM CMOS CONFIGURATION 256K 525000 20005 R92 R93 R94 R210 RESISTOR SMD METAL FILM 1 10W 2000HMS 515128 105 4 5 REF ADJ PECISION 431I 525000 68115 R95 R96 R97 R98 R99 R100 R101 R102 R103R212 IRESISTOR SMD METAL FILM 1 10W 6 81K 1 525067 15 x5 IC BIPOLAR TIMER SOIC 14 515018 115 50 IC SMD CMOS SWITCH ANALOG QUAD 201 55 525000 12125 R105 R106 IRESISTOR SMD METAL FILM 1 10W 12 1K 1 525000 10015 R107 R108 R109 R110 R111 R112 R113 R114 R115 R116 R117 R118 R119 R120 R121 R122 R123 R124 R125 R126 R127 R128 R129 R130 R131 R132 R133 R134 R135 R136 R137 R138 R378 RESISTOR SMD METAL FILM 1 10W 10 0K 1 S25000 1001SMT R139 R140 R147 R142 R143 R144 R145 R146 R148 R149 R150 R151 R152 R153 R154 RESISTOR SMD METAL FILM 1 10W 1 00K 1 525000 47525 CAUTION THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY LINCOLN ELECTRIC TO SEE E2454 BEFORE HANDLING PLACE CONNECTOR KEYING PLUG OVER HEADER PIN IN LOCATION SHOWN PLUG SHOULD BE INSERTED BELOW CONNECTOR TOP SURFACE 6 PLACES SECURE P C BOARD ASSEMBLY IN PLACE WITH ITEM 4 2 PLACES 5 3 5 IN LBS PLACE BARCODED ASSEMBLY NUMBER IDENTIFICATION AND BARCODED SERIAL NUMBER IDENTIFICATION I
98. SVM151 A September 2002 Multi Weld 350 Arc Converter For use with machines having Code Numbers 10645 10736 Return to Master TOC View Safety Info Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be in creased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info ols S9 21 e z E19 al View Safety Info LINCOLN Copyright 2000 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 FAX 216 486 1751 WEB SITE www lincolnelectric com pReturn to Master TOC SAFETY WARNING 5 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 8 Above For Diesel Engines The Above For Gasolin
99. TCH INDICATES LOW OIL PRESSURE LOGIC AT ENG_ALT_VOLTS_SW INDICATES FAILED ALTERNATOR ENGINE MUST SHUT DOWN MUST SHUT ENGINE DOWN BATT COM FLASH IS HI WHEN DIL_PRES_SWITCH 5V_BATT FUEL_LEVEL_SWITCH 12351 FUEL SENDER SENSE CIRCUIT 1 J31 9 amas c i TO SENDER INPUT 1 POST ON FUEL GAUGE M 4 nz lt 10 432 Ojo ojo Ele og o t gls ge E E 818 o o HELLA 517900 8 ui cz 972 7 5 022 an R37 332K D x3 COM Vcom MCL4L3BP Li LOGIC AT FUEL LEVEL SWITCH INDICATES LOW FUEL LOW FUEL LAMP MUST TURN ON ENGINE TO SHUT DOWN AFTER 30 MIN GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 m CAPACITORS 022 50 UNLESS OTHERWISE SPECIFIED C 46 RESISTORS Ohma 1 4W UNLESS OTHERWISE SPECIFIED LABELS 2 2 DIODES 1A400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION FILENAME 93663_1b 77 FRAME CONNECTION THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN ELECTRIC E AND IS NOT REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION
100. They may be left covered as factory set or set up as desired with or without the hinged cover secured 7 8 9 10 Hot Start Control is provided to enhance arc starting in both CC and CV modes with extra output boost at the arc strike that returns to the setting level in less than a second about 0 30 sec in CC mode and 0 045 sec in CV mode This extra Hot Start amplitude is adjustable from 0 no extra to 10 100 of setting extra with the factory set 5 center position typically good for most weld starting However 0 may provide smoother starting for fine wire CV MIG Arc Force Control is only functional in the CC mode with Stick Gouge slope See below Arc Force prevents stubbing of the electrode by pro viding extra weld current if the arc voltage drops below about 14 V This extra weld current is adjustable from 10 no extra to 10 60 of setting extra with the factory set 0 center position typically good for most welding CC Slope Switch is provided to enhance stick welding on fast freeze type electrodes such as E6010 and E7010 typically used on pipe welding applications for fast root pass vertical down drag technique not whipping For this type of application improved operating appeal may be obtained if the CC Slope is switched from the fac tory set STICK GOUGE position to the PIPE position NOTE The PIPE position uses a drooping t
101. area under the curve the more power is present MULTI WELD 350 LINCOLN 8 Return to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC THEORY OF OPERATION CHOPPER TECHNOLOGY FUNDAMENTALS The new era of welding machines such as the Multi Weld 350 employ a technology whereby a DC source is turned on and off chopped up at high speed then smoothed through an inductor to control an arc Hence the name Chopper The biggest advantage of chopper technology is the high speed control of the arc similar to how inverter machines operate A block diagram for this is as follows INDUCTOR ARC EXTERNAL DC SOLID STATE SOURCE SWITCH ARC CONTROL In this system current from a DC source such as the MULTI SOURCE is applied through a solid state switch to an inductor By turning the switch on and off current AND DIODE in the inductor and the arc can be controlled The fol lowing diagram depicts the current flow in the system when the switch is open and closed 70 80VDC DIODE B CURRENT WITH SWITCH OPEN 221 CURRENT WITH SWITCH CLOSED When the switch is closed current is applied through the inductor to the arc When the switch opens current stored in the inductor
102. chnician 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing and replacing stud type diodes on the aluminum heat sinks of the Multi Weld 350 MATERIALS NEEDED 3 8 Nut driver wrench or socket wrench 1 2 socket wrench and extension 17 mm Wrench or socket wrench 1 Open end wrench Penetrox A13 joint compound Loctite 271 Slip type torque wrench No 000 fine steel wool Diagonal cutters Wiring Diagram This procedure should take approximately 45 minutes to perform MULTI WELD 350 LINCOLN F 45 Retum to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 5 rA Retum to Master TOC F 46 F 46 TROUBLESHOOTING amp REPAIR INPUT DIODE REMOVAL AND REPLACEMENT CONTINUED FIGURE F 11 INPUT DIODE ASSEMBLY DETAILS CONTACTOR STRAP PIGTAILS THERMOSTAT LEADS 306 amp 307 POINT
103. control presets amps in the 30 to 350 A range and then adjusts actual welding current to match the preset when welding In CV mode machine output is at the voltage level set at the OUTPUT control The OUTPUT control presets volts then adjusts the actual arc voltage to match the preset when welding A HOT START control is provided to enhance arc start ing with an adjustable output boost in either CC or CV mode The ARC FORCE control CC mode only pro vides extra weld current to prevent electrode stubbing An additional CC SLOPE switch improves fast freeze stick electrode performance during vertical pipe weld ing when set to the PIPE position NOTE Unshaded areas of Block Logic Diagram are the subject of discussion MULTI WELD 350 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 8 5 rA Retum to Master TOC E 6 E 6 THEORY OF OPERATION PROTECTION FEATURES The Multi Weld 350 design features electronic protec tion systems to help assure reliable operation even under adverse conditions These systems include FAN AS NEEDED F A N The cooling fan will turn on when the arc starts and remain on for about a minute after the arc is out to cool down the power components This feature electronically controls the fan so it does not run continuously when the power switch is
104. crew and insert them into the holes Using the torque wrench and 7 16 socket tighten each screw between 30 and 40 in Ibs Install the 7 16 bolt lock washer flat washer heavy lead and negative strap to the negative terminal on the capacitor Tighten the bolt to 50 60 in Ibs Remove the wooden blocking and careful ly lower the tunnel assembly onto the machine base Support the tunnel assem bly and turn the machine onto its side With the 3 8 wrench install the four screws that hold the tunnel assembly to the machine base Turn the machine back upright Perform the Case Cover Assembl Replacement procedure Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 60 TROUBLESHOOTING amp REPAIR Retest a machine RETEST AFTER REPAIR F 60 If itis rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics OR f you repair or replace any electrical components IDLE AMPS Input Volts Maximum Idle Amps 50 118 VDC 1 Amp Mode OPEN CIRCUIT VOLTAGES Input Voltage Open Circuit Voltage CC Stick CC Stick CC Pipe 200 A preset CV Min Preset CV Max Preset Mode 72 113 VDC 60 72 VDC 72 118 VDC 60 113 VDC 60 113 VDC LOAD TEST Input
105. ction the Multi Weld case will be electrically hot to the work if the clip is removed without first switching OFF the panel switch Refer to the Work clip WARNING INTER CONNECTION OF CONVERTERS The input and electrode cables of the Multi Weld 350 Converters may be inter connected in a Multi Weld system using any combination of Distribution Box es see Figure B 1 paralleling CC mode only and daisy chaining see Figure A 2 Choose the config uration that best fits the field application setup within the capacity of the power source supplying the system Power Source Volts x Amp capacity 1 1x Sum of Converters Volts x Amps arcs A WARNING Paralelled units may be powered from more than one source Disconnect all inputs including outputs from other sources before working on the equipment Before removing the parallel jumper be sure both Converters are switched OFF If not the male side of the first disconnection will be electrically hot to work MULTI WELD 350 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 5 rA Retum to Master TOC A 5 TOPOWER qf SOURCE TO POWER INSTALLATION FIGURE A 2 INTER CONNECTING CONVERTERS FIXED PARALLEL OPERATION ELECT ELECT A 5 e e TO e WORK
