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Lincoln Electric MULTI-SOURCE SVM155-A User's Manual

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2. e PC BOARD DESIGNATORS ITEM PART NO DESCRIPTION
3. 9 69 5 ALTERNATE CONNECTION iu FIRING CIRCUIT 204 Di 50 25 amp 2 06 E 5 D TRIGGER CIRCUIT 55 o uod S He us 15K RIB5 a 074 9 95 gt 1 619 g P 2 15 mt Clay 204 RIB 1N4007 072 eae lt R262 R37 e e p e eo o o 50 018 rd 144907 TK 1M4004 15w E 15W m 5 5 1006 1505 15 Li 1N4007 e 10 0K E EA 078 5 8 a c39 028 ur oc 32 LS E 1 4007 SCR2 44 i D 144007 Di J5 DIE 203 s e pi ope e lt 064 lt 3 1 031 267K 002 023 50 017 102v THERMOSTATIC FAN 071 N Giad 15w 144807 2 1 SNUBBER PCB 51 2 5 De 02 2932 2N6027 sw 184004 144007 e gla 2 023 z hue E 4 51 1
4. 6924 9eedj Ojo 515 818 5 2 1 ON HOLE SIZES PER E 2065 THE LINCOLN ELECTRIC CO 4 DC 600 MULTI SOURCE ON 2 PLACE DECIMALS IS 02 m PLACE DECIMALS IS 002 CLEVELAND OHIO U S A FIRING P C BOARD ASSEMBLY ON ALL ANGLES IS 5 DEGREE SCALE _ FULL MATERIAL TOLERANCE 82598 085 REF G2899 1 6380 119073 3 3742 1 Return to Section Return t
5. B 3 Recommended Equipment Processes sise B 3 Return to Master TOC Design Features and Advantages ie B 3 Recommended Equipment Connections iii B 4 Controls and Settings tr ege rere B 4 Return to Master TOC 0 iv z o c tc Return to Master TOC MULTI SOURCE LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 OPERATION Read and understand this entire section before operating your machine SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous 9 Keep your head out fumes Use ventilation or exhaust to remove fumes from breathing zone A NE WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on closed containers ARC RAYS can burn eyes and skin Wear eye ear and body 2 4 protection Only qualified personnel should operate this equipment See additi
6. NEG 10 R142 100K 10 0K 1 B OVREF NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE NUMBER THIS SHEET CONTAINS PROPRIETARY INFORMATION AND IS NOT TO BE REPRODUCED UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E 2056 ON 2 PLACE DECIMALS IS 02 ON 3 PLACE DECIMALS 15 002 ON ALL ANGLES OF DEGREE MATERIAL TOLERANCE TO AGREE WITH PUBLISHED STANDARDS NED BY THE LINCOLN ELECTRIC CLOSED OR USED WITHOUT Ich ge Sht No XPRE PERMISSION OF THE LI YBAS GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS 022 50V UNLESS OTHERWISE SPECIFIED d UNLESS OTHERWISE SPECIFIEDI UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W DIODES 1A 400V FILENAME G3727 2B THE LINCOLN ELECTRIC CO XA 10 13 2000 CLEVELAND OHIO U S A SCALE NONE LO 232 6 gt 029 51V GREEN LED ON WHEN DUTPUT n VOLTAGE SAFE 233 8 JGHT OFF 340 ENABLE SIGNAL FOR FIRING BOARD ENABLED WHEN LOW xs 7530114 LAST NO USED masa 0
7. 2 2 Safety Precautions o Ptr rer A 3 2 Select Proper Location inerenti teer nen rt rk E E CR HEX Ree Dd A 3 A 3 ILES LC HET A 3 Electrical Input 5 A 3 Wire 4 Input Grounding Connections A 4 Reconnect Proc dure sentent Rea XXE E 4 e Output sisi esse vri Fo EXE Ey tienne AFER Ere BER FACER AERE A 5 5 ach eT A 5 o Multi Source Output 5 Distribution BOX c a E TERR ERAEN 5 Pig Leads and Connections sise 5 2 O 1i g E p o E 2 MULTI SOURCE LINCOLN B A 2 A 2 INSTALLATION TECHNICAL SPECIFICATIONS Multi Source K1752 1 INPUT THREE PHASE ONLY Standard Voltage Frequency Input Current at Rated Output 100926 Duty Cycle 380 415 50 400 60 440 50 460 60 550 50 575 60 Return to Section TOC Return to Master TOC RATED OUTPUT 60 Hz 40 kW Volts at Rated Amperes Duty Cycle 75 100 Duty Cycle _ 50 C 122 50 Hz 36 kW Amps Volts at Rated Amperes 475 75 8 CURRENT RANGE OCV Maximum Open C
8. gt gt gt 7 5 2 IE IE ER gt IE Il 25 IE J1 gt IE gt IE J3 Control Board MULTI SOURCE LINCOLN F 50 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 51 F 51 TROUBLESHOOTING amp REPAIR FIRING BOARD REPLACEMENT PROCEDURE WARNING Service repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the firing board for replacement MATERIALS NEEDED 3 8 Nut Driver Phillips Head Screwdriver Pliers optional This procedure takes approximately 30 minutes to perform MULTI SOURCE LIN
9. e 6 lead 201 to Plug J1 pin 9 lead 2224 If the voltage is correct but is not lit the control may be faulty LED 2 indicates the level of the control sig nal that is passed to the firing board The brightness of LED 2 is inversely propor tional to the output of the machine As the control signal decreases LED 2 gets dim mer the machine s output increases The control signal can be measured at Plug J1 pin 4 lead 231 to Plug J1 pin1 lead 3201 Normal range is about 12VDC at open circuit to about 3VDC when high or maximum output is required LED 3 indicates that the machine s output is greater than 10 amps and the control board is developing a signal for the cool ing fan to operate This signal activates a fan motor driver circuit that is incorporated within the control board See step 10 LED 6 LED 4 is an indication that either a ther mostat output current or output over cur rent is calling for the fan motor to operate See Figure F 15 LED 5 lights when the current feedback signal from the output shunt is too high If LED 5 is lit for 5 8 seconds the enable signal from the control board to the firing board is sent high over 12VDC LED2 If the output current overload is of a short time duration LED 5 may only be lit briefly In either case the machine s output will be zero and the output will remain off for about 75 seconds See Figure 15 MULTI SOURCE
10. 5 8 9 5 1 Remove main supply power to the 3 Lower the front control panel elg 4 Remove Plug J4 from the firing board See 2 Remove the roof and case sides Figure F7 5 5 Pc FIGURE F 7 FIRING BOARD LED amp PLUG LOCATIONS FIRING BOARD O LED3 LED1 Return to Section TOC Return to Master TOC gt se se A A A J A A J A A A A J Fz FP A A se J J 33 599999 7335 99999979 Ojo 515 818 JE 2 1 Return to Section Return to Master TOC MULTI SOURCE LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Return to Section TOC Return to Master TOC 2 2 5 F 23 F 23 TROUBLESHOOTING amp REPAIR STATIC SCR TEST Continued FIGURE 8 Shunt and Lead Connections 4 Using the 9 16 wrench remove the two a If alowresistance is indicated in either positive output leads connecting the out direction one of the SCRs may be put bridge to the shunt See Figure F8 faulty Further isolation will be neces This will partially electrically isolate the sary to determine which SCR is faulty SCR Bridge for testing purposes See This isolation can
11. DAM AMPS gt CURRENT AMPLIFIER AND FILTER 20A 104 392K R43 260 FEED BACK VOLT PULLED LOW CONTROL HIGH FOR SOFT START WHEN CONTACTOR CLOSES R32 LTSK 931 C17 08 1 400V 267K 50V COMPARATOR TURNS WHEN gt 15 5 2 1 31 074A 15 0K 4 A 231 FIRING CIRCUIT CONTROL VOLTAGE 3V MAX OUTPUT LOW AFTER POWER UP 030 TURNS FAN ON WITH OVER LOAD MAIN TRANSFORMER IRON FRONT THERMOSTAT TO TURN FAN ON WITH HIGH IDLE TEMP A 2 261 263 030 400v COIL DRIVER VS 241 5 1 3074A 138V LOW WHEN V OVER 110V FOR 025 SEC 8 0 043 Wik 10007 1 LED7 5181
12. F 51 5 SCR Bridge Heat Sink Assembly Removal F 53 R test After 59 1i g E tc p o E 5 MULTI SOURCE LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC 515 818 5 2 1 Return to Section Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty 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 listed 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 exhibiting Symptoms are grouped into two main ca
13. A 901 Je1Se A 0 901 Je1Se A 0 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH F 34 DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 35 F 35 TROUBLESHOOTING amp REPAIR FIRING BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD TEST DESCRIPTION The Test determines whether or not the Firing Board is receiving the correct voltages and gate signals The LEDs Light Emitting Diodes will help you determine if the Firing Board is Generating gate signals to the main SCRs MATERIALS NEEDED Vo
14. DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes F 48 NOTES o A 901 Je1Se A 0 901 Je1Se A 0 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH F 48 DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 49 F 49 TROUBLESHOOTING amp REPAIR CONTROL BOARD REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the control board for replacement MATERIALS NEEDED
15. If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct voltages are being a applied to the primary windings of the Main Transformer T1 b induced on the secondary windings fan winding and phase angle windings MATERIALS NEEDED Volt Ohm Meter MULTI SOURCE wiring diagrams See Electrical Diagram Section of Manual 3 8 Nut Driver This procedure takes approximately 45 minutes to perform MULTI SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 18 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 5 Input Contactor Reconnect Panel and Primary Leads to Main Transformer Locations Reconnect Panel Input Contactor TEST PROCEDURE 1 Disconnect main AC input power to the machine 2 Using a 3 8 nutdriver remove roof and sides of case cover 3 Inspect the input contactor reconnect panel and primary leads to the main trans former for loose or faulty connections See Figure F 5 4 C
16. 3 8 Nut Driver Phillips Head Screwdriver Pliers optional This procedure takes approximately 30 minutes to perform MULTI SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 TROUBLESHOOTING amp REPAIR CONTROL BOARD REPLACEMENT PROCEDURE Continued FIGURE F 22 FRONT PANEL W OUT COVER Firing Board REMOVAL PROCEDURE Disconnect input power to the machine Using a 3 8 nut driver remove screws and lower the front control panel to access the control board on the right side of control box while facing the machine See Figure F22 Disconnect plugs J2 J1 J3 from the control board Remove the four phillips head screws and associated washers from the corners of the control board See Figure E23 5 Control Board Carefully remove the control board REPLACEMENT PROCEDURE 1 2 Replace the control board Mount the control board to the machine in its proper position using the four phillips head screws and associated washers pre viously removed Reconnect plugs J3 J1 and J2 to the con trol board Replace the four screws previously removed from the front control panel FIGURE F 23 MOUNTING SCREW LOCATIONS MOUNTING SCREWS
17. x 341 230 LED CENTER 4 235 254 LED LEFT 233 232 zc L 1 _ CONTROL PC BOARD 0 252 1 0 253 10 A FAN CIRCUIT BREAKER Return to Section TOC Return to Master TOC IRON 261 PARALLELING CONNECTIONS TO PRIMARY 263 SECONDARY LEAD HH i dd 1234 COILS J6 440 460V CONNECTION 2 O O1 N c 300 300W BOTTOM 5 05 BYPASS O o Fle 5 gt g g 5 5 1 O1 CO 380 415 CONNECTION G TO A SYSTEM GROUND PER NATIONAL ELECTRIC CODE FIRING PC BOARD TO T1 AUXILIARIES RESISTOR BANK t 2 1 3 1 4 15 1 3 4 4 6 5 8 6 10 9 6 FR E 203 ELECTRICAL SYMBOLS 1537 26 T T OUTPUT SHUNT 204 CONNECTORS VIEWED FROM INSERTION END 202 215A 50 mV 800 A SCR 215 201 9 9 THERMOSTAT 215B i KLE INPUT WELDER TRANSFORMER CONTROL BOX BASE BRACKET BOX COVER ELECTRODE PROTECTIVE BONDING CIRCUIT 10 13 2000 111414 NOTE This
18. F 41 F 41 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM NO LOAD 50 volts 2 ms This is the typical DC open circuit volt age waveform generated from a properly Scope Settings operating machine Note that each ver tical division represents 50 volts and that each horizontal division represents 2 mil liseconds in time Volts Div Horizontal Sweep Coupling Trigger Note Scope probes connected at machine output terminals 4 probe to positive terminal probe to negative terminal MULTI SOURCE LINCOLN F 42 F 42 TROUBLESHOOTING amp REPAIR ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM ONE OUTPUT SCR NOT FUNCTIONING NO LOAD Return to Section TOC Return to Master TOC Return to Master TOC Rt o 2 5 2 ate S 8 FRE 5 gt This is NOT the typical DC output volt ps age waveform One output SCR is not 5 5 functioning Note the gap in the wave Scope Settings 2 form One SCR gate is disconnected to simulate an open or non functioning out put SCR Each vertical division repre Volts Div sents 50 volts and each horizontal divi Horizontal Sweep sion represents 2 milliseconds in time Coupling Trigger Note Scope probes connected at machine output terminals 4 probe to positive terminal probe to negative terminal Return to Section TOC Return to Master TOC MULTI SOU
19. LINCOLN F 32 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 33 10 11 12 TROUBLESHOOTING amp REPAIR CONTROL BOARD TEST Continued LED 6 indicates that the fan motor driver circuit has been activated and the fan motor should be running LED 6 and the fan motor will be on for about 5 minutes after LED 4 goes off See Figure F 15 LED 7 will light if a positive voltage is pre sent on the negative output terminal AC instead of DC This is an indiction of a shorted SCR in the output bridge rectifier See The input contactor will open and will remain deenergized until the power switch is turned off for a minimum of 1 second See Figure 15 The green light located on the front con trol panel is lit when the machine s output voltage is present and at a safe level The voltage range is from 40VDC to 113VDC peak This voltage can be measured at the output terminals and verified at Plug J1 pin 6 lead 215 to Plug J2 pin 1 lead 2220 See Figure F 15 If the output voltage is within range but the green light is not lit either the green light is faulty or the control board is faulty Normal operat ing voltage for the green light is about 3 5VDC A voltage of about 5 0VDC would indic
20. SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place MULTI SOURCE LINCOLN B RETURN TO MAIN MENU MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page a LL CDU UL i iv Installation cineres A III int Section A X H Section B ACCOSSOMIOS m Section C METEO Section D Theory of Operation ss Section E Troubleshooting and Repair ee Section F Electrical Diagrams eterno RE e SERRE FEBRE Section G Pars Man al P 367 SERIES MULTI SOURCE LINCOLN B Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION O 5 00 Section o E Technical
21. 0 DOL 901 49 SEMN 0 DOL uonoeg D 4 NOTES 48 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 DOL 181SEIN 01 DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Section E 1 Section E 1 TABLE OF CONTENTS THEORY OF OPERATION E Theory of Operation Section Section E z General Descr flo sei etn E 2 Input Voltage Filter Contactor and Control Transformer E 2 5 Main Transformer Control Board Cooling Fan Motor Digital Meter amp LED S E 3 SCR Bridge Resistor Bank Firing Board amp Output Capacitor Resistor E 4 Protection Devices amp CICUS sininen aant ite c D REPE EE E 5 SCR Operation 6 Q 5 FIGURE MULTI SOURCE BLOCK LOGIC DIAGRAM TERMINAL Ti SURGE o NOISE MAIN TRANSFORMER FILTER WORK LT INPUT TERMINAL SCR OUTPUT RECTIFIER CONTACTOR EINER CAPACITOR 2 9 LIMITING RESISTOR c
22. Disconnect input AC power supply lines to the machine before performing periodic maintenance tightening cleaning or replacing parts Figure D 1 Perform the following daily 1 Check that no combustible materials are in the welding or cutting area around the machine 2 Remove the debris dust dirt or materials that could block the air flow to the machine for cooling 3 Inspect the welding cables for any splits or punc tures in the cable jacket or any condition that would affect the proper operation of the machine Perform Periodically Clean the inside of the machine with low pressure air stream Clean the following parts Refer to Figure Main Transformer Electrode and Work Cable connections SCR rectifier bridge and heat sink fins Control Board Firing Board Fan Assembly NOTE The fan motor has sealed bearings which require no maintenance MULTI SOURCE LINCOLN B D 3 D 3 MAINTENANCE FIGURE D 1 MAJOR COMPONENT LOCATION gt gt 5 9 N 209 lt C x 2 5 mo C DOL J91S N 0 DOL uonoeg 6 Roof 7 Rectifier Assembly 201 J81Se N 0 DOL uonoeg JO ess BY MULTI SOURCE LINCOLN SOL
23. MULTI SOURCE LINCOLN F 54 F 54 TROUBLESHOOTING amp REPAIR SCR BRIDGE HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE FIGURE F26 Bolt and Lead Locations 9 16 Bolts Return to Section TOC Return to Master TOC Rt 2 5 2 Return to Master e e Assembly olg 8 2 Mount 2 ala Pc REMOVAL PROCEDURE 4 Lower the control panel using a 3 8 nut driver 1 Disconnect input power to the machine 5 Remove plug J4 from the firing board and 2 Using a 3 8 nut driver remove the case feed the disconnected plug down through sides and roof the hole in the bottom of the P C board control box 3 Locate label and remove leads 301 and 264 from the thermostat See Figure F 26 Return to Section TOC Return to Master TOC MULTI SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 2 Return to Section Return to Master TOC 2 2 5 F 55 6 7 8 9 10 TROUBLESHOOTING amp REPAIR SCR BRIDGE HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE FIGURE F 27 Bolt Lead and Shunt Locations Copper Leads Positive Output Leads 251 Using a 9 16 nut driver remove the two positive output leads connecting the out put brid
24. coil If the contactor does NOT activate Replace any cable ties and loom previous the input contactor is faulty Replace the ly removed Replace the roof and left case input contactor side Ojo 515 818 5 2 1 4 With the contactor activated check the continuity across the contacts Zero ohms or very low resistance is normal See Return to Section TOC Return to Master TOC MULTI SOURCE LINCOLN amp F 16 NOTES o A 901 Je1Se A 0 901 Je1Se A 0 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH F 16 DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 17 F 17 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual
25. gt 45 7 IE IE I Ay IE J8 eg ary Firing Board MULTI SOURCE LINCOLN F 52 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 53 F 53 TROUBLESHOOTING amp REPAIR SCR BRIDGE HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty 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 tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the SCR bridge and or an individual heat sink assembly for repair or replacement MATERIALS NEEDED 3 8 Nut Driver 9 16 Nut Driver 1 2 Nut Driver Solder Solder Gun lron T12837 Dow Corning 340 Heatsink Compound This procedure takes approximately 2 Hours to perform
26. ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on
27. must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper
28. AWG welding cable is recommended Connection of Electrode and Work Leads to Output terminals 1 Set the POWER ON OFF Toggle Switch to OFF 2 Raise the hinged cover protecting the output termi nals 3 Insert the electrode lead up through the elliptical hole in the machine base below the positive output terminal Pull through enough cable to reach the out put terminal 4 Connect electrode lead to the terminal 5 Tighten the output terminal nut with a wrench 6 Connect the work lead to the negative output termi nal following steps 3 5 7 Lower the cover to protect the output terminals FIGURE A 4 Output Terminal Connections PARALLELING Machines may be paralleled for increased output The S20428 paralleling kit permits paralleling of two MULTI SOURCE power supplies for supplying currents of up to 1000 amps 100 duty cycle MULTI SOURCE OUTPUT LIMITATIONS The number of Multi Weld Converters that may be con nected to a single Multi Source Power Source is deter mined by the following formula Power Source Volts x Amps capacity gt 1 1 x Sum of Converters Volts x Amps arcs The number of Multi Weld 350s the procedures used and the combined duty cycle of the arcs are only limit ed by the 40 000 36 000 watts on 50Hz watt rating of the Multi Source supply The machine is 235 rated and is designed for outdoor applications DI
29. E 4 E 4 TROUBLESHOOTING amp REPAIR O o S FIGURE E 4 SCR BRIDGE RESISTOR BANK FIRING BOARD amp OUTPUT CAPACITOR RESISTOR c 2 2 ziv 39 2 SURGE MEN o NOISE 814 FILTER TRANSFORMER WORK 82 INPUT TERMINAL 29 SCR OUTPUT RECTIFIER Em 1 CAPACITOR _ ni m gt MES SIOR ELECTRODE N TERMINAL E boli 4 f BN gt TO CONTROL CONTROL BOARD TRANSFORMER THERMOSTAT SWITCH TO CONTROL MMMM GATE SIGNALS BOARD FAN VOLTAGE 32 VAC 32 VAC CONTACTOR CONTROL BOX HD RESISTORL FIRING BANK BOARD CONTROL BOARD CONTROL See OOQ DIGITAL METER LED LED LED Return to Section TOC Return to Master TOC SCR BRIDGE RESISTOR BANK FIRING BOARD AND OUTPUT CAPACITOR RESISTOR The neutrals of the main transformer secondary wind ings are connected together and the six starts are con nected to the six SCR assemblies to form a six phase output This six phase AC output is rectified and con trolled through the SCR bridge The firing board receives power through the current limiting resistor bank The firing board is a three phase circuit Each phase provides two firing pulses one for each of the two Silicon Controlled Rectifiers SCRs controlled by that particular phase The firing circuit supplies the proper amount of energy to the gates of the power SCRs When the gate signal is applied at the correc
30. Guidelines detailed in the beginning of this manual OUTPUT PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTIONS PROBLEMS The Multi Source machine will not 1 Remove all external loading to 1 The ON OFF power switch shut off when the ON OFF switch the Multi Source and then may be faulty See the Wiring is in the OFF position carefully remove the input Diagram power 2 The input contactor may be stuck closed Perform the Input Contactor Test CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 MULTI SOURCE LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 TROUBLESHOOTING amp REPAIR F9 CONTROL TRANSFORMER T2 VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe al
31. K1736 1 Distribution box Connects up to 10 Multi Welds K449 LN 25 Across the arc wire feeder K1788 1 Roll Cage Protect power source facilitate moving store cable K1806 1 Multi Weld Four pack Mounting lift rack for M S and four M Ws K1807 1 Multi Weld Eight Pack Mounting lift rack for M S and eight M Ws S20428 Paralleling Kit Allows two machines to equally share double load MULTI SOURCE LINCOLN B Return to Master TOC Return to Master TOC 0 iv z o c tc Return to Master TOC D 1 TABLE OF CONTENTS MAINTENANCE Maintenance iE aAA Section D Safety PRECAUTIONS seisis te tre etes dat e etes inner D 2 Routine and Periodic Maintenance iii D 2 Major Component Locations siemens D 3 MULTI SOURCE LINCOLN amp D 1 Return to Section TOC Return to Master TOC Return to Section TOC O10 E E 515 gt 818 5 2 1 Return to Section Return to Master TOC Return to Master TOC D 2 D 2 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this mainte nance Turn the input power OFF at the disconnect switch or fuse box before working on this equipment not touch electrically charged hot parts ROUTINE AND PERIODIC MAINTE NANCE 1