106. d the input contactor does not acti vate when the ON OFF Mode Selector switch is turned on Make sure the power source is working properly and supplying at least 50VDC to the Multi Weld 350 The electrode cable must be positive polarity and the work cable negative polarity Check the electrode and work cables for loose or faulty con nections Measure the input voltage to the Multi Weld 350 It must be between 50 and 113VDC The ON OFF Mode Selector switch 51 may be faulty Check and replace if faulty See the Wiring Diagram Also check associated wiring The input diode D1 D2 may be open Check See the Wiring Diagram Perform the DC Buss Suppl Board Test Perform the Analog Control Power Supply Board Test The Weld Control Board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or 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 MULTI WELD 350 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 5 F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The meters light but the input con tactor does not activate when
107. derstand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing and replacing the input con tactor on the Multi Weld 350 Retum to Section TOC Retum to Master TOC MATERIALS NEEDED 3 8 Nut driver wrench or socket wrench 17 mm Wrench or socket wrench Diagonal cutters Wiring Diagram This procedure should take approximately 30 minutes to perform Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC MULTI WELD 350 LINCOLN 43 43 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR REMOVAL AND REPLACEMENT CONTINUED FIGURE F 10 INPUT CONTACTOR ASSEMBLY DETAILS LEAD 331 COPPER Retum to Section TOC Retum to Master TOC LEADS X1A X1 XBP5 INPUT 303A 330 BASE BOLTS 2 2 Retum to Master Return to Section TOC INPUT DIODE HEAT SINK HEAT SINK BOLTS amp NYLON INSULATORS 2 5 8 9 8 Return to Section Y 4 2 5 rA Retum to Master TOC REMOVAL PROCEDURE Refer to Figure F 10 3 1 Set the CC CV power switch to OFF 2 Remove input power to the machine WARNING 2 ELECTRIC SHOCK can kill
108. ds that con nect to Base Module Base Module item 3 is the mounting and connection platform for the other modules This module assembly includes Base sheetmetal with input output connection cham bers with pigtail leads Input contactor input diodes heat sink assembly and Work clip lead Output chokes and current shunt Lead harness sealed plugs connect to Tunnel and Control Module receptacles FIGURE D 2 MAJOR COMPONENT LOCATIONS 1 CONTROL MODULE 2 TUNNEL MODULE 3 BASE MODULE 4 CASE WRAPAROUND MULTI WELD 350 LINCOLN 8 4 NOTES MULTI WELD 350 LINCOLN 9 D 4 DOL WINDY DOL UNY DOL OF DOL OF DOL DOL DOL UMY DOL UMY Section E 1 Section E 1 TABLE OF CONTENTS THEORY OF OPERATION SECTION 5 5 General Description erue Ieri E 2 g Input Power Source Contactor and DC Buss Power Supply E 2 8 Power Modules and Feedback de E 3 E Analog Control Power Supply Board and Weld Control Board E 4 74 Mode Selector and Output 5
109. e wire feeder offers constant wire feed speed in a rugged case CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS A WARNING ELECTRIC SHOCK can kill Only qualified personnel should per form this maintenance gt Turn the input power OFF at the dis connect switch or fuse box before working on this equipment Do not touch electrically hot parts MULTI WELD 350 LINCOLN 8 Retum to Section Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC C 3 C 3 ACCESSORIES CONNECTION OF THE LN 25 TO THE MULTI WELD 350 ACROSS THE SEE FIGURE C 1 1 Shut the welder off 2 Connect the electrode cable from the LN 25 to the terminal of the welder NOTE Welding cable must be sized for current and duty cycle of application 3 Attach the single lead from the LN 25 to the work using the spring clip on the end of the lead This is only a sense lead it carries no welding current A CAUTION If you are using an LN 25 without an internal contactor the electrode will be HOT when the Multi Weld 350 is turned ON 4 Set the MODE switch to CV Adjust wire feed speed at the LN 25 Adjust the HOT START CONTROL to the desired level Use O for fine wire 7 Set VOLTMETER switch to the positive position FIGURE C 1 MULTI WELD 350 LN 25 ACROSS TH
110. e Engines 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 Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in 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 6 T FOR ENGINE vd f us 1 h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment AW ey ln 1 a the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors Retum to Master TOC ELECTRIC AND 3 MAGNETIC FIELDS E may be dangerous 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 2 a Electric current flowing through any conductor causes ing to prevent spilled fuel fr
111. e area on the heat sink around the diode mounting surface using a putty knife or similar tool DO NOT SCRATCH THE DIODE MOUNTING SURFACE 14 Polish the heat sink s mounting surface to provide a bright clean surface where the diode seats on the heat sink Wipe the sur face clean with a lint free cloth or paper towel 15 Inspect the mounting surfaces of each new diode Remove all burrs and wipe clean Do not use steel wool or any abrasive cleanser on the diode mounting surface 16 Apply a thin 0 003 to 0 007 uniform layer of Penetrox A13 joint compound to the heat sink mounting surface 17 Do not apply compound to the diode stud or mounting threads 18 Apply two drops of Loctite 271 to the diode stud threads before tightening NOTE The diode threads must be clean and free of defects so that it can be finger tightened before applying torque slip type torque wrench must be used to tighten the diode 19 Tighten the diode to the specifications in the following table DIODE STUD FOOT POUNDS INCH POUNDS SIZE 3 4 16 25 27 300 324 INPUT DIODE REMOVAL AND REPLACEMENT CONTINUED REPLACEMENT PROCEDURE Refer to Figure F 11 1 Set the input diode assembly into the machine base Connect the heat sink to the input terminal strap with the 1 2 bolt wash ers and nut Note order see removal pro cedures 2 Install the heat sink to the choke using the 3 8 bolt and nylon insulat
112. e external DC source voltage is applied to parallel capacitors incorporated within each of the two Power Chopper Modules These capacitors function as fil ters and as power supplies for the IGBTs See IGBT Operation in this section The IGBTs act as high speed switches operating at 20KHZ These devices are switched on and off by the Weld Control Board through pulse width modulation gate signals See Pulse Width Modulation this section This chopped DC output is applied through choke coils and a shunt to the welding output terminals The chokes function as current filters Free wheeling diodes are incorporated in the power circuit to provide a current path for the stored energy in the chokes when the IGBTs are turned off See Chopper this section Output voltage and current feedback information is fed to the Weld Control Board This information is sensed from the output terminal circuits and the shunt The feedback information is processed by the Weld Control Board which regulates output voltage and current NOTE Unshaded areas of Block Logic Diagram are the subject of discussion Retum to Section TOC Retum to Master TOC MULTI WELD 350 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC E 4 E 4 THEORY OF OPERATION FIGURE E
113. e 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 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 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 from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards Use suitable clothing made from durable flame resistant material
114. eads and plugs for loose or faulty connections See the Wiring Diagram If the correct voltage IS present and the fan is not running the fan motor may be faulty If the correct voltage 40VDC is not present in the above test perform the DC Buss Supply Board Test 3 The Weld Control Board may be faulty Replace 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 1 800 833 9353 MULTI WELD 350 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 10 F 10 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS The welding output is high with no 1 Check all input and output control cables for shorts Check the positive input and output cables for grounded connections to the machine s case TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check shunt feedback leads R326 327 R226 227 plugs P21 and P6 for loose or faulty connections See the Wiring Diagram Check the continuity of leads 401 301 201 plugs P20
115. ear the engine fan Do not attempt to side the work cable should also be on your right side override the governor or idler by pushing on the throttle con trol rods while the engine is running d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance d 5 Do not work next to welding power source work disconnect the spark plug wires distributor cap or magneto wire as appropriate Retum to Master TOC LINCOLN 8 Retum to Master TOC Retum to Master TOC Y 4 2 8 5 A Retum to Master TOC SAFETY 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 workpiec