32. NOTE This diagram is for reference only may accurate for all machines covered by this manual LINCOLN ELECTRIC os ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY FIRING 0280 EM C1 03 05 06 09 012 013 014 19 516668 5 022 50 C15 C16 C23 025 C26 C28 29 34 35 037 44 02 04 010 01 025 022 Je i 1 S 199 1 TRIO um 027 D28 029 D30 081 032 033 034 035 036 038 043 044 047 049 050 051 052 053 054 059 060 061 D62 D63 D64 12199 2 N4007 D18 D20 D22 D39 040 041 042 055 056 057 058 065 066 D67 D68 D69 D70 712705 46 1000V SAMP DIODE DS 0710 0711 0712 0713 T12702 29 1N4744A 0215 a Eos LED7 LED8 LED9 LED10 OCI OOS 2 51500010 1 oPTOISOLATOR 2 03 050607 6 71270473 MOSFET 55 R18 R36 R64 R82 R116 RIA 1 146506 RESISTOR WW 150550 R44 R45 R46 R195 R227 R229 13 S19400 1002 10 1 4W R251 R254 R255 R258 R259 R262 R263 R83 R91 R135 R139 R163 18 19400 1500 150 1 4W R164 R184 R188 R202 R203 R206 R245 R249 184 802 8167 8174 1207 1219 Ce SES R85 R86 R87 R88 R89 R90 38 S19400 2000 200 1 4W R93 R94 R95 R96 R97 R98 R143 R168 R169 R170 R171 R172 R173 R175 R176 R177 R178 R179 R180 R208 R209 R210 R211 R212 R213 R220 R221 R222 R223 R224 R225 R266 R136 R140 R160 R185 R189 M 19400 2670 267 1 4W R196 8214
33. Paint Return to Section TOC Return to Master TOC 5 Remove the red insulating paint from heat NOTE Do not disassemble the heat sinks sink test points See Figure F 12 6 Perform test procedure as follows Refer to Figure F 13 Repeat test for all six SCRs E E 5 818 5 2 1 Return to Section TOC Return to Master TOC MULTI SOURCE LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Return to Section TOC Return to Master TOC 2 2 5 F 29 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST Continued FIGURE 13 SCR Test Setup 6 VOLT LANTERN BATTERY F SW2 R12 4 ohms 10 watts R2 3 ohms 10 watts To test SCRs construct the circuit outlined above Resistor values are plus or minus ten percent The voltmeter scale should be low approximately 0 5 or 0 10 volts DC To test SCRs construct the circuit outlined in Figure 13 Use one 6V lantern battery Resistor values are in ohms 1096 The voltmeter scale should be low approxi mately 0 5 or 0 10 volts BATTERY TEST Check the battery by shorting leads A and C and then close switch SW1 Repla
34. R233 50 25 024 5 15 LED2 f 9 022 ds 392 100 4 Z 033 ram ce 8 267 4 lt c32 ALTERNATE CONNECTION E amp 1 a 18 2 5 267 Sav AU eve TO CONTROL BOARD E 2 5 4 2 4 CLOSURE e e e e e e e e 027 CONTROL SIGNAL Aas J5 144004 els ACTIVATOR 1 gt gt 2 gt 02 1 e e 0S oe o 819 44 GATE DRIVE J4 GATE DRIVE J6 CHOKE ALTERNATE CONNECTION hd d 2 NB THERMOSTAT 206 lt _ 214 CONNECTED TO R3 JE 50 25W 035 30 OHM 100 WATT LATCHING RESISTOR ON 06 655 15 09 8 8 144007 gt 55 14 o gt Kt bi 04 5 3 J7 gj 206 7 R64 192 2 4 2 042 e B 184007 g g zw 5 9 gt 8133 5 S c 057 0 0K 1 ET gt ay R258 5 32 T E 184007 Es lt S id 4807 p pes MM 2 400v ojo ue m tO 039 m 205 e R82 50 144007 18 io 4 ete Di e SCR7 T 043 063 08 C20 144804 LATCHING 2N6397 E A 267 144027 5 L RESISTOR 50 25W 128 a ENABLE ce 332 2 6 27 26 2259 8 475 sx ALTERNATE CONNECTION _ 1 RUA 1006 re z 267 8 15
35. REMOVED FROM THE SLAVE FIRING PCB zl 8 cu ig 100 FIRING CIRCUIT 5 dc s ENABLE 150 C28 aav 1207 6 4 prm 5 N 028 S C33 8 267 iv m LL cas 25 cz 58 x 2 5 NI 100 E 2 GENERAL_ INFORMATION R 266 0 7 LED 10 215 ELECTRICAL SYMBDLS PER E1537 H 9 9 e Ti 2 10 OUTPUT ne CAPACITORS 1022 50 UNLESS OTHERWISE SPECIFIED 0 44 04 3 SCR 7 95 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 0 71 07 50 3 G6 7 DIODES UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET D J4 cert DRIVE J amp Q POWER SUPPLY SOURCE POINT gt se 57 COMMON CONNECTION 3 gt hate come THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CD a AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OFTHE LINCOLN ELECTRIC co FILE 03741186 E ON CROUNDAEONNED TION 9 UNLESS OTHERWISE SPECIFIED TOLERANCE 27958 THE LINCOLN ELECTRIC CO pu DC 6 0 MULTI SOURCE D HOLES SIZES PER E 2056 2 PLACE DECIMALS 15 CLEVELAND OHIO U S A _FIRING PC BOARD SCHEMATIC E ON 3 PLACE DECIMALS 5 202 5 8 rus ON ALL ANGLES S 5 OF A DEGREE SCALE __ __ SHT 2 MATERIAL TOLERANCE TD AGREE or MJK DATE 72 99 CHK DR SUPSDG v 03741 WITH PUBLISHED STANDARDS 9
36. back of the machine See Figure F 1 MULTI SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 5 a 818 5 2 1 Return to Section TOC Return to Master TOC F 11 F 11 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST 6 Carefully apply primary power and test for NOTE If the correct main AC input power to the correct secondary voltages See Table the Control Transformer is present and the F1 secondary voltages are not correct the Control Transformer may be faulty Replace TABLE 1 Primary 1 amp H2 Approximate Secondary Voltage Voltage X1 X3 575 VAC 43 0 VAC 460 VAC 34 50 VAC 380 VAC 28 50 VAC on anne 60 Ohms X2 X3 Thermostat 0 Ohms MULTI SOURCE LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 5 818 5 2 1 Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST FIGURE F2 Thermostat Secondary X1 X3 Thermostat NOTE If the secondary voltage is not pre 7 Replace any leads previously removed sent at terminal X3 but is present at terminal X2 the internal thermostat is faulty See Figure F 2 8 Replace right side and roof MULT
37. be accomplished by Wiring Diagram disconnecting the transformer sec 5 Remove the red insulating paint from heat SER under 166l sink test points See Figure F 9 NOTE DO DISASSEMBLE THE SINKS 6 Using an analog ohmmeter test the resis tance from anode to cathode of SCR 1 Reverse the meter leads and check from cathode to anode of SCR 1 R x 1000 scale See Figure F 9 MULTI SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC E E 5 818 5 2 1 Return to Section TOC Return to Master TOC F 24 Anode I Cathode F 24 TROUBLESHOOTING amp REPAIR STATIC SCR TEST Continued FIGURE F 9 SCR HEAT SINK TEST POINTS Q 2 Remove Cit Hed Paint 0 N 7 previous step s testing SCR 2 9 Reconnect any secondary leads removed SCR 3 SCR 4 SCR 5 and SCR 6 from the SCRs To further check the SCRs functions use 10 Reconnect Plug J4 into the firing board SCR tester and proceed to Active SCR Test 11 Replace the case top sides and control 8 When test is completed reconnect the panel positive bridge leads to the shunt MULTI SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Se
38. board NOTE Allow the machine to heat up so that all elec trical components can reach their operating temperature 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom Return to Master TOC 2 Check for loose connections at the PC board to assure that the PC board is properly connected Return to Section TOC 6 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem Recalibrate if required 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 a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and termi nal strips PC Board can be damaged by static electricity e Remove your body s static Ojo E 515 818 5 2 1 Return to Section Return to Master TOC IWAN ATTENTION Static Sensitive Devices Handle only at Static Safe Workstations Reusable Container Do Not Destroy charge before opening the stat ic shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm
39. on to D ber board and cathode heatsink to the heatsink mounting studs i bly See Fi F 29 Ne 2 Place positive buss bar back in original 3 Carefully remove the SCR heatsink from position the mounting studs Replacement will be made with a new SCR assembly 3 Replace 9 16 nuts and washers previous ly removed 4 Replace snubber assembly if necessary A CAUTION DO NOT DISASSEMBLE THE SCR FROM THE HEAT SINK REPLACE THE SCR ONLY AS AN ASSEMBLY Return to Section TOC Return to Master TOC MULTI SOURCE LINCOLN amp F 58 F 58 TROUBLESHOOTING amp REPAIR SCR BRIDGE HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE INSTALLATION OF SCR OUTPUT BRIDGE NOTE Upon reassembly apply a thin layer of T12837 Dow Corning 340 heat sink compound to all bolted elec trical connections on the aluminum heat sinks including positive buss bar Return to Section TOC Return to Master TOC 1 Carefully maneuver SCR bridge back into original position 2 Using a solder iron reconnect lead 251 to the main transformer and insulate 3 Replace the two 9 16 mounting bolts pre viously removed Be sure to position insu lation bushing washer and nut correctly sic See Figure F 26 9 4 Replace the two 1 2 mounting bolts on 2 the right side of the machine previously removed These bolts mount the SCR ala bridge to the main transformer E Figure 27
40. resistive cord connected to a grounded part of the equipment frame If you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to pre vent static build up Be sure not to touch any electrically live parts at the same time e Tools which come in contact with the PC Board must be either conductive anti static or static dis sipative MULTI SOURCE LINCOLN amp 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 recalibrate if required and test the machine 7 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and write on the war ranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual OUTPUT PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Return to Section TOC Return to Master TOC Major physical or electrical dam Contact the Lincoln Electric Contact the Lincoln Electric age is evident Service Dept Service Dept 1 800 833 9353 WELD 1 800 833 9353 WELD Machine Multi Source is dead and Check for blown or missing The
41. should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the Input Contactor for maintenance repair or cleaning MATERIALS NEEDED 3 8 Nut Driver 7 16 Nut Driver 11 16 Nut Driver 1 2 Nut Driver This procedure takes approximately 40 minutes to perform MULTI SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR CLEANING AND OR REPLACEMENT Continued FIGURE F 19 INPUT CONTACTOR top view TOP VIEW 8 REMOVAL PROCEDURE Disconnect input power to the machine Remove case sides and roof using a 3 8 nut driver Label leads
42. 0 lt 68 0 190v 2 120K amp 25 150 Cu 158 9 267 8 267 150 33 E c 2 2 Sav Ao 2 e e ke V v S3 gt 63 L__S45 14 GATE DRIVE J4 GATE DRIVE Je e O 1 NB 5 5 0 ALTERNATE CONNECTION 5 o 208 o 50 250 oz gt D6 051 olg 2 8 Al Kt TS 5 c c 25 100v 208 5 e e R239 x aL 030 amp 5 5 z Fm i E 28 Tim ips R240 3 06 10 0 055 619 9 R254 m p 1N4007 Le 184007 25 mx 8 F 221 058 066 07 144207 lt gt 1809 14007 SCR6 15 055 IL 207 5 e e gt 2r 2 T FIRING SIGNAL 50 FROM CONTROL 15w e Kt 053 231 5 Ds 4 267 45 NA SINCE COMPDNENTS DR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 1457 144804 a t 14004 WITHOUT AFFECTINC THE INTERCHANCEABILITY OF COMPLETE BOARD THIS DIACRAM MAY 50 25W v Sax NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY CONTROLS HAVING A COMMON CODE 8 NUMBER C26 J8 16 USED TO CONNECT THE FIRING PCBS IN TWO LIKE MACHINES 207 gt 2 7 232 4 5 SOURCE TO PARALLEL THEIR OUTPUTS ALTERNATE CONNECTION 08 144004 m FIRING ENABLE J7 REMAINS IN THE MASTER FIRING PCB Le LEDS 5 200 026 J7 6