116. ected to each Converter The current contribution of each Converter will depend on its remote output setting Partial Range remote control can be accomplished with a single Remote Control connected to the output Converter The input Converter must be preset with its panel Output Control to below the minimum desired output range The Remote Control connected to the output Converter will control its output to add to the preset level Remote Output On Off switching may be set up for each of the paralleled Converters Electrically isolated switches must be used to activate each separately but simultaneously TRANSPORTING AND STORAGE OF THE MULTI WELD 350 CABLE HANDLING The input and electrode cables are easily disconnect ed from the quick connect pig tails The Work lead can be reeled around the Multi Weld 350 case cradled by the base skid handles to which the clip can be secured MULTI WELD 350 LINCOLN 8 Return to Section Retum to Section TOC 5 8 9 8 Return to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION TRANSPORTING The Converter may be carried by one or two persons using the front and rear top and bottom handles It can also be set vertically on a two wheel cart or horizon tally on a wagon to move it longer distances STORAGE The Multi Weld 350 may be set on a floor or shelf hor izontally on its skid or vert
117. ection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans 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 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 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 metallique 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 defonctionnement 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 soud er 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 Dans le cas de travai
118. ectric 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This procedure will insure that the large capacitor in each chopper power module has been discharged This procedure should be performed whenever work is to be attempt ed on or near the power modules MATERIALS NEEDED 3 8 Wrench or socket wrench Volt Ohmmeter Resistor 25 1000 ohms and 25 watts minimum Jumper leads This procedure should take approximately 15 minutes to perform MULTI WELD 350 LINCOLN F 15 Retum to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 5 rA Retum to Master TOC F 16 F 16 TROUBLESHOOTING amp REPAIR POWER MODULE CAPACITOR DISCHARGE PROCEDURE CONTINUED FIGURE F 2 POWER MODULE CAPACITOR TERMINAL DISCHARGE PROCEDURE 1 Set the CC CV power sw
119. edure Carefully turn the machine onto its side 6 Using the 3 8 wrench remove the four 10 11 12 screws holding the tunnel assembly to the machine base Support the tunnel assem bly then carefully turn the machine back upright With the slot head screw driver carefully raise the tunnel assembly unit about one inch and block it with the piece of wood This will allow access to the bottom allen head screws on the Chopper PC Board Peel away the adhesive backed rubber stripping if present Use care the strip ping may tear Disconnect the plug harness connection above the Chopper PC Board Slip the wires out of the cord clip Using the 7 16 wrench loosen the bolt at the positive capacitor terminal Then remove the two nuts lock washers and flat washers holding the positive strap to the Chopper PC Board Hold the screw heads behind the board with your finger to remove the nuts Note the placement of the reverse diode lead on the bottom bolt Note the fastener order for reassembly flat washer lock washer nut With the 7 16 wrench remove the two hex head bolts lock washers and flat washers holding the Chopper PC Board to the heat sink Catch the copper stand offs behind the board Using the 3 16 allen head wrench remove the two allen head screws and lock wash ers holding the Chopper PC Board to the heat sink Swing the positive capacitor strap out of the way and remove the Chopp
120. elding bag Wear an anti static wrist ATTENTION strap For safety use a 1 Meg Static Sensitive ohm resistive cord connected to a Devices grounded part of the equipment Handle only at frame Static Safe e you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent sta tic build up Be sure not to touch any electrically live parts at the same time Workstations Reusable Container 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 t 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 shielding bag e If the PC Board uses protective shorting jumpers don t remove them until installation is complete e 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 symp tom has been corrected by the replacement PC board NOTE Allow the machine to heat up so that all electri cal components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the o
121. ent for electrical trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the input contactor is functioning properly MATERIALS NEEDED Volt Ohmmeter 3 8 Nut driver Needle nose pliers Wiring Diagram External isolated 40 VDC power supply This procedure should take approximately 40 minutes to perform Retum to Section TOC Retum to Master TOC Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC MULTI WELD 350 LINCOLN 18 18 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR COIL RESISTANCE AND SUPPLY VOLTAGE TEST CONTINUED FIGURE F 3 INPUT CONTACTOR DETAILS Retum to Section TOC Retum to Master TOC 303A LEADS 330 1 Retum to Master TOC 5 5 B 8 Vigo PP HE b g COIL TEST PROCEDURE 8 8 1 Set the CC CV power switch to OFF 4 Perform the Power Module Capacitor 5 5 2 Remove input power to the machine Discharge procedure cic 5 Locate the input contactor and coil leads and 330 See Figure 6 Label and disconnect leads and ELECTRIC SHOCK can kill 330 at their in line connectors Disconnect input power before removing the 7 Check the coil resistance Normal coil case cover and performing tests or making resistance is approximately 100 ohms repairs to the machine
122. ent procedure the Replacement procedure 39 39 TROUBLESHOOTING amp REPAIR AMPS VOLTS DIGITAL METER AND POTENTIOMETER 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 Retum to Section TOC Retum to Master TOC 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing and replacing the Amps or Volts Digital Meter or the Output Control potentiometer on the Multi Weld 350 Retum to Section TOC Retum to Master TOC MATERIALS NEEDED 3 8 Nut driver wrench or socket wrench 5 16 Nut driver Phillips screw driver Allen head wrench Diagonal cutters Wiring Diagram This procedure should take approximately 30 minutes to perform Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC MULTI WELD 350 LINCOLN 40 40 TROUBLESHOOTING amp
123. er PC Board REPLACEMENT Refer to Figure F 14 1 Make sure the mating surfaces between the copper and the heat sink are clean dry and free of grease Apply a thin coating of electrical thermal joint compound Penetrox A 13 to the mat ing surfaces between the copper and the aluminum heat sink Using the torque wrench and 3 16 allen head socket install the two allen head screws and lock washers that hold the Chopper PC Board to the heat sink Tighten the screws finger tight then to between 24 and 28 in lbs then again to between 40 and 48 in lbs Using the 7 16 socket and torque wrench install the two bolts lock washers and flat washers that hold the Chopper PC Board to the heat sink Note the two spacers required Tighten the bolts finger tight then to between 50 and 60 in lbs Put the positive strap in position and the proper heavy lead Using the 7 16 wrench tighten the bolt at the positive capacitor ter minal to between 50 and 60 in lbs Then put the flat washers lock washers and nuts on the board side of the strap with the reverse diode lead on the bottom connec tion Tighten to between 50 and 60 in lbs Remove the wooden blocking and carefully lower the tunnel assembly onto the machine base Support the tunnel assem bly and turn the machine onto its side With the 3 8 wrench install the four screws that hold the tunnel assembly to the machine base Turn the machine back upright Connect
124. for CV constant voltage welding mode 2 3 Only VOLTS digital meter is lit displaying the preset voltage setting Output will be on at the output voltage setting Output Control has 3 3 4 turn resolution with slip clutch to prevent control pot damage In CC mode it presets AMPS 30 350A range when not welding and adjusts actual arc current while welding CV mode it presets VOLTS 15 40v range when not welding and adjusts actual arc voltage while welding AMPS Digital Meter is a 3 1 2 digit LED meter which displays Preset AMPS in CC mode when not welding Blank in CV mode when not welding Actual AMPS while welding in both CC and CV modes MULTI WELD 350 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 8 E 5 rA Retum to Master TOC 4 5 6 OPERATION Average AMPS for about 7 seconds after welding stops in CC and CV modes only The 5 second memory display is indicated by the display s left most decimal point blinking and is interrupted if arc is restarted Accuracy of Actual AMPS is within 396 and typical ly within 10 amps of Preset An Actual AMPS meter calibration adjustment trimmer is provided See the Maintenance sec tion Two front screws secure the meter bezel which holds a replaceable spatter shield lens Lincoln par