43. 1 4W 61 9K 136 C47 1 516668 7 CAPACITOR 820p 50V 5 El ts s 000 eso 88H d Blefs R92 1 519400 2673 RESISTOR MF 1 4W 267K 1 cri 1 COSMETIC TRACE COSMETIC TRACE 2 d 3 ed 18H a amp ha R95 R96 R97 R98 4 519400 1623 RESISTOR MF 1 4W 162K 1 D1 D44 2 T12705 47 DIODE AXLDS 4 200V UFR o 8 E 8 89 E emm t 4 R99 1 519400 5111 RESISTOR MF 1 4W 5 11K 1 D2 D6 D7 D8 D9 D10 D11 D12 44 T12199 1 DIODE AXLDS 1A 400V M zea 1 z R108 1 s19400 2213 RESISTOR 1 4W 221K 1 013 014 015 016 017 018 2 9582 z 1 9 R119 R138 2 519400 39 2 RESISTOR MF 1 4W 39 2 1 D19 D20 D21 D22 D23 D24 9 55 l 1 Le R121 1 519400 2212 RESISTOR MF 1 4W 22 1K 1 025 026 027 029 030 031 58 R126 1 519400 8251 RESISTOR MF 1 4W 8 25 1 D32 D33 034 35 36 038 P 5 R128 1 T10812 62 TRIMMER ST 1 2W 500 10 LINEAR 039 040 041 042 045 046 3 2 Lt Ga R136 1 519400 3570 515 1 4 357 1 047 048 049 050 051 052 L AE Seu R137 519400 4750 RESISTOR MF 1 4W 475 1 3 04 05 3 T12705 34 DIODE AXLDS 400V FR 184936 a E 8 R146 R147 2 519400 2430 RESISTOR MF 1 4W 243 1 D28 D37 D43 3 T12199 2 DIODE AXLDS 1 1000 N x 8 8 R149 1 519400 2210 RESISTOR MF 1 4W 221 1 021 028 2 T12702 11 ZENER DIODE 1W 16V 5 1N4745A i 1 S20375 1 TRANSFORMER PCB PWM FLYBACK 072 076 079 3 T12
44. 102 R113 R118 R135 a genas R141 R142 R143 R145 R148 an 889 R26 R27 R30 R81 R83 R106 6 S19400 1004 RESISTOR MF 1 4W 1 00M 1 5 8 62 E R28 1 19400 7501 RESISTOR MF 1 4W 7 50K 1 FIEF zza NP 99H vou tou eia R29 R31 R32 R63 R65 R110 10 519400 4751 RESISTOR MF 1 4W 4 75K 1 e R131 R140 R144 R151 5 o E er m er o 3 e o 90 L I 2 2 8 2 Chg Seite X INFO DESIGN INFORMATION JREFERENCE EQUIPMENT TYPE MULTI SOURCE 07320004 SUBIECT CONTROL BOARD ASSEMBLY eiu APPROVED SCALE 11 DATE 4 20 2000 DRAWNG No G 3726 2 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN machine ELECTRIC ELECTRICAL DIAGRAMS SCHEMATIC FIRING PRINTED CIRCUIT BOARD
45. 2 5 F 32 TROUBLESHOOTING amp REPAIR CONTROL BOARD TEST Continued Firing Board Control Board FIGURE F 14 CONTROL BOARD LOCATION TEST PROCEDURE FOR NORMAL CON TROL BOARD OPERATION 1 Remove main supply power to the Multi Source 2 Remove screws loosen and lower the front panel to access and inspect the con trol board located in the right side of the control box See Figure 14 3 Apply the correct three phase input power to the Multi Source Turn on the machine WARNING WHEN THE MULTI SOURCE IS TURNED ON THE OUTPUT TERMINALS ARE ELECTRICAL LY HOT 4 The white power light located on the front control panel indicates the control board is receiving the DC voltage that is supplied from the rectified secondary voltage of the control transformer This voltage can range from 38VDC with 345VAC applied to the machines input to 58VDC with 600VAC applied to the Multi Source This voltage can be measured at Plug J2 pin4 lead 274 to plug J2 pin2 lead 273 Normal voltage on the white light is 3 5VDC If 5 0VDC is present the light may be open This can be measured at plug J1 pin 7 lead 230 to plug J1 pin 8 lead 341 5 LED 1 is an indication of the machine s output voltage At normal output voltages LED1 should be brightly lit Normal open circuit voltage OCV at the welding output terminals is approximately 80VDC This voltage can be checked at Plug J1 pin 1
46. 2 10 1 1 0 7 TR 1 00 2 Ta 0 52 LABELS SUPPLY VOLTAGE POWER SUPPLY SOURCE POINT COMMON CONNECTION 17 7 FRAME CONNECTION a EARTH GROUND CONNECTION EQUIP MULTISOURCE POWER SOURCE suasect CONTROL BOARD SCHEMATIC reference only It may be accurate for all machines covered by this manual pate 09 22 00 SUP S D G G 3727 sil ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY CONTROL
47. 5 Replace previously removed cable ties 6 Replace the 3 8 mounting screw previ ously removed from the front of the machine located behind the control panel 7 Reconnect plug J4 to the firing board 8 Replace the four screws previously removed from the front control panel 9 Reconnect the six copper transformer sec ondary leads previously removed 10 Reconnect the two positive output leads to the shunt Ojo 5 5 gt 818 5 2 1 11 Reconnect leads 264 301 previous removed from the thermostat 12 Replace the case sides and roof Return to Section TOC Return to Master TOC MULTI SOURCE LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 515 818 5 2 1 Return to Section Return to Master TOC D TROUBLESHOOTING amp REPAIR didi RETEST AFTER REPAIR Testing is required after the removal of any mechanical part that could affect the machine s elec trical characteristics or if any electrical components are repaired or replaced NO LOAD READINGS FAN OFF Input Volts Phase Hertz Maximum Idle Amps Maximum Idle KW 380 3 50 400 3 50 415 3 50 460 3 60 500 3 50 575 3 60 MAXIMUM OPEN CIRCUIT VOLTAGE Open Circuit Volts 79 5 80 VDC PERFORM METER ACCURACY TEST MULTI SOURCE
48. 518104 3 55 is 8EY go UNLESS OTHERWISE SPECIFIED R1 1 T14648 10 RESISTOR WW 5W 1 2K 5 50 2 14 AA 5 RESISTANCE 5 R2 R3 2 519400 3322 RESISTOR MF 1 4W 33 2K 1 519 8 8 2 ERE C yu R4 R72 2 519400 2670 RESISTOR MF 1 4W 267 1 9 SE amp R5 R71 2 519400 3010 RESISTOR MF 1 4W 301 1 72 gt veu R6 R80 2 519400 6811 RESISTOR MF 1 4W 6 81K 196 1 SE R7 R18 R19 R23 519400 1372 RESISTOR 1 4W 13 7K 1X ot ES R8 1 519400 1503 RESISTOR 1 4W 150K 1 c Eg SE 8 98 Figs zsa R9 1 519400 1501 RESISTOR MF 1 4W 1 50K 1 n gt n d 8 0 0 2 2 Sum R10 R132 2 519400 1301 RESISTOR MF 1 4W 1 30K 1 R11 1 519400 3320 RESISTOR 1 4W 332 1 ojo ae R12 1 519400 2687 RESISTOR MF 1 4W 26 7 1 LU 8 R13 R124 2 12300 80 RESISTOR 5W 0 5 5 818 KA y Les R14 R114 2 T14648 9 RESISTOR WW SW 2 5K 5 50 R15 R139 2 519400 1500 RESISTOR MF 1 4W 150 1 R16 1 519400 6191 RESISTOR MF 1 4W 6 19K 1 5 R17 R117 2 519400 2801 RESISTOR MF 1 4W 2 80K 1 5 R20 R21 R105 3 19400 8252 RESISTOR MF 1 4W 82 5K 1 8 R22 1 516296 5 TRIMMER MT 1 2W 10K 10 LINEAR R24 R25 R45 R69 R75 R76 22 519400 1002 RESISTOR MF 1 4W 10 0K 1 EN 5 18 R85 R86 R87 R90 R91 R94 R100 R
49. 702 52 ZENER DIODE 1W 5 1V 5 1N4733A E F E 8 B 1 1 T13640 11 MOV 150VRMS 45J 14MM DZ3 DZ7 2 T12702 29 ZENER DIODE 1W 15V 5 1N4744A rus TRI1 1 518395 27 TRIAC T220 8A 800V WITH 518104 3 5 DZ4 DZ5 DZ10 3 T12702 27 ZENER DIODE 1W 10V 5 1N4740A n 1 92H x1 1 515128 16 IC 0P AMP QUAD HIGH PERF 1014 J1 1 524020 16 CONNECTOR MOLEX MINI PCB 16 PIN TIN X2 X3 X4 X5 4 515128 18 OP AMP QUAD HIGH PERF 33074 12 1 524020 8 CONNECTOR MOLEX MINI PCB 8 PIN TIN E e dac ac ge Fe X6 X7 2 515128 11 IC COMPARATOR QUAD 29011 J3 1 524020 10 CONNECTOR MOLEX MINI PCB 10 PIN TIN T 3 B gt x8 1 15018 9 IC CMOS MULTIVBRTR MONO DUAL 4538 55 LED1 LED2 LED3 LEDA LEDS 7 T13657 2 LED T 1 3 4 RED HLMP 3003 1 lad I Ove X9 X10 2 515018 13 IC CMOS TIMER PROGRAMMABLE 4536 55 LED6 LED7 du 11 1 15458 4 IC PWM CONTROLLER IMODE 2842A 1 1 515000 8 OPTOCOUPLER PHOTO SCR 400V 52401 feo ele 12 1 515128 10 VOLTAGE REF ADJ PRECISION 4311 1 515000 12 OPTOCOUPLER TRIAC DRIVER 3023 Im TES iy 8 5 X13 1 518395 3 REGULATOR HEAT SINKASBLY 15128 5 518104 3 01 02 03 04 05 06 07 7 712704 68 TRANSISTOR NPN T0226 0 5A 40V 2N4401 S so a Q8 1 112704 69 TRANSISTOR PNP TO226 0 5A 40V 2N4403 rir 5 iw 2 09 010 2 518395 5 MOSFET HEATSINK ASBLY T12704 61 amp
50. 8 CONTACTOR COL 200V n CMS 240 09 00 10 kHz FIXED OFF TIME CURRENT LIMITED VBIAS 6 4138V D27 7 Eb 100K z 03 05 40V s SH RTED SCR PROTECTION 5 MINUTE TIMER TIME STARTS WHEN RESET GOES LOW SET RESET 915 A AVE TRIP EN gt LED 2 1 com MONO IN OSC INH DUTI B BYPASS OUT DECODE B D 2010 A PEAK TRIP 3074A 100M OUTPUT LEAD THERMOSTAT OR SCR HEAT SINK THERMOSTAT OPEN TO DISABLE OUTPUT WITH OVER CURRENT OR TEMP 26 ul BRIDGE J2 33 V AVE AT 345 V INPUT 58 V AVE AT 600 V INPUT 234 W Ji 13 51 YELLOW LED FOR THERMAL OVERLOAD Ji 12 235 4 214 230 WHITE LED FOR PRIMARY ON INDICATION 341 B POWER SUPPL
51. ACITOR PEMF 0 33 200V 10 eza eza 81847 a R50 R133 R134 3 s19400 7500 RESISTOR 1 4W 750 1X C17 1 516668 3 CAPACITOR CEMO 100P 100 5 Le 4 R51 R152 2 519400 1001 RESISTOR 1 4W 1 00K 1 18 33 34 37 41 45 10 516668 5 CAPACITOR CEMO 022 50 20 ES R52 1 19400 3012 RESISTOR 1 4 30 1 1 C60 C61 C62 C63 E R53 R73 2 519400 2802 RESISTOR MF 1 4W 28 0K 1 21 1 516668 9 CAPACITOR CEMO 150p 100V 5 1 18 EI seu mi Era R54 R64 R66 R123 R129 5 519400 1000 RESISTOR MF 1 4W 100 1 22 1 513490 104 CAPACITOR TAEL 39 20V 10 1 1 uU 1 R55 R56 R57 R58 R59 R60 8 519400 8250 RESISTOR MF 1 4W 825 1 1 513490 40 CAPACITOR TAEL 2 7 50V 10 b 4 BEI Fd R61 R62 C26 1 513490 63 CAPACITOR TAEL 47 50V 10 s c 1 44 4 all 8 A R67 R68 R70 R111 R112 R120 7 519400 5621 RESISTOR MF 1 4W 5 62K 1 C30 1 513490 66 CAPACITOR TAEL 47 35V 10 6 8 5 Fr evi R122 C38 C39 2 T11577 57 CAPACITOR PEF 0 1 400V 10 1 x E NT 699 3 R74 R79 R127 3 519400 2001 RESISTOR 1 4W 2 00K 1X C43 C48 2 513490 42 CAPACITOR TAEL 1 0 35V 10 7 d 5 sk seq R77 R78 R103 R104 R115 5 519400 5110 RESISTOR MF 1 4W 511 1 C46 1 516668 6 CAPACITOR 4700p 50V 10 TES a 1 5 E R84 1 519400 6192 RESISTOR
52. COLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 52 TROUBLESHOOTING amp REPAIR FIRING BOARD REPLACEMENT PROCEDURE Procedure FIGURE 24 FRONT PANEL W OUT COVER Firing Board REMOVAL PROCEDURE Disconnect input power to the machine Using a 3 8 nut driver remove screws and lower the front control panel to access the firing board on the left side of control box while facing the machine See Figure F 24 Disconnect plugs J5 J8 and J4 from the firing board Remove the four phillips head screws and associated washers from the corners of the firing board See Figure F 25 Carefully remove the firing board Control Board REPLACEMENT PROCEDURE Replace the firing board Mount the firing board to the machine in its proper position using the four phillips head screws and associated washers previously removed Reconnect plugs J4 J8 and J5 to the fir ing board NOTE Be sure plug J7 is installed in the new board 4 Replace the four screws previously removed from the front access panel FIGURE F 25 MOUNTING SCREW LOCATIONS MOUNTING SCREWS IE IE ER IE sexo sx IR IE J5 IE FE J6 IE
53. ELECTRODE tc domzzoomzaz V NV WV WV V TO CONTROL BOARD CONTROL TRANSFORMER THERMOSTAT SWITCH TO CONTROL GATE SIGNALS BOARD FIRING BOARD CONTROL SIGNAL 120 VAC FAN VOLTAGE CONTROL BOX RECTIFIER CONTACTOR Return to Master TOC MULTI SOURCE LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 515 gt 818 JE 2 1 Return to Section Return to Master TOC E 2 E 2 THEORY OF OPERATION FIGURE 2 INPUT VOLTAGE CIRCUIT T1 SURGE Tr uid TRANSFORMER WORK INPUT TERMINAL CONTACTOR m CAPACITOR E BN ns RESISTOR 9 ma gt ELECTRODE SHUNT TERMINAL gt E 5 TO CONTROL CONTROL BOARD TRANSFORMER SWITCH TO CONTROL Ll 3 5 C Y GATE SIGNALS BOARD ah CONTROL Q 8 BOX gt RECTIFIER 5 2 RESISTORE FIRING o E BANK BOARD CONTROL BOARD CONTROL SIGNAL GENERAL DESCRIPTION The Multi Source is designed to supply power to the Multi Weld Arc Converter welders The Multi Source is an SCR controlled constant voltage CV DC power supply that can operate with a wide range of three phase input voltages The machine s peak output voltage helps regulate against wide variati
54. F 1 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION Troubleshooting amp Repair Section Section F 8 How to Use Troubleshooting Guide sis F 2 PC Board Troubleshooting Procedures and F 3 E Mroubleshooting SANA n F 4 5 Test F 9 Control Transformer T2 Test F 9 Input Contactor OR ee ns dattes F 13 Main Transformer T1 Voltage Test is F 17 Statie SCR m 21 Active SCR 25 Control Board Test tet IEEE RR EERRY ARI ET ERR F 31 FIRING Board MH 35 Multi Source Meter Accuracy Test F 39 Normal Open Circuit Voltage Waveform No Load F 41 Abnormal Open Circuit Voltage Waveform 1 SCR Functioning Load F 42 Typical SCR Gate Voltage Waveform No Load F 43 Replacement uer 45 gt Input Contactor Cleaning and or Replacement iii F 45 2 Control Board Removal Replacement se F 49 Firing Board Removal Replacement
55. I SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 13 F 13 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD TEST DESCRIPTION This test will determine if the input contactor is receiving the correct coil voltage and if the contacts are functioning correctly MATERIALS NEEDED Ammeter MULTI SOURCE wiring diagrams See Electrical Diagram Section of Manual 3 8 Nut Driver External 120VAC supply This procedure takes approximately 30 minutes to perform MULTI SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Mas
56. IES 50kHz CURRENT MODE CONTROL 4 Visi 50V 5 01 zm 2700pF Sov BOVREF 138V NOTE This diagram CLOCK INH 75 SECOND TIMER TIME STARTS WHEN RESET GOES LOW R97 CW 500 2901N ADJUST FOR 11 A HOLD CURRENT PULL IN CURRENT 5 A FOR 100mS 160 4 ser RESET DIGITAL AMMETER CONNECTOR 5V tay gt mo gt gt SUPPLY COM B gt gt gt gt gt 38 5 D DAM AMPS S 9 gt INPUT nur ton V Veer SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY x10 5 MONO IN 4 OSC INH 6 8 55 DECODE B 45368 D CLOCK INH 115VAC SECONDARY FAN MOTOR
57. LINCOLN F 60 NOTES o A 901 Je1Se A 0 901 Je1Se A 0 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH F 60 DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Return to Master TOC Return to Master TOC 0 iv z o c tc Return to Master TOC G 1 ELECTRICAL DIAGRAMS G 1 TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION ELECTRICAL DIAGRAM S SECTION G WIRING DIAGRAM 2 2 CONTROL PC BOARD 5 G 3 CONTROL BOARD ASSEMBLY 6 4 FIRING PC BOARD SCHEMATIC G 5 FIRING PC BOARD ASSEMBLY G 6 SNUBBER PC BOARD ASSEMBLY G 7 MULTI SOURCE LINCOLN G 2 ELECTRICAL DIAGRAMS WIRING DIAGRAM MULTI SOURCE WIRING DIAGRAM INPUT SNUBBER ASSEMBLY Return to Section TOC Return to Master TOC L 550 575V CONNECTION 241 240 1CR CONTROL BOX DIODE BRIDGE 274 REAR 271TRANSFORMER IRON 250 Ay 253 208 260 FRONT TRANSFORMER LED W RIGHT
58. ON OFF switch may be the input contactor does not oper fuses in the input lines faulty Check switch and asso ate The white power light is NOT ciated leads See the Wiring lit Checkthe three phase input line Diagram voltage at the Multi Source The input voltage must match The thermostat located on the the rating plate and reconnect rear of the main transformer panel iron may be faulty This is nor mally a closed device The control box diode bridge may be faulty Also check associated wiring for loose or faulty connections See the Wiring Diagram 4 Perform the T2 Control Transformer Test 5 Perform the Control Board Return to Section TOC Return to Master TOC The input contactor does not oper Check the three phase input line 1 Perform the Input Contactor ate The white power light is ON voltage at the Multi Source The input line voltage must 2 Check leads 240 and 241 match the rating plate and between the control board and reconnect panel the input contactor for loose or faulty connections See the Wiring Diagram Ojo 515 gt 818 5 2 1 Turn the power switch OFF wait a few seconds Turn the power switch back ON If the Perform the Control Board problem is not resolved contin 2 Eu ii 4 Perform the SCR Rectifier Bridge Test CAUTION If for any reason you do not understand the test procedures or are
59. PC BOARD DESIGNATORS ITEM PART NO DESCRIPTION cmd R33 519400 6810 RESISTOR MF 1 4W 681 19 4 513490 138 CAPACITOR ALEL 1200 100V 75 20 0 R34 1 519400 3321 RESISTOR MF 1 4W 3 32K 1 c2 1 513490 73 CAPACITOR ALEL 20 50V 75 10 2 R35 R116 R125 R153 4 519400 2671 RESISTOR MF 1 4W 2 67K 1 C3 C5 C6 3 516668 4 CAPACITOR CEMO 2700PF 50 5 R36 1 524000 1500 RESISTOR WW 3 4W 150 5 C4 C16 C24 C27 C29 C31 22 516668 11 CAPACITOR CEMO 0 1 50V 10 2 8 R37 R39 R48 R89 R93 5 519400 2211 RESISTOR MF 1 4W 2 21K 1 32 35 36 44 49 50 R38 1 519400 1080 RESISTOR MF 1 4W 10 0 1 C51 C52 C53 C54 C55 C56 elslslels uem p R40 1 519400 6812 RESISTOR MF 1 4W 68 1K 1 57 58 59 8 ES Le p Ael RA1 R42 R88 3 519400 1502 RESISTOR 1 4W 15 OK 1 1 513490 121 CAPACITOR ALEL 1000 35V 30 20 Ba B sar 33 R43 1 519400 3923 RESISTOR 1 4W 392K 1 C8 C9 C12 C25 C40 5 513490 25 CAPACITOR TAEL 4 7 35V 10 4 R44 R101 R107 R109 R130 5 519400 1003 RESISTOR 1 4W 100K 1 C10 1 513490 4 CAPACITOR PEF 022 200V 10 8 4 AN R46 R150 2 19400 2002 RESISTOR MF 1 4W 20 0K 1 cit 1 513490 93 CAPACITOR TAEL 27 35V 10 zb 4 M RAT 1 519400 1211 RESISTOR MF 1 4W 1 21K 1 C13 C19 C20 3 T11577 38 CAPACITOR CD 02 600V 80 20 92d 08 4 4848 i gt YI 1 s16296 3 TRIMMER MT 1 2W 500 10 LINEAR C15 C28 C42 3 513490 94 CAP
60. R246 R250 R137 R138 R141 R142 R186 13 S19400 10R0 10 1 4W R187 R190 R191 R237 R238 R247 R248 R253 ito Hc mr R240 EE marema Sco L2 LL SCR1 SCR2 SCR3 SCR4 SCR5 ER 4A 400V SCR SCR6 SORT 91839521 SOR ASBLY SOME R NG BOAR D CAPACITORS MFD VOLTS RESISTORS OHMS Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC 820 9614
61. RCE LINCOLN F 43 F 43 TROUBLESHOOTING amp REPAIR TYPICAL SCR GATE VOLTAGE WAVEFORM NO LOAD Return to Section TOC Return to Master TOC volts Rt 2 5 2 Return to Master O10 915 5 8 2 8 This is the typical SCR gate pulse volt 5 age waveform The machine was an Scope Settings tc open circuit condition no load and operating properly Note that each verti Volts Div cal division represents 1 volt and that Horizontal Sweep each horizontal division represents 2 mil Coupling liseconds in time Trigger Note Scope probes connected at SCR gate and cathode probe to gate probe to cathode Return to Section TOC Return to Master TOC MULTI SOURCE LINCOLN F 44 NOTES o A 901 Je1Se A 0 901 Je1Se A 0 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH F 44 DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 45 F 45 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR CLEANING AND OR REPLACEMENT WARNING Service and repair
62. RETURN TO MAIN MENU SVM1 55 A July 2001 MULTI SOURCE For use with machines having Code Numbers 10668 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 increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Return to Master TOC View Safety Info w gt lt 2 gt O is o 9 gt E SERVICE MANUAL Copyright 2001 Lincoln Global Inc LINCOLN S NCOLN ELECTRIC 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 Return to Master TOC View Safety Info Return to Master TOC Return to Master TOC iv gt c tc Return to Master TOC SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to
63. STRIBUTION 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 TIONS Accessory pig tail leads and Twist Mate connectors are available from Lincoln for extra connections to the Multi Weld 350 or the Distribution Box LEADS AND CONNEC Order No Description 1012705 22in 56cm long 2 0 70 cable with 0 13mm 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 95mm cable K1759 70 Twist Mate female insulated recepta cle for 1 0 2 0 50 70mm cable K1759 95 Twist Mate female insulated recepta cle for 2 0 3 0 70 95 cable MULTI SOURCE LINCOLN B A 6 NOTES 48 901 Je1Se A 0 901 Je1Se A 0 901 J91Se N 01 DOL 181SEIN 01 DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Section B 1 Section B 1 TABLE OF CONTENTS OPERATION SECTION Operation Section Safety Instructions iii B 2 General
64. T1 T2 U V W and their respective terminals See Figure F 19 Using a 11 16 nut driver remove the six leads connected to the input contactor Using a 7 16 nut driver remove the four bolts mounting the input contactor to the frame of the machine Note washer posi tions for replacement See Figure F 20 Disconnect leads 240 and 241 using quick connects located in loom Carefully lift input contactor out of machine For contactor cleaning or inspection see Figure 21 REPLACEMENT PROCEDURE 1 Mount input contactor to machine frame using the four bolts washers and nuts previously removed Reconnect leads 240 and 241 Reconnect leads T1 T2 T3 U V W previ ously removed Replace case sides and roof previously removed FIGURE 20 7 16 MOUNTING BOLTS Mounting Bolts i 9 o 9 a e vi B on 1 ix i ILI LEFT SIDE MULTI SOURCE LINCOLN amp F 46 F 47 CONTACTS CONTACTOR COVER Les lt FIGURE F 21 INPUT CLEANING INSPECTION MULTI SOURCE LINCOLN TROUBLESHOOTING amp REPAIR INPUT CONTACTOR CLEANING AND OR REPLACEMENT Continued CONTACTOR COIL 4 240 F 47 DOL 0 DOL 181SEIN 0 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH
65. TOGGLE SWITCH This toggle 4 WHITE LED This LED indicates that the switch turns the machine ON or OFF control board is energized 2 CIRCUIT BREAKER This 10 amp 5 GREEN LED This LED indicates that the breaker protects the 120 VAC fan circuit machines output voltage is within the safe operating range 3 AMBER LED This LED indicates that the temperature of the machine is too 6 DIGITAL METER Provides the user with high an indication of the percentage of avail able power MULTI SOURCE LINCOLN Return to Master TOC Return to Master TOC 0 iv z o c tc Return to Master TOC Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES T Section Factory Installed Options Accessories sis C 2 Field Installed Options Accessories C 2 MULTI SOURCE LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 B Return to Section TOC Return to Master TOC 2 2 5 ACCESSORIES FACTORY INSTALLED OPTIONS FIELD INSTALLED OPTIONS ACCESSORIES ACCESSORIES There are no factory installed options K1735 1 Multi Weld 350 Multi process controller K857 K857 1 Remote control Control multi weld remotely 25 or 100 ft
66. ads but each application would have to be tested The output is peak voltage regulated and at light resistive loads maximum ripple the average voltage deviates from peak voltage the most The Multi Weld 350 K1752 1 is the recommended means by which to control the Multi Source power sup ply Connections between Multi Source and Multi Weld may be easily made using Twist Mate male and female connectors and the K1736 1 distribution box The Multi Weld 350 has multi process capability and may be used with manual and semi automatic processes When a wire feeder is required an LN 25 K449 is recommended The Multi Source 40kW 36kW on 50Hz 80VDC buss power source K1752 1 is recommended for use in the Multi Weld system DESIGN FEATURES AND ADVAN TAGES 80 volt peak OCV 40 000 watts of output 36 000 watts on 50Hz at 10095 Duty Cycle 75 volts at 533 amps 75 8 volts at 475 amps on 50 Hz over 900 amps for 5 seconds without harming the machine The machine has copper windings and a varnish dipped transformer for added environmental protec tion Sealed external controls Voltage ratings have been upgraded and used with higher voltage MOVs Input lines are protected by the most rugged surge protection we ve ever used Indicator lights and digital display are extra bright to enhance visibility outdoors HP Cooling fan can operate on a wider range of voltage MULTI SOURCE LINCOLN Return to Section TOC Return to Ma