125. g Control Power Supply PC Board F 20 DC Buss Power Supply PC Board F 23 5 Chopper Board Input Voltages and Resistance F 26 5 Oscilloscope Waveforms 29 g Normal Open Circuit Voltage Waveform CC Mode g Input Voltage Applied 75 F 29 Normal Open Circuit Voltage Waveform CV Mode 5 Output Control at 30 Normal Weld Voltage Waveform CC Stick Mode Machine Loaded to 350 Amps at 34 nenne F 31 Normal Weld Voltage Waveform CV Mode Machine Loaded to 350 Amps at 34 F 32 Normal Open Circuit Voltage Waveform CV Mode Output Control at nennen ener F 33 T Replacement Procedures b erue F 34 Case Front Assembly Removal and F 34 8 Weld Control Board Removal and F 36 3 Amps Volts Digital Meter and Potentiometer Removal and Replacement F 39 Input Contactor Removal and F 42 5 Input Diode Removal and 45 Fan Motor Assembly Removal and
126. he tunnel assembly ELECTRIC SHOCK can kill 6 Disconnect the plug harness connection Disconnect input power before removing the above RET PE GOA case cover and performing tests or making repairs to the machine Return to Section TOC Retum to Master TOC MULTI WELD 350 LINCOLN P Retum to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 5 rA Retum to Master TOC F 53 F 53 TROUBLESHOOTING amp REPAIR POWER CAPACITOR REMOVAL AND REPLACEMENT CONTINUED 7 Using the slot head screw driver remove 10 11 12 13 the two screws and lock washers from the tunnel assembly top cover Then remove the four screws lock washers and flat washers that mount the Analog Control Power Supply PC Board This will allow you to access the clamps that hold the capacitors to their brackets in the heat sinks Lift off the top cover of the tunnel assem bly Peel away the adhesive backed rub ber stripping if present as necessary Use care the stripping may tear Using the slot head screw driver loosen the clamp from around the bracket of the capacitor you want to remove Using the 7 16 wrench remove heavy leads X1 X4 and small leads 401 and 401A left side or 1 and X4A right side of the capacitor terminals Note the fasteners for reassembly bolt lock wash
127. ibiting Symptoms are grouped into four main categories Output Problems Function Problems and Welding Problems Step 2 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 con ducted without removing the case 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 sub ject 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 section 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 elec trical 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
128. ibra tion and Adjustment Test in the Maintenance section 4 Perform the Analog Control Power Supply Board Test 5 The Weld Control Board may be faulty Replace 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 1 800 833 9353 MULTI WELD 350 LINCOLN 8 Ozone 9 9 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual Retum to Section TOC Return to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC PROBLEMS SYMPTOMS The fan motor does not run when the machine is turned on POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS Normal operation The Multi Weld 350 utilizes a Fan On Demand system The fan should activate when welding The fan does not run when welding The fan should turn on when the arc starts and remain on for about a minute after the arc is out RECOMMENDED COURSE OF ACTION 1 Carefully check for approxi mately 40VDC at the fan motor leads 303 to 300 This test must be performed while the machine is connected to a resis tive load or welding If the 40VDC is NOT present check the associated l
129. ically standing on its rear top and bottom handles PROTECTION FEATURES The Multi Weld 350 design features electronic protec tion systems to help assure reliable operation even under adverse conditions These systems include FAN AS NEEDED F A N The cooling fan will turn on when the arc starts and remain on for about a minute after the arc is out to cool down the power components This feature electronically controls the fan so it does not run continuously when the power switch is turned on This will minimize the amount of contaminate and clogging debris which may be drawn into the Converter It enhances the Central Air system design which intakes lower velocity air through the higher side louvers and blows it out through the lower back louvers with higher velocity OVER VOLTAGE PROTECTION The Multi Weld 350 input contactor will open if the input supply voltage is above 113 VDC and will automatical ly reclose if the voltage drops back below During Over Voltage Shutdown the panel displays will be as appro priate for the non welding mode See FRONT PANEL 5 this section CAUTION When the contactor recloses the output of the Converter will reactivate Switching OFF input power prevents unexpected reactivation This feature protects internal components of the Converter from excessive voltage levels OVER CURRENT PROTECTION The maximum output current of the Multi Weld 350 is electronical
130. itch to OFF 4 2 Remove input power to the machine A WARNING gt ELECTRIC SHOCK can kill Disconnect input power before removing the case cover and performing tests or making repairs to the machine 3 Perform the Case Cover Assembl Removallprocedure MULTI WELD 350 LINCOLN P POWER MODULE CAPACITOR TERMINALS Locate the power module capacitors on the right and left sides of the tunnel assembly See Figure F2 Using the resistor and jumper leads CARE FULLY discharge the capacitor terminals NEVER USE A SHORTING STRAP FOR THIS PURPOSE DO NOT TOUCH THE TERMINALS WITH YOUR BARE HANDS Repeat the procedure for the second capacitor Using the volt ohmmeter check the voltage across the capacitor terminals It should be zero volts 17 17 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR COIL RESISTANCE AND SUPPLY 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 your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Retum to Section TOC Retum to Master TOC 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 Departm
131. its The cir cuitry on the Weld Control Board determines how the output should be controlled to optimize welding results and it sends the correct PWM gate signals to the IGBT driver circuits The Weld Control Board commands the voltmeter and ammeter which display both preset and actual while welding voltage and current The Weld Control Board also controls the cooling fan motor and the thermal indicator light NOTE Unshaded areas of Block Logic Diagram are the subject of discussion MULTI WELD 350 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC 55 THEORY OF OPERATION lii FIGURE 5 MODE SELECTOR AND OUTPUT CONTROLS MULTI WELD 350 BLOCK LOGIC DIAGRAM INPUT LEFT AND RIGHT DIODES CHOPPER MODULES CONTACTOR CR1 gt IGBT FREEWHEELING DIODE TO ELECTRODE CHOPPER MODULE CABLE NRBEM Es CURRENT FEEDBACK OU Doge DIODE TO WELD CONTROL BOARD a E m CHOPPER MODULE c NEC _ PT EXTERNAL ANALOG WELD O CONTROL PEAUTATED CONTROL RECEPTACLE POWER BOARD supply C mc BOARD 40 VDC O gt O amp PERIPHERAL BOARD ore O WORK MODE SELECTOR AND OUTPUT CONTROLS In CC mode machine output is at open circuit voltage The OUTPUT
132. l D3 m 27 35V 600V 21 C14 04 100pF 1A 1007 F 30V e Ojo ojo Ele og o t gls 2 BIZ o o ENERAL INFORMATIO AST NO USED LECTRICAL SYMBOLS PER E1537 R 9 Mov 2 CAPACITORS UNLESS OTHERWISE SPECIFIED _ C 17 LED 1 RESISTORS Ohms UNLESS OTHERWISE SPECIFIED E 0 5 DZ 6 NOTES DIODES UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET N A SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE oe s WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY POWER SUPPLY SOURCE POIN NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 57 COMMON CONNECTION NUMBER E 19330_1 71 FRAME CONNECTIO THIS SHEET CONTAINS PROPRIETARY INFORMATION BY THE LINCOLN ELECTRIC CO EARTH GROUND CO AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO zi UNLESS OTHERWISE SPECIFIED TOLERANCE EI A E E COLN ELECTRIC CO 0 MULTI SYSTEMS 40 VDC BUSS ON 3 PLACE DECIMALS 152 002 ELAND OHIO U S A supsecy POWER SUPPLY PCB SCHEMATIC ON ALL ANGLES IS 5 OF DE
133. l au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier 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 augmente le risque de voir passer le courant de soudage par les chaines de lev age 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 forte ment t