67. ain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc 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 CYLINDER
68. ake certain that plug J7 jumper plug is in place See Figure F17 and the wiring diagram Control Board NOTE To verify that the control board is sending the correct output enable signal to the firing board check from plug J8 pin 7 lead 340 to plug J5 pin 12 lead 215 See Figure 17 the wiring diagram Normal voltage is approximately less than 1 0 VDC If not correct the control board may be faulty 7 Locate LEDs 1 thru 6 Each LED should glow with equal brightness NOTE LEDs 1 through 6 indicate that the gate firing signals are being generated to send to each of the output SCRs 8 If LED 2 located on the control board is bright along with LEDs 7 8 and 9 on the Firing Board and LEDs 1 through 6 are unequal in brightness check to make sure lead 231 is not loose or broken See the wiring diagram Normal voltage range at plug J5 pin 13 lead 4231 to plug J5 pin 12 lead 215 is 3 to 13 VDC At an open circuit condition the normal voltage is approximately 10 VDC 9 If one or two of the LEDs 1 through 6 are dimmer or brighter than the others this could indicate an open or shorted gate on an output SCR Perform the Static and Active SCR Tests MULTI SOURCE LINCOLN F 37 F 37 TROUBLESHOOTING amp REPAIR FIRING BOARD TEST Continued TABLE F2 LED 7 8 and 9 Check List Return to Section TOC Return to Master TOC LED 7 is ON AC power is being supplied to t
69. al codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations MULTI SOURCE LINCOLN B Return to Master TOC Return to Master TOC 2 2 E 5 Return to Master SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan
70. an open switch As the name suggests the SCR is a rectifier so it passes current only during positive half cycles of the AC sup ply The positive half cycle is the portion of the sine wave in which the anode of the SCR is more positive than the cathode When an AC supply voltage is applied to the SCR the device spends a certain portion of the AC cycle time in the on state and the remainder of the time in the off state The amount of time spent in the ON state is controlled by the gate LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED An SCR is fired by a short burst of current into the gate This gate pulse must be more positive than the cathode voltage Since there is a standard PN junc tion between gate and cathode the voltage between these terminals must be slightly greater than 0 6 Once the SCR has fired it is not necessary to contin ue the flow of gate current As long as current contin ues to flow from anode to cathode the SCR will remain on When the anode to cathode current drops below a minimum value called holding current the SCR will shut off This normally occurs as the AC supply volt age passes through zero into the negative portion of the sine wave If the SCR is turned on early in the pos itive half cycle the conduction time is longer resulting in greater SCR output If the gate firing occurs later in the cycle the conduction time is less resulting in lower SCR output MULTI SOURCE LINCOLN Section
71. arefully apply input power turn on and make sure the input contactor 1CR ener gizes 5 Carefully test with an AC voltmeter for the proper main AC input voltage to the line side of the input contactor 1CR See Wiring Diagram See Figure F5 U to V VtoW U toW NOTE If proper voltage is not present in any or all of the three phases check input fuses and leads 5 Test with an AC voltmeter for proper main AC input voltage from the output side of TOP VIEW INPUT CONTACTOR the input contactor 1CR Diagram See Figure F 5 T1 to T2 T2 to T3 T1 to T3 a f the correct voltage is present the contactor is working properly See Wiring b If the correct voltage is not present for any or all of the three phases the con tactor may be faulty 6 Test with an AC voltmeter for approximate ly 97 VAC from each of the six main trans former secondary leads to the common buss connected to the negative output ter minal See Figure a f one or more of the above voltage tests are incorrect check for loose or faulty wiring If the wiring is good then the main transformer may be faulty NOTE A long wire with a clip or a long probe may be required to reach the lower middle lead MULTI SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 5 818 5 2 1 Return to Se
72. ary These are normally closed devices Also check associated leads for loose or faulty connections See the Wiring diagram The control board may be faulty The amber thermal light is lit The machine does not have welding output the fan does NOT run and the digital output display never reads a value greater than 100 Check the fan circuit breaker located on the front panel Reset if tripped The fan motor may be faulty Disconnect and test using an isolated 120VAC supply Check the leads 250 253 and 252 between the fan motor the circuit breaker and the control board See the Wiring Diagram Make certain the 120VAC fan voltage is being developed by the main transformer See the Main Transformer Test 4 Make sure the shunt and the output display are operating properly See Display CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 MULTI SOURCE LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 9 2 5 z INSTALLATION TROUBLESHOOTING GUIDE Observe Safety
73. ate the light is open and the control board circuit is operating correctly 18 This can be measured at Plug J1 pin 16 lead 232 to Plug J1 pin 15 lead 233 See Figure F 15 The yellow amber light located on the front panel will light if the open thermo stat secondary and SCR heat sink sig nal is sent to the fan control and output disable circuits The voltage on the two thermostat circuit is from 24VDC to 38VDC This voltage is dependent upon the input voltage applied to the Multi Source This voltage can be verified at Plug J1 pin 3 lead 263 to Plug J1 pin 11 lead 4264 This voltage will be pre sent if only one of the thermostats are open or an associated lead is disconnect ed See the Wiring Diagram Normal operating voltage for the amber light is about 2 2VDC A voltage reading of about 5 0VDC would indicate the amber light is open and the control board is supplying the correct signal This can be verified at Plug at Plug J1 pin 13 lead 4234 to plug J1 pin 12 lead 4235 This light voltage will normally be present ONLY when the thermostat circuit is open See the Wiring Diagram See Figure F 15 FIGURE F 15 Control Board with LED Plug and Lead Locations CONTROL BOARD 2 e a 232 234 SI 235 204 1 2224 LED 1 LED 7 6 MULTI SOURCE LINCOLN amp F 33 F 34 NOTES o
74. c tor to open until the iron cools 10 amp circuit breaker protects the 120VAC fan cir cuit This is located on the front panel of the machine and may be reset if tripped Return to Section TOC Return to Master TOC An independent safety circuit on the control board monitors the output voltage peaks and opens the input contactor if the upper limit is exceeded for over 300 ms If the output current of the machine should exceed the set limitations the control board will disable output for about 75 seconds 5 5 818 5 2 1 Return to Section TOC Return to Master TOC MULTI SOURCE LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC 5 5 gt 818 5 2 1 Return to Section Return to Master TOC Return to Master TOC E 6 E 6 TROUBLESHOOTING amp REPAIR FIGURE E 5 SCR OPERATION INPUT OUTPUT ee NOTE AS THE GATE ANODE SCR OPERATION A silicon controlled rectifier SCR is a three terminal device used to control rather large currents to a load An SCR acts very much like a switch When a gate signal is applied to the SCR it is turned ON and there is current flow from anode to cathode In the ON state the SCR acts like a closed switch When the SCR is turned OFF there is no current flow from anode to cathode thus the device acts like
75. cal troubleshooting assistance before you proceed Call 1 800 833 9353 MULTI SOURCE LINCOLN amp F 2 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES AND REPLACEMENT 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 sta tic shielding bag WARNING e ELECTRIC SHOCK can kill Have an electrician install and ser vice this equipment Turn the machine OFF before working on equipment Do not touch electrically hot parts Return to Section TOC Return to Master TOC e f the PC Board uses protective shorting jumpers don t remove them until installation is complete e f you return a PC Board to The Lincoln Electric Company for credit it must be in the static shield ing bag This will prevent further damage and allow roper failure analysis Sometimes machine failures appear to be due to PC y board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards 5 please use the following procedure 4 Perform any necessary PC Board calibration pro cedures See the flow chart on the next page Test the machine to determine if the failure symp tom has been corrected by the replacement PC
76. can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Mar 95 MULTI SOURCE LINCOLN B Return to Master TOC Return to Master TOC 7 iv gt c E tc Return to Master TOC 7 WELDING SPARKS lt 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 cert
77. cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines Ihe Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING 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 FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS _ may be dangerous 2 a Electric current flowing through any con
78. ce bat tery if voltage is less than 4 5 volts A Connect SCR into the test circuit as shown A lead to anode C lead to cath ode and G lead to the gate Close switch SW1 switch SW2 should open voltmeter should read zero If the voltmeter reads higher than zero than the SCR is shorted NOTE Do not disassemble the heat sinks 8 With switch SW1 closed close switch SW2 for two seconds and release The 10 11 12 18 voltmeter should read 3 to 6 volts before and after switch SW2 is released If the voltmeter does not read or reads only while SW2 is depressed the SCR or bat tery is defective repeat battery Test Procedure Open switch SW1 disconnect the gate lead G and reverse the A and C leads on the SCR Close switch SW2 The volt meter should read zero If the voltage is higher than zero the SCR is shorted Replace any SCR assembly that does not pass test When test is completed reconnect the positive bridge leads to the shunt Reconnect Plug J4 into the Firing Board Replace the case top sides and control panel MULTI SOURCE LINCOLN F 30 NOTES o A 901 Je1Se A 0 901 Je1Se A 0 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH F 30 DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC Return to Ma
79. ction TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 25 F 25 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD TEST DESCRIPTION The active SCR Test will determine if the device is able to be gated ON and conduct current from anode to cathode MATERIALS NEEDED An SCR Tester as outlined in this procedure Analog Volt Ohm Meter Multimeter MULTI SOURCE wiring diagrams See Electrical Diagram Section of Manual 3 8 Nut Driver 9 16 Wrench This procedure takes approximately 45 minutes to perform MULTI SOURCE LINCOLN F 26 F 26 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST Continued 1 Remove main supply power to the Multi 3 Low
80. ction TOC Return to Master TOC F 19 7 Test for 120 VAC between leads 250 to 251 See Figure F6 See Wiring Diagram a F 19 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 6 Main Secondary Lead Test Points Transformer Secondary Leads Lift Bail ZN 77 N MOSS m SS 547 Y gt V n Transformer Assembly Phase Angle Winding Test Points Common Buss 251 9 Test with voltmeter for 32 VAC for each phase angle winding as shown See If the 120 VAC is not present check for loose or faulty wiring If necessary untape and track the continuity of leads 250 and 251 through the entire harness See the Wiring Diagram If the wiring is good and the 120 VAC is not present then the main trans former may be faulty NOTE the main supply voltage varies the Main Transformer voltages will vary proportionately 10 Be sure to replace any and all insulation materials that were removed for testing purposes 11 Replace roof and sides of case cover MULTI SOURCE LINCOLN F 20 NOTES o A 901 Je1Se A 0 901 Je1Se A 0 uunjeH 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH F 20 DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Re
81. diagram is for reference only may not be accurate for all machines covered by this manual wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine Return to Section TOC Return to Master TOC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 5 818 5 2 1 Return to Section Return to Master TOC G 3 ELECTRICAL DIAGRAMS G 3 SCHEMATIC CONTROL PC BOARD LINCOLN ELECTRIC POS STUD 1 02 LEO 600V C28 033 200V PEAK DETECT OCV TRIM NEG 10 EQUALS BOVREF cw 80V ON NEG STUD sc RTT R78 10K R24 222 SIL NEG STUD 5 Sit CURRENT FEED BACK CAP OPTIONAL 500 R49 DIGITAL GAIN 30 AMPLIFIER AND FILTER REV 301K R52 100K NEG 10 gt 215 POS STUD DUTPUT VOLT PEAK DETECT SET AT 105V NEG STUD 099 PER 500 5 SHUNT 800 50
82. ductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in posi tion 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 All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety rd 3 de minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with ta
83. ectric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 MULTI SOURCE LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE OUTPUT PROBLEMS SYMPTOMS The amber thermal light is lit The machine does not have welding output the fan runs and the digital output display reads a value greater than 100 Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS The machine is being over loaded and thus overheated Reduce the load to conform to the rated output limits of the Multi Source machine See the Technical Specifications RECOMMENDED COURSE OF ACTION The amber thermal light is lit The machine does not have welding output and the fan runs The dig ital output display reads a value greater than 100 The machine may be internally clogged with dirt and dust Clean the machine with clean dry compressed air The cooling vents may be obstructed or blocked The ambient cooling air may be too hot The secondary lead thermostat or SCR heat sink thermostat may be faulty Check and replace if necess
84. er the front control panel and remove Source Plug J4 from the Firing Board See Figure 2 Remove the roof and case sides rag Return to Section TOC Return to Master TOC FIGURE F 10 FIRING BOARD LED amp PLUG LOCATIONS FIRING BOARD Return to Section TOC Return to Master TOC gt Il IE IE IE IE J5 SES J6 ATE 5 sp tr se 2 J7 2 p trx gt 25 IE IE J8 IE 25 gt J4 515 818 JE 2 1 Return to Section Return to Master TOC MULTI SOURCE LINCOLN amp F 27 F 27 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST Continued 4 Using a 9 16 wrench remove the two positive output leads connecting the out put bridge to the shunt See Figure F 11 This will partially electrically isolate the SCR bridge for testing purposes See the Wiring Diagram Return to Section TOC Return to Master TOC FIGURE 11 Shunt and Lead Connections Return to Section TOC Return to Master TOC 5 5 818 5 2 1 Return to Section TOC Return to Master TOC MULTI SOURCE LINCOLN amp F 28 F 28 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST Continued FIGURE F 12 SCR Heat Sink Test Points Return to Section TOC Return to Master TOC Hemove Hed
85. everal thermostats This feedback information is processed by the control board The control board then sends the appropriate gate firing signals to the firing board output informa tion to the digital meter and command signals to the MAIN TRANSFORMER DIGITAL METER LED LED LED WORK TERMINAL FILTER CAPACITOR LIMITING RESISTOR BS ELECTRODE TERMINAL TO CONTROL BOARD TO CONTROL GATE SIGNALS BOARD FIRING BOARD CONTROL SIGNAL cooling fan motor and the input contactor The cooling fan is controlled by the control board The FE A N fan as needed will be activated with an output current greater than 20 amps It can also be activated via the control board by a thermostat located on the main transformer iron A current sensing circuit on the control board controls the digital meter display This meter provides the user with an indication of the percentage of available power that is being drawn from the Multi Source There are three indicator lights located on the front panel of the Multi Source The green safe output light indicates when the machine s output voltage is within the safe operating range Other indicator lights include the amber thermal light that indicates the ther mostat located on the negative output lead has opened due to an over temperature condition The white power light indicates when the control board is energized MULTI SOURCE LINCOLN
86. fety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Remove all external welding cables from the Multi Source machine If the open circuit voltage 75 80VDO is present and constant at the output ter minals there may be a short circuit external to the Multi Source Check the welding cables and the Multi Weld machines If the problem is not resolved with the welding cables removed there is a fault within the Multi Source machine RECOMMENDED COURSE OF ACTION 1 Check all heavy current carry ing leads within the Multi Source for possible shorting conditions See the Wiring Diagram 2 Perform the SCR Rectifier Bridge Test 3 Perform the Control Board The Multi Source has momentary output only The green light is OFF and the input contactor opens Check the three phase input voltage Make certain it is not too high for the machine s rat ing and the reconnect panel configuration Check the output filter circuit resistor R9 capacitor C3 and leads 222C 292 294B See the Wiring Diagram Check the voltage feedback leads 215B and 222A for loose or faulty connections See the Wiring Diagram 3 Perform the SCR Rectifier Bridge Test 4 Perform the Control Board CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln El
87. filter and cover 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 787 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 9 FUMES AND GASES can 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
88. ge to the shunt See Figure F 27 Using a 1 2 nut driver disconnect the six copper transformer secondary leads con nected to the SCR bridge from the main transformer Three leads are located on the top and three on the bottom See Figure F 27 Using a 3 8 nut driver remove the right bolt mounting the SCR bridge to the front assembly The bolt is located below the control board See Figure F 28 Cut any necessary cable ties Using a 1 2 nut driver remove the two mounting bolts on the right side of the machine mounting the SCR bridge to the main transformer 1 2 Bolts RIGHT SIDE 11 12 Using a 9 16 nut driver remove two bolts covered in red insulating paint on the left side of the machine only These two bolts are located above leads 301 and 264 Note position of insula tion nut bushing and washer placement upon removal See Figure F 26 Locate label and remove lead 251 from main transformer The solder connection must be broken to disconnect See Figure F 27 MULTI SOURCE LINCOLN amp F 55 F 56 F 56 TROUBLESHOOTING amp REPAIR SCR BRIDGE HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE FIGURE F 28 Mounting Bolt Return to Section TOC Return to Master TOC Firing Board Return to Section TOC Return to Master TOC Mounting Bolt 13 Clear all leads and carefully maneuver SCR bridge out of the right side of the machine NOTE Upon reassembly apply a thin layer
89. he Firing Board from leads 283 and 284 connected through the resistor bank to the phase angle winding in the Main Transformer See Figure F 17 Normal voltage at leads 283 to 284 is 25 LED 7 is OFF or is DIM The proper AC voltage may not be reaching the Firing MER than other LEDs Board Check for loose or faulty connections Main Transformer Test Also check resistors R3 and R4 located in the resistor bank Normal resistance is 50 ohms LED 8 is ON AC power is being supplied to the Firing Board from leads 285 and 286 connected through the resistor bank to the phase angle winding in the Main Transformer See Figure F 17 Normal voltage at leads 285 to 286 is 25 Return to Section TOC Return to Master TOC LED 8 is OFF or is DIM The proper AC voltage may not be reaching the Firing MER than other LEDs Board Check for loose or faulty connections Perform Main Transformer Test Also check resistors R5 and R6 located in the resistor bank Normal resistance is 50 ohms LED 9 is ON AC power is being supplied to the Firing Board from leads 287 and 288 connected through the resistor bank to the phase angle winding in the Main Transformer See Figure F 17 Normal voltage at leads 287 to 288 is 25 Ojo O10 515 818 5 2 1 LED 9 is OFF or is DIM The proper AC voltage may not be reaching the Firing MER than other LEDs Board Check for loose
90. he contactor does NOT activate then the input contac tor coil may be faulty or the contactor s moving parts may be stuck The normal coil resistance is approximately 4 0 ohms If the 1 amp DC current is NOT present check the continuity of the leads between the contactor and the control board See the Wiring Diagram The contactor may also be tested by dis connecting leads 240 and 241 from the coil and applying an external 120VAC sup ply to the contactor coil The contactor should activate MULTI SOURCE LINCOLN F 15 F 15 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST Continued FIGURE F 4 INPUT CONTACTOR TEST CONNECTIONS Return to Section TOC Return to Master TOC Test Points Test Points Test Points Return to Section TOC Return to Master TOC TEST FOR CONTACT Figure F4 the resistance is high the input contactor is faulty Replace the input CONTINUITY Cor 1 Disconnect the main input supply power to 5 When the contactor is NOT activated the the machine resistance should be infinite or very high 2 Remove the two leads connected to the across the contacts the resistance is input contactor coil 240 and 241 low the input contactor is faulty Replace Figure location the input contactor See Input Contactor Removal and Replacement Procedure 3 Using the external 120VAC supply apply 120VAC to the leads of the input contactor 6 Reconnect any leads previously removed