134. ly limited to protect internal power compo nents so as not to exceed about 375 amps average and 500 amps peak When the current load starts to exceed these limits the output is reduced lower volt age to sustain these maximum levels until the current is reduced even to a shorted output Prolonged output at this maximum current limit level may eventually overheat the Converter s internal power components causing over temperature shut down See following section Short circuit protection is also provided to reduce max imum output current to about 200 amps if the output voltage is reduced by loading or current limiting to below 14 volts for over 7 seconds indicating a shorted output The output current must be interrupted to reset this reduced protective level This maximum 200 amp short circuit level will allow using the Multi Weld 350 for pipe thawing applica tions without causing over temperature shutdown See following section OVER TEMPERATURE SHUTDOWN A second over load protection switch in the Imbalance Protector Module was added to Multi Weld 350 models with codes 10736 and higher This module senses for an imbalance of current between the paralleled Chopper boards by sensing the differential choke volt age If this voltage exceeds 1 V for a sustained time the Imbalance Protector will also activate over temper ature shutdown to protect the higher current Chopper board from over heating A CAUTION Whe
135. mbly four plugs total Perform the Case Cover Assembl Replacement procedure Retum to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 54 F 54 TROUBLESHOOTING amp REPAIR CHOPPER PC BOARD AND DIODE MODULE 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will aid the technician in the removal and replacement of the Chopper PC Board and the diode module assembly MATERIALS NEEDED 3 8 Wrench or socket wrench 7 16 Wrench or socket wrench 1 2 Wrench 3 16 Allen head wrench 9 64 Allen head wrench Torque wrench with 7 16 hex and 1 4 and 9 64 allen head sockets Phillips head screw driver Diagonal cutters Electrical thermal joint compound Penetrox A 13
136. mo OL PRES SWITCH 131 pr gg 1 01482 14 01 R126 p UNDER VOLTS 101581 1 01582 FUEL CONT SOL FLASH 16 02 101681 101682 te 5A 4 cd 18 y o1781 1001782 40 50v com Suzi 8 1 0 GCK2 1 0 GCK3 1 0 GI 51 1 0 GTS2 4 1 0 GSR nag 4 I3 SI zi RS L 3 3 33 1 43 1 0 GCK Return to Section Return to Master TOC EE 1HZ_OSC COM Vcom LOGIC HI OIL TEMP INDICATES HOT ENGINE MUST SHUT ENGINE DOWN OILPRESSURENCOOLER FLOW 10V 15V 45V BATT mn SWITCH SENSE CIRCUIT vee R158 gt 45 51 01 PRES SWITCH ENG ALTERNATOR SENSE COOLER SELECT CIRCUIT HEILA 517900 8 OlL PRESSURE REFI THE ix 4 BATT ENGINE MULTIWELD CODLER 4 6 R125 132 13 150 TO ENG ALT 1 2 TACH POST 400v 25 SMD 01 i 177 026 V 4 6 517900 8 50 9 i amp 18 25 QU SMT SMT 31 31 LOGIC HI AT OlL PRES SWI
137. modules that can be simply swapped out at the job site to minimize down time More prolonged troubleshoot ing and repair of the module may be done later on the service bench Figure D 2 shows the three assembly modules of the Converter which are covered with the Case Wraparound item 4 Control Module item 1 is removed from the Base Module assembly by removing the two bottom accessed screws and disconnecting the three sealed harness plugs from the receptacles on the back of the Control box This module is a sealed enclosure containing replace able electronic components Sealed back cover which mounts the internal pot ted Weld Control and Peripheral PCBs Front panel with plug n play instruments that indi vidually plug to the Control PCB Interchangeable potted digital meters with front replaceable spatter shield lenses Harness lead receptacles that connect to Base Module harness lead plugs Tunnel Module item 2 is removed from the Base Module assembly by removing the four bottom accessed screws and disconnecting the two sealed harness plugs and power leads NOTE Removal of Control Module improves access to disconnect Tunnel Module power leads This module assembly includes Heatsinked power switching IGBT boards and iso lated diodes Capacitors and potted power supply boards Fan and sheetmetal bulkhead tunnel and component enclosure Harness lead receptacles and power lea
138. mp TERMIN COMP PRESET 8403ARU10 C INT PENSATION Ojo ojo Ele og o t gls ge E E BIZ o o cnn e403ARU10 LABELS FTH FRAME THE LINCOLN ELECTRIC ANALOG WELD CONTROL CLEVELAND OHIO U S A E DISPLAY AND IDLER SCALE _NONE pate 03 23 00 Return to Section Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 9 MULTI WELD 350 Return to Section Return to Section TOC Return to Master TOC Ojo ojo
139. n the thermostat resets the output of the Converter will reactivate Switching OFF input power prevents reactivation but also shuts off the cooling fan which prolongs the reset time During Over Temperature Shutdown the panel displays will be as appropriate for the non welding mode See in this section The fan will remain running and the Thermal Shutdown yellow Light will be lit until reset Typically if shutdown occurs repeatedly below 300 amps output with fan running imbalance of the Chopper board current may likely be the cause MULTI WELD 350 LINCOLN 8 10 NOTES MULTI WELD 350 LINCOLN 9 B 10 DOL UNY DOL UNY DOL OF DOL OF DOL MEY DOL DOL UMY DOL UMY Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES SECTION ACCeSSOLFIGS iive dcos vei a Section C a stun Fuere breve BE ena C 2 Field Installed Option cen les 2 Semiautomatic Welding 2044 00 C 2 Retum to Master TOC Connection of Lincoln Electric Wire 4 4 440000 C 2 Connection of the 25
140. nformation 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 machine MULTI WELD 350 ELECTRICAL DIAGRAMS SCHEMATIC PERIPHERAL PRINTED CIRCUIT BOARD 10V 15V 10V 15V t ey eraut A 10V 15V Hi SAT Lay n WELD HAVE 1 MELD BOARD 1 i 209 POSITIVE SUPPLY iw iw DALE Vinx 034 m OL TEMPNCEOLER 475K 131 FUEL LEVEL LAMP 475K FLT LAMP 166 R135 R134 R143 R144 R139 CONTACTOR CONTROL 2 25K 25K 25 AR 5 1 6 Rss gt me 1 R34 2 0047 SW SW Sw 5 SIT 200 ENG ALT VOLT LAMP 475K FUEL LEVEL LAMP n 1 2 05 3000V R33 3 3 5 1W GW SMT 5V_BATT 17900 8 231 e INPUT VDLTS LAMP 475K NG ALT VOLT LAMP Kc 025 5 MD x Return to Master TOC MCL413BP 517900 8 109 5 05 SuppL TIK Return to Section TOC 51 1 567
141. nnec tions at the top of the tunnel assembly Using the phillips head screw driver remove the two screws holding the fan motor housing to the tunnel assembly Carefully remove the fan motor assembly FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT CONTINUED REPLACEMENT PROCEDURE 1 MULTI WELD 350 LINCOLN P Set the fan motor assembly into the machine against the tunnel assembly with the motor nameplate label facing into the tunnel assembly Connect the red motor lead to leads 303 and 303A and the blue motor lead to lead 300 at their in line connectors Mount the fan motor housing to the tunnel assembly with two phillips screws Connect the two plug harness connections at the top of the tunnel assembly Replace any cable ties previously removed Perform the Input Diode Replacement procedure Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 51 TROUBLESHOOTING amp REPAIR POWER CAPACITOR 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 th
142. nput power to the machine A WARNING 2 ELECTRIC SHOCK can kill T Disconnect input power before removing the case cover and performing tests or making repairs to the machine 3 Perform the Case Cover 8 dure 4 Perform the Power Module Capacitor Discharge procedure MULTI WELD 350 LINCOLN P P42 ANALOG CONTROL POWER SUPPLY PC BOARD Locate the Analog Control Power Supply PC Board and plugs P41 and P42 See Figure F 4 Carefully apply the correct input power to the Multi Weld 350 50 118 VDC Set the Multi Weld 350 to either CC or CV mode Make sure the input contactor acti vates If it does not increase the input volt age but do not exceed 113 VDC The LED on the DC Buss Power Supply PC Board should light Check the Analog Control Power Supply PC Board input and output voltages according to Table See Figure F 4 and the Wiring Diagram Retum to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 22 TROUBLESHOOTING amp REPAIR F 22 ANALOG CONTROL POWER SUPPLY PC BOARD TEST CONTINUED 9 If all the voltages are correct the Analog 11 Control Power Supply PC Board is operat ing properly 10 If any of the output voltages are not correct and the input voltage is correct the Analog If the i
143. nput voltage is not correct check leads 436 437 and their associated plugs for loose or faulty connections See Control Power Supply PC Board may be the Wiring Diagram Perform thel DC Buss Power Supply PC Board Test faulty TABLE F 1 ANALOG CONTROL POWER SUPPLY PC BOARD VOLTAGE TABLE Positive Meter Probe Negative Meter Probe Acceptable Voltage Conditiens Gomments Test Point Test Point Reading _ Supply from Buss Plug P41 Pin 1 Plug P41 Pin 2 38 0 42 0 VDC Power Supply Board _ Supply for right side Plug P42 Pin 1 Plug P42 Pin 6 18 0 21 0 VDC Chopper PC Board Supply for left side Plug 42 Pin 3 Plug P42 Pin 8 18 0 21 0 VDC Chopper PC Board 15 VDC Supply to Plug P42 Pin 10 Plug P42 Pin 4 14 0 16 0 VDC Peripheral Board 15 VDC Supply to Plug P42 Pin 5 Plug P42 Pin 7 14 0 16 0 VDC Weld Control Board 5 Supply to Plug P42 Pin 2 Plug P42 Pin 7 4 5 5 5 VDC Weld Control Board 15 VDC Supply to Plug P42 Pin 9 Plug P42 Pin 7 14 0 16 0 VDC Weld Control Board 12 If finished testing perform the Case Cover Replacement procedure MULTI WELD 350 LINCOLN P Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 23 TROUBLESHOOTING am