91. ight is on the output voltage is within it designed operating range e SELECT PROPER LOCATION Place the power supply where clean cooling air can freely circulate in through the front louvers and out through the rear louvers Dirt dust or any foreign mate rial that can be drawn into the welder should be kept at a minimum Failure to observe these precautions can result in excessive operating temperatures and nui sance shut downs STACKING WARNING FALLING EQUIPMENT can cause injury Two Multi Source machines can be stacked Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Do not stack more than two high Do not stack the Multi Source on top of any other machine Two MULTI SOURCE machines can be stacked Follow these guidelines when stacking 1 Select a firm level surface capable of supporting the total weight of up to two machines 1984 pounds 901 kilograms 2 Set the bottom machine in place 3 Stack the second machine on top of it by aligning the two holes in the base rails on the second machine with the two pins on top at the front of the bottom machine Note The machines must be stacked with the Case Front of each machine flush with each other See Figure A 1 below STACKING HOLE STACKING PIN FIGURE A 1 Stacking the MULTI SOURCE TILTING The MULTI SOURCE must be placed on a stable level surface so it will not top
92. ircuit Voltage Return to Section TOC Return to Master TOC RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT HERTZ VOLTAGE COPPER COPPER WIRE IN WIRE IN 380 415 460 50 60 O 9 o 9 575 60 E D iv gt o 52 5 PHYSICAL DIMENSIONS HEIGHT DEPTH NET WEIGHT 30 8 in 41 992 lbs 781 mm 1040 mm 450 5 kg TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 40 to 122 F 40 to 185 F 40 to 50 40 10 85 Return to Section Return to Master TOC MULTI SOURCE LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 A 3 A 3 INSTALLATION Read entire Installation Section before installing the MULTI SOURCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts The Multi Source power supply should not be used if the green Safe Output light is not lit The machine is designed to open its input contactor if output voltage peaks exceed the limits set by certain approval agencies If the Safe Output l
93. l 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 tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct voltage is being induced on the secondary winding of the control transformer MATERIALS NEEDED Volt Ohm Meter Multimeter MULTI SOURCE wiring diagrams See Electrical Diagram Section of Manual 3 8 Nut Driver This procedure takes approximately 30 minutes to perform MULTI SOURCE LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 5 818 5 2 1 Return to Section TOC Return to Master TOC F 10 TEST PROCEDURE 1 10 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST FIGURE 1 CONTROL TRANSFORMER LOCATION amp LEADS Control Transformer T2 X1 H2 SS gt X3 4 Locate the Control Transformer primary leads H1 amp H2 See Wiring Diagram See Disconnect main AC input power to the Figure F 1 machine 5 Locate control transformer terminals X1 and 2 Remove the Top and Right case side X3 See Figure F 1 3 Locate the Control Transformer T2 on the left side of the input box facing the
94. lt Ohm Meter Multimeter MULTI SOURCE Wiring Diagram and Firing Board Schematic Diagram See Electrical Diagram Section of Manual This procedure takes approximately 30 minutes to perform MULTI SOURCE LINCOLN F 36 F 36 TROUBLESHOOTING amp REPAIR FIRING BOARD TEST Continued FIGURE F 16 FIRING BOARD LOCATION Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 2 Return to Section Return to Master TOC 2 D 2 5 z Firing Board TEST PROCEDURE FOR NORMAL FIRING BOARD OPERATION 1 Disconnect main AC input power to the machine 2 Remove screws loosen and lower the front panel to access the firing board on the left side of control box while facing the machine See Figure F 16 3 Visually inspect the Firing Board for loose or faulty connections and obvious physi cal damage WARNING Electric Shock can kill With the input power there are high voltages inside the machine Use caution when reaching into the machine or touching any internal part of the machine while the power is on High voltage is present 4 Reconnect the input power and turn the MULTI SOURCE on 5 Locate LEDs 7 8 9 on the Firing Board See Figure F 17 Each LED should be ON and equally bright Use Table F2 to check LED operation 6 M
95. may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition B Always keep cylinders in an upright position 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 Oylinders 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 loc
96. o 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 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 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY SNUBBER L clevt IN REQ D IDENTIFICATION C7 C8 T11577 46 05 600V TP7 8 T13640 18 160J Return to Section TOC Return to Master TOC 7 Return to Section TOC Return to Master TOC C8 TP8 o OUTPUT SNUBBER O10 515 gt 818 5 2 1 CAD LINCOLN ELECTRIC CO TRANSFORMER WELDERS LL CLEVELAND OHIO USA OUTPUT SNUBBER BD ASSEMBLY SCALE FULL SHT DATE 8 18 92 CHK REF SUP S D G NO M 14312 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 Indi
97. of Lincoln Electric T12837 Dow Corning 340 heat sink compound to all bolted electrical connections on the alu minum heat sinks CAUTION UPON REASSEMBLY THE SCR BRIDGE ASSEMBLY MUST BE ELECTRICALLY ISOLATED FROM GROUND MINIMUM ACCEPTABLE RESISTANCE TO GROUND IS 500K OHMS Ojo E 515 818 5 2 1 Return to Section Return to Master TOC MULTI SOURCE LINCOLN amp F 57 F 57 TROUBLESHOOTING amp REPAIR SCR BRIDGE HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE FIGURE 29 Individual Heatsink Removal 2 2 Return to Master Positive Assembly SCR Bridge Anode olo Assembly Heatsink 5 5 Cathode 3 Heatsink 2 218 SCR Assembly ES Mounting Studs Dlo aja REMOVAL OF INDIVIDUAL INSTALLATION OF INDIVIDUAL SCR HEAT SINK ASSEMBLIES SCR HEAT SINK ASSEMBLIES e e 1 Using a 9 16 nut driver remove the nuts NOTE Upon reassembly apply a thin layer of c E and respective washers securing the posi Lincoln T12837 Dow Corning 340 8 tive buss bar position Remove buss heat sink compound to all bolted elec bar See Figure F 29 trical connections on the aluminum heat sinks including positive buss bar 212 2 Using a 9 16 nut driver remove the nut and respective washers securing the snub 1 Carefully position new SCR assembly
98. onal warning information at the front of this operators manual MULTI SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Ojo O10 515 818 5 2 1 Return to Section Return to Master TOC Return to Master TOC B 3 OPERATION GENERAL DESCRIPTION The Multi Source is designed to supply power to the Multi Weld welders It has a wide range three phase AC input and can be operated on 50 or 60 Hz The Multi Source output peak voltage regulates against wide changes in output loading and input line voltage variations to supply a consistently stable voltage high enough to allow the Multi Welds to provide good man ual electrode capability Primary input voltage taps are selected by a single movable link on the reconnect panel Main transformer auxiliary windings power the firing circuit and fan motor The control auxiliary transformer has a single wide range primary and is not reconnectable The Fan As Needed feature is activated by an output current of 20 amps DC or a thermostat on the main transformer iron An independent safety circuit on the Control board monitors the voltage peaks and opens the input con tactor if the limit is exceeded The green Safe Output light indicates when the machine output voltage is with in the safe operating range Other indicator lights include the amber Thermal light that signals when the long term
99. ons in out put loading and or variations in input line voltages This ability provides for a consistently high stable volt age applied to the Multi Welds so as to provide good manual electrode welding capability INPUT VOLTAGE FILTER CONTAC TOR AND CONTROL TRANS FORMER The desired three phase power is connected to the Multi Source via a reconnect panel located in the input box at the rear of the machine The reconnect panel allows the user to configure the machine for the desired input voltage The three phase input power is also applied to a filter assembly that is located in the input box Two phases of the input voltage are applied to the T2 control transformer The control transformer has a single primary to secondary ratio no taps that spans the full input range up to 600VAC The sec ondary voltage developed on the secondary of the control transformer is applied to the control box full wave bridge rectifier via a thermostat and the input power switch The input contactor which is activat ed and controlled by the control board applies the three phase AC input voltage to the primary windings of the T1 main transformer NOTE Unshaded areas of Block Logic Diagram are the subject of discussion MULTI SOURCE LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo 515 gt 818 5 2 1 Return to Section Re
100. or faulty connections Main Transformer Test Also check resistors R7 and R8 located in the resistor bank Normal resistance is 50 ohms Return to Section TOC Return to Master TOC MULTI SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC 5 5 a 818 5 2 1 Return to Section TOC Return to Master TOC Return to Master TOC iid TROUBLESHOOTING amp REPAIR FIRING BOARD TEST Continued FIGURE F 17 FIRING BOARD PLUG amp PIN LOCATIONS FIRING BOARD o r a a OgO amp uOCu l m 3333333 3 77977797 LED3 LED J FR lt gt oa 7997 MULTI SOURCE LINCOLN amp 231 215 340 287 F 38 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 39 F 39 TROUBLESHOOTING amp REPAIR MULTI SOURCE METER ACCURACY CHECK WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For you
101. output current limit has been exceeded This limit is determined by a thermo stat sensing the temperature of the negative output lead from the secondary coils The white Power light indicates when the Control board is energized The three lights are high intensity LEDs for improved visi bility in daylight The Output Power display uses high intensity LEDs to indicate the percentage of full rated output the machine is supplying Two additional thermostats protect the machine in the case of fan failure or blocked air flow The SCR heat sink thermostat responds first to loss of air flow at nor mal output loads This thermostat will disable the machine output The transformer iron rear thermostat senses that the lamination and thus the coil insulation is over heating which can happen even if the output is disabled This thermostat will interrupt power to the Control board causing the input contactor to open until the iron cools The only user controls are an on off toggle Power switch that energizes the machine and a 10 A cir cuit breaker protecting the fan auxiliary against short circuits RECOMMENDED EQUIPMENT PROCESSES The only recommended use for the Multi Source is to power the Multi Weld welders