144. om vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines 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 Keep all equipment safety guards covers before welding and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known Y 4 2 8 5 2 All welders should use the following procedures order to minimize exposure to EMF fields from the welding circuit 1 6 In some cases it may be necessary to remove safety 2 d 1 Route the electrode and work cables together Secure guards to perform required maintenance Remove them with tape when possible guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 2 Never coil the electrode lead around your Always use the greatest care when working near moving parts 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right Do not put your hands n
145. on to the work to complete the DC input supply and output power circuits of the Multi Weld 350 A WARNING Do not disconnect the Work clip lead without first switching OFF the Converter panel switch Failure to do so will allow the Work lead clip to be electrically hot to work and hot to the electrode through the circuit of the Converter for about 5 seconds until the input con tactor opens CASE GROUNDING As shipped the case of the Multi Weld 350 is isolated from all of the DC input and output welding terminals It is equipped with a grounding terminal screw 31 7 9 mm marked with the symbol located on the bottom rear of the base assembly Refer to the bot tom view figure In order to comply with CSA and UL case grounding specifications this terminal is provided for connection to weldment work that must be properly grounded per methods meeting local and national elec trical codes Refer to Safety in Welding Cutting and Allied Processes ANSI 249 1 US W117 2 Canada Since any case fault would only involve the DC welding circuit the size of the grounding lead should have the Capacity to ground the potential fault current without burning open Use at least 6 AWG 13 mm but need not exceed the size of the input cable supplying the Multi Weld 350 Connect the Multi Weld grounding lead to the work piece separately from the Work clip If the same clip is used for both ground and work conne
146. or location Using the 3 8 nut driver remove the two screws holding the case front assembly to the machine base Support the case front assembly as you remove the second screw Carefully remove the case front assembly and set the machine back upright REPLACEMENT PROCEDURE Carefully turn the machine onto its side Position the case front assembly on the base and attach it with two screws previ ously removed Set the machine back upright Connect the three wiring harness plug assemblies Replace the case cover Retum to Section TOC Retum to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 36 TROUBLESHOOTING amp REPAIR WELD CONTROL OR PERIPHERAL PC 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCR
147. ors along with the mylar insulation sheet The mylar sheet fits between the nylon insulators 3 Connect thermostat leads 306 and 307 See the Wiring Diagram 4 Perform the Input Contactor Replace ment procedure Be sure to connect the input diode pig tails to the contactor strap at the contactor rear terminal 5 Replace any cable ties cut at disassembly 6 Perform the Case Front Assembly Replacement procedure 7 Perform the Case Cover Assembl Replacement procedure MULTI WELD 350 LINCOLN P 48 48 TROUBLESHOOTING amp REPAIR FAN MOTOR ASSEMBLY 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 Retum to Section TOC Retum to Master TOC 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing and replacing the cooling fan and motor of the Multi Weld 350 Retum to Section TOC Retum
148. ory provided with two 21 53 cm long 2 0 AWG 70 mm pig tail cables Their 0 5 13 mm hole lug ends are routed through the INPUT on back and ELECTRODE on front cable channels of the Converter They are attached to the bottom accessed covered cable con nection studs Attach the preferred standard user provided Quick connect terminal such as Lincoln Twist Mate or Tweco 2 MPC type to the cut off end of these cables Use the female connector on the ELECTRODE cable and the male connector on the INPUT cable ATTACHMENT AND ARRANGEMENT OF PIG TAILS To best suit the desired inter connection of the Converters the pig tail cables may be routed into the front or back cable channels For single or double pig tail cables route through the bottom accessed cov ered cable connection studs See Figures A 1 and B 1 FIGURE A 1 PIG TAIL CONNECTIONS TO POWER 0 SOURCE WORK TO ELECT Fd E yaa pod bg I L 7 k IN ELECT 3 X BOTTOM VIEW IN 9 ELECT n 7 0 E Lo to i 1 1 1 Low TO ELECT TO POWER SOURCE To connect the pig tail cables to the Converter 1 Stand the Converter vertically on its rear handle and skid to gain access to the bottom stud covers Then remove
149. osition securely chained to an undercarriage or fixed support Oylinders 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 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 Retum to Master TOC Retum to Master TOC Y 4 2 5 2 to Master SAFETY PR CAUTIONS DE S RET Pour votre propre prot
150. oxique ou autres produits irritants 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 jamais enrouler le c ble lectrode autour de n importe quelle PR CAUTIONS DE S RET POU R partie du corps LE S MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillaant proximit au soudage l aide d crans appropri s et non inflamma bles 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 pantalons sans revers et chaussures montantes LINCOLN 5 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif 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 fai
151. p REPAIR DC BUSS POWER SUPPLY PC BOARD TEST A 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the DC Buss Power Supply PC Board is receiving and process ing the proper signal voltages MATERIALS NEEDED 3 8 Nut driver Analog Volt Ohmmeter Wiring Diagram This procedure should take approximately 30 minutes to perform MULTI WELD 350 LINCOLN F 23 Retum to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 5 rA Retum to Master TOC F 24 F 24 TROUBLESHOOTING amp REPAIR DC BUSS POWER SUPPLY PC BOARD TEST CONTINUED FIGURE F 5 DC BUSS POWER SUPPLY PC BOARD P46 P47 TEST PROCEDURE 1
152. put at this maximum current limit level may eventually over heat the converter s internal power components causing over temperature shut down Short circuit protection is also provided to reduce max imum output current to about 200 amps if the output voltage is reduced by loading or current limiting to below 14 volts for over 7 seconds indicating a shorted output The output current must be interrupted to reset this reduced protective level This maximum 200 amp short circuit level will allow using the Multi Weld 350 for pipe thawing applica tions without causing over temperature shutdown A CAUTION When the contactor recloses the converter output will reactivate Switching OFF input power prevents unex pected reactivation This feature protects internal components of the con verter from excessive voltage levels OVER VOLTAGE PROTECTION The Multi Weld 350 input contactor will open if the input supply voltage is above 113 VDC and it will automati cally reclose if the voltage drops back to 113 VDC During over voltage shutdown the panel displays will be as appropriate for the non welding mode MULTI WELD 350 LINCOLN 8 Retum to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC THEORY OF OPERATION FIGURE E 6 IGBT OPERATION BODY REGION lt DRAIN DRIFT REGION
153. qualified personnel do the maintenance work Always use the greatest care when working near mov ing parts If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop See additional warning information throughout this manual MAINTENANCE The only maintenance that may be required for the Multi Weld 350 is to clean out any accumulated dirt and debris Clogging could contaminate internal compo nents or obstruct proper cooling of the power compo nents resulting in premature over temperature shut down The recommended cleaning procedure is as follows 1 Be sure to disconnect the Converter input cable to remove its input power 2 Remove the four screws securing the rear louver panel and remove the panel to expose the cooling tunnel heatsinks See Figure D 1 below FIGURE D 1 TUNNEL HEATSINKS 3 Holding the unit by the front handles so the back is facing down shake the loose debris out of the unit Raking out the heatsink fins may be necessary for jammed debris 4 If necessary remove the case wraparound cover Using the skid handles to hold the unit upside down carefully dump out any remaining loose debris or carefully blow out using low pressure air 5 Reassemble the cleaned out Converter by reversing the above steps DIGITAL METER CALIBRATION If calibration of either digital meter is ever necessary meter calibration adjustment trimmer
154. re 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 Retum to Master Retum to Master TOC Retum to Master TOC Retum to Master TOC RUS WELDING SPARKS can gt 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 the
155. re you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing and replacing the case front assembly on the Multi Weld 350 MATERIALS NEEDED 3 8 Nut driver wrench or socket wrench Wiring Diagram This procedure should take approximately 15 minutes to perform MULTI WELD 350 LINCOLN F 34 Retum to Section Return to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 5 rA Retum to Master TOC F 35 F 35 TROUBLESHOOTING amp REPAIR CASE FRONT ASSEMBLY REMOVAL AND REPLACEMENT CONTINUED FIGURE F 7 CASE FRONT ASSEMBLY REMOVAL PLUG ASSEMBLIES 3 REMOVAL PROCEDURE 1 Set the CC CV power switch to OFF 6 2 Remove input power to the machine A WARNING ELECTRIC SHOCK can kill Disconnect input power before removing the case cover and performing tests or making repairs to the machine 3 Perform the Case Cover Assembl Removal procedure 4 Perform the Power Capacitor Discharge procedure 5 Label and disconnect the three wiring har ness plug assemblies that connect to the case front assembly See Figure F 7 and 4 the Wiring Diagram MULTI WELD 350 LINCOLN P BASE SCREWS 2 ACCESS FROM BOTTOM Carefully turn the machine onto its side See Figure F 7 f
156. rent CC stick mode or the constant voltage CV wire mode A 40 VDC Buss Power Supply Board supplies 40 VDC power to the Analog Control Power Supply Board which in turn feeds regulated voltages to a Weld Control Board and 15 VDC to the Peripheral Board The Peripheral Board powers the input contactor coil and the input indicator light on the front panel The 40 VDC is also supplied to the Peripheral Board and is passed on to the Weld Control Board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion MULTI WELD 350 LINCOLN 5 E 3 E 3 THEORY OF OPERATION FIGURE E 3 POWER MODULES AND FEEDBACK Retum to Section TOC Return to Section TOC 5 8 9 8 Retum to Master Retum to Master TOC Retum to Master TOC MULTI WELD 350 BLOCK LOGIC DIAGRAM INPUT DIODES INPUT CONTACTOR CR1 INPUT CAPACITORS ON OFF MODE ci Ra vb 1 2 EXTERNAL IGBT FREEWHEELING DIODE CHOPPER MODULE LEFT AND RIGHT CHOPPER MODULES Kt TO ELECTRODE CABLE CURRENT FEEDBACK TO WELD CONTROL BOARD FREEWHEELING DIODE K ON OFF VOLTS AMPS STI SWITCH _ 2 GATE SIGNALS 40 ANALOG CONTROL CONTROL RECEPTACLE POWER BOARD SUPPLY STICKIGOUGE or PIPE BOARD SONUS M Q THERMAL PERIPHERAL BOARD O WORK POWER MODULES AND FEED BACK Th
157. res des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page SANE ERE i iv DEICUCUT Section Operations Accessories Section C Maintenance Section D Theory of Operation eenen Section E Troubleshooting and Section F Electrical 2 111111111 G Parts Mahal ioc 5 3 MULTI WELD 350 LINCOLN 8 V Section 1 Section 1 TABLE OF CONTENTS INSTALLATION SECTION 5 5 Metalai on ses cscs cesses aaa Section A g 5 2 8 ciui CAUNON emm A 3 E Quick Connect Pig Tails 3 4 Attachment and Arrangement of A 3 Work COMMECTION 4 Gase Grounding AE 4 Inter Connection of 4 Power Source Setup ceni 6 4 2
158. riginal problem a f 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 termi nal strips 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 MULTI WELD 350 LINCOLN 8 Retum to Section Return to Section TOC 5 8 9 8 Retum to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC F 4 F 4 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical damage is evident POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact your Authorized Facility Lincoln Service local Field TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Contact the Lincoln Electric Service Department at 1 800 833 9353 WELD The Multi Weld 350 is completely dead The meters do not light an
159. rn to Section TOC Return to Master TOC 22 to 32 Vac R1 L4 24 2 VS VS X2 MIC4451BN GND ojo Ele og o t gls 2 BIZ o o GENERAL INFORMATION LAST NO USED ELECTRICAL SYMBOLS PER E1537 R 20 x CAPACITORS MFD 022 50 UNLESS OTHERWISE SPECIFIED C 7 004 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS D 8 025 NOTES DIODES 1 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY POWER SUPPLY SOURCE POINT NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE 57 COMMON CONNECTION NUMBER f 1 1 FRAME CONNECTION THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO EARTH GROUND CONNECTION AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO FILENAME M19303_1DA UNLESS OTHERWISE SPECIFIED TOLERANCE EQUIP ON HOLES SIZES PER E 2056 THE LINCOLN ELECTRIC CO CHOPPER 200 ON 2 PLACE DECIMALS IS 02 Bere 42 CLEVELAND OHIO U S A SUBJECT SCHEMATIC MATERIAL TOLERANCE t TO AGREE SCALE NONE dir ce DR EB DATE 11 11 07 CHK SUP S D G no M 19303
160. roughout 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will aid the technician in the removal and replacement of the power capac itors on the Multi Weld 350 MATERIALS NEEDED 3 8 Wrench or socket wrench Slot head screw driver 7 16 Wrench Resistor 25 1000 ohms 25 watts minimum Wiring Diagram This procedure should take approximately 30 minutes to perform MULTI WELD 350 LINCOLN F 51 52 52 TROUBLESHOOTING amp REPAIR POWER CAPACITOR REMOVAL AND REPLACEMENT CONTINUED FIGURE F 13 POWER CAPACITOR MOUNTING DETAILS Retum to Master TOC 5 0 u 8 5 2 CLAMP Q PP PIY ANALOG CONTROL SCREWS 2 MES SUPPLY PC BOARD 5 4 SCREWS JE cuc CHOPPER PC BOARD CAPACITOR POSITIVE STRAP CAPACITOR NEGATIVE STRAP 9 LEADS EIE RIGHT J 1 LEFT 9 5 SIDE Un 401 SIDE 3 4 401A 8 8 5 5 PROCEDURE cic Refer to Figure F 13 3 Perform the Case Cover Assembl 1 Set the CC CV power switch to OFF Removal procedure 2 Remove input power to the machine 4 Perform the Power Capacitor Discharge procedure 5 Disconnect the two plug harness connec WARNING tions at the top of t
161. s are provided on the Weld Control PC board inside the Control Module See Figure D 2 Calibration must be done with an Output current load so meters are displaying Actual not Preset values It is recommended that the cali bration levels be near the rating plate values for best accuracy and compared to master meters with better than 296 accuracy The accuracy of Actual AMPS meter should be within 396 of the welding amps monitored The AMPS meter trimmer R561 is located near the center of the Weld Control PC board just below the VOLTS meter trimmer R562 Clockwise rotation of the trimmer adjustment screw will decrease the meter reading The accuracy of Actual VOLTS meter should be within 396 of the welding volts monitored The VOLTS meter trimmer R562 is located near the center of the Weld Control PC board just above the AMPS meter trimmer R561 Clockwise rotation of the trimmer adjustment screw will decrease the meter reading The master voltmeter should be connected as close as possible to the ELECTRODE stud and WORK lead bolt for best accuracy MULTI WELD 350 LINCOLN 8 Return to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Y 4 2 5 rA Retum to Master TOC D 3 D 3 MAINTENANCE SERVICE The Multi Weld 350 was designed for easy service using quick to replace components and assembly
162. sibly splice back together again at some future time 3 Replace the case wraparound 4 Connect a user provided remote switch be tween pins D and E of an MS3106A 18 12P plug Lincoln part no S12020 27 with S12024 1 cable clamp See the diagram below Pin Remote Function A Max of 10K pot B Wiper of 10K pot C Min of 10K pot D Output Switch E Output Switch F No connection 5 Connect this switch plug to the Multi Weld 350 Remote Control Receptacle 10 with switch opened Closing the switch activates the Converter output PARALLELED CONVERTERS Multi Weld 350 converters that are paralleled see INTER in the Installation section must each be set up in the same manner in order to manage the arc current drawn from each 1 Set to CC mode with CC SLOPE switch set to STICK GOUGE 2 Preset Output Controls of both paralleled Converters to 1 2 desired total AMPS If arc current from each Converter gets too out of bal ance primarily a problem if trying to use CV mode the hotter running Converter could go into current limiting and or Thermal shutdown See TURE SHUTDOWN in the Installation section This might then overload the other or at least interrupt the operator s process However no damage will occur to the Converters REMOTE CONTROL OF PARALLELED CONVERTERS FOR CC STICK GOUGE MODE ONLY Full Range remote control can be accomplished with a separate optional see the Installation section conn
163. sustains flow in the arc and through the diode The repetition rate of switch closure is 20Khz which allows ultra fast control of the arc By varying the ratio of on time versus off time of the switch Duty Cycle the current applied to the arc is con trolled This is the basis for Chopper Technology Controlling the switch in such a way as to produce superior welding MULTI WELD 350 LINCOLN 8 10 NOTES MULTI WELD 350 LINCOLN 9 E 10 DOL UNY DOL UNY DOL OF DOL OF DOL MEY DOL DOL UMY DOL UMY Section F 1 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION 8 Troubleshooting 8 Repair nennen nennen nnns Section F g How to Use Troubleshooting Guide F 2 8 Board Troubleshooting Procedures uu d acrin vga c rati nidore v aep ad oaa edi F 3 E Troubleshooting Guide ttt 4 F 12 ec Test e 13 Case Cover Assembly Removal and Replacement Procedure F 13 Power Module Capacitor Discharge Procedure F 15 Input Contactor Coil Resistance and Supply Voltage F 17 Analo
164. t no T14807 9 VOLTS Digital Meter is a 3 1 2 digit LED meter which displays Preset VOLTS in CV mode when not welding Blank in CC mode when not welding Actual VOLTS while welding in both CV and CC modes Average VOLTS for about 7 seconds after welding stops in CV and CC modes only The 7 second memory display is indicated by the display s left most decimal point blinking and is interrupted if arc is restarted Accuracy of Actual VOLTS is within 396 and typi cally within 1 volt of Preset An Actual VOLTS meter calibration adjustment trimmer is provided See the Maintenance sec tion Two front screws secure the meter bezel which holds a replaceable spatter shield lens Thermal Shutdown yellow Light turns on if out put is shutdown because internal overheating has occurred See Over Temperature Shutdown in this section Input Voltage green Light indicates appropriate level of input supply voltage On for adequate input voltage over 50 V for CC or CV mode for inadequate input voltage under 50 V input or Power Switch OFF NOTE green light is blinking the input voltage may be drifting above and below the 50 V level due to loads on supply and cables This may also cause the input contactor to chatter RECESSED PANEL CONTROLS These instruments are recessed behind a screw secured hinged cover panel and are not typically required for normal operator access
165. ts 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 machine MULTI WELD 350 4 15 ELECTRICAL DIAGRAMS 6 15 SCHEMATIC BY PASS PRINTED CIRCUIT BOARD Return to Section TOC Return to Master TOC ELECTRODE Bi INPUT capacitors 175 Return to Section TOC Return to Master TOC ojo E og o EE 515 ge E E Ble NOTES LABELS LAST USED GENERAL INFORMATION SINCE COMPONENTS OF CIRCUITRY ON PRINTED 3 R 1 CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING ELECTRICAL SYMBOLS PER 5 c 5 THE INTERCHANGEABILITY COMPLETE BOARD CAPACITORS MFD UNLESS OTHERWISE SPECIFIED power SUPPLY SOURCE POINT EARTH GROND nical THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS RESISTORS Ohms t UNLESS OTHERWISE SPECIFIED OR CIRCUITRY DF CONTROLS HAVING COMMON NUMBER DIODES UNLESS OTHERWISE SPECIFIED COMMUN CONNECTION FILENAME 574726 SPECIFIED TOL ON HOLES SIZES PEF E2056 ON 2 PLACE DECIMALS 15 02 ON 3 PLACE DECIMALS 12 002 DN ALL ANGLES IS 5 OF DEGREE MATERIAL TOLERANCE
166. ts 50us in 9 8 5 The machine was loaded with resis 4 tance grid bank to 350 amps at 34 volts 8 8 5 5 SCOPE SETTINGS ec Volts Div 50V Div Horizontal Sweep 50us Div Coupling DC Trigger etes Internal Retum to Section TOC Retum to Master TOC MULTI WELD 350 LINCOLN 32 32 TROUBLESHOOTING amp REPAIR NORMAL WELD VOLTAGE WAVEFORM MACHINE LOADED TO 350 AMPS AT 34 VOLTS CV MODE Retum to Section TOC Retum to Master TOC 0 volts 50V 50us Retum to Master TOC 5 5 9 8 This is the typical CV output voltage generated from a properly operating machine Note that each vertical divi sion represents 50 volts and that each horizontal division represents 50us in 9 8 5 The machine was loaded with a resis 4 tance grid bank to 350 amps at 34 volts 8 8 E HE SCOPE SETTINGS 50V Div Horizontal Sweep 50us Div Coupling DC Trigger Internal Retum to Section TOC Retum to Master TOC MULTI WELD 350 LINCOLN 33 33 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM CV MODE OUTPUT CONTROL AT MINIMUM Retum to Section TOC Retum to Master TOC 0 volts
167. turn to Master TOC 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 MULTI WELD 350 es ELECTRICAL DIAGRAMS G 13 SCHEMATIC ANALOG PRINTED CIRCUIT BOARD Return to Section Return to Master TOC gt 010 1A FR 1000V Return to Section TOC Return to Master TOC 02 OCI1 18 19 C23 C10 1 CNY17 3 600V 1007 10077 100 AN 01 je 20v 20v sov E MNs LA ER P c
168. turned on This will minimize the amount of contaminate and clogging debris that may be drawn into the converter The Central Air system design intakes lower velocity air through the higher side louvers and blows it out through the lower back louvers with higher velocity OVER TEMPERATURE SHUTDOWN The Multi Weld 350 has a temperature sensing ther mostat on the input diode heat sink to protect the power components within the converter from overheat ing If this thermostat temperature exceeds about 95 degrees C 203 degrees F the converter will electron ically shut off the output and turn on the Thermal Shutdown yellow Light until the thermostat is cooled enough to reset A CAUTION When the thermostat resets the converter output will reactivate Switching OFF input power prevents reac tivation but also shuts off the cooling fan which pro longs the reset time During over temperature shutdown the panel displays will be appropriate for the non welding mode However the fan will remain running and the Thermal Shutdown Light will be lit until reset OVER CURRENT PROTECTION The maximum output current of the Multi Weld 350 is electronically limited so as not to exceed 375 amps average and 500 amps peak to protect internal power components When the current load starts to exceed these limits the output is reduced lower voltage to sustain maximum levels until the current is reduced even to a shorted output Prolonged out
169. understand the test procedures or 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 MULTI WELD 350 LINCOLN 8 13 13 TROUBLESHOOTING amp REPAIR CASE COVER ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE A 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 Retum to Section TOC Retum to Master TOC 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the case sheet metal cover Retum to Section TOC Retum to Master TOC MATERIALS NEEDED 3 8 Wrench or socket wrench This procedure should take approximately 5 minutes to perform Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC MULTI WELD 350 LINCOLN 14 14 TROUBLESH
170. ws from the control box rear panel Carefully remove the potentiometer molex plug from the Weld Control PC Board Press and hold the keeper on the plug as you remove it Using the diagonal cutters cut the cable tie holding the potentiometer to the back panel Using the allen wrench remove the set screw holding the potentiometer knob to the shaft Remove the knob shaft seal and spacer Pull the potentiometer out from the panel REPLACEMENT PROCEDURE 1 Fit the potentiometer into position verifying proper orientation Install a new cable tie Install the spacer shaft seal and knob 3 Tighten the knob onto the shaft with the set Screw Attach the molex plug to the Weld Control PC Board See the Wiring Diagram Attach the rear panel with seven 5 16 Screws Perform the Case Front Assembl Replacement procedure Perform the Case Cover Assembl Replacement procedure 42 42 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR 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 Retum to Section TOC Retum to Master TOC If for any reason you do not un
171. y 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 Wear 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 SAFETY LINCOLN 8 CYLINDER may explode 22584 gt if damaged 7 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 p
172. y 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 trou bleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if there are shorted IGBTs or Chopper PC Boards This test will also verify that the Chopper PC Boards are receiving the correct operating voltages Retum to Section TOC Retum to Master TOC MATERIALS NEEDED Volt Ohmmeter 3 8 Nut driver 7 16 Wrench Wiring Diagram This procedure should take approximately 50 minutes to perform Retum to Master TOC 5 8 9 8 Retum to Section Retum to Master TOC MULTI WELD 350 LINCOLN 27 27 TROUBLESHOOTING amp REPAIR 0 E p CHOPPER PC BOARD INPUT VOLTAGES AND RESISTANCE TEST CONTINUED z 2 8 FIGURE F 6 POWER MODULE ASSEMBLY DETAILS EIE i CLAMP BRACKET g IGBT 5 5 3 n SINK REMOVE CASE 2 45 45 BACK PANEL 8 8 123 HEAT SINK 5 gn cic COPPER CAPACITOR POSITIVE STRAP COPPER CAPACITOR NEGATIVE STRAP LEADS 1 4 401 401A 1r S HE 8 8 E cic TEST PROCEDURE 1 Set the CC CV power switch to OFF 3 Perform the Case Cover Hemoval proce dure 4 Perform the Power Module Capacitor WARNING Discharge procedure ELECTRIC SHOC
173. ype slope 22v 100A so preset current not actual current accuracy may be affected if arc length voltage is not maintained at the typical 28 V used for these electrodes Typically this error should not be more than about 10 A Remote Control Receptacle is provided to per mit the use of an optional Remote output control to provide operator control even closer to the arc Connecting the Remote plug to this receptacle automatically transfers output control from the panel Output Control item 2 above to the Remote pot control which will function the same but with only single turn resolution MULTI WELD 350 LINCOLN 8 Retum to Section Retum to Section TOC 5 8 9 8 Return to Section Retum to Master TOC Retum to Master TOC Retum to Master TOC Retum to Master TOC OPERATION Disconnecting the Remote plug from this recepta cle automatically transfers output control back to the panel Output Control item 2 above Remote output On Off switching can also be done through this Remote Control receptacle by per forming the following wiring changes 1 Making sure the input to the Converter is removed remove the case wraparound 2 Locate the 4 pin plug P21 on the back panel of the control box module and cut the jumper lead looping from the back of the plug Refer to the Wiring Diagram in the Electrical Diagrams section Insulate the cut lead ends and leave long enough to pos

Lincoln Electric MULTI-WELD SVM151-A User's Manual

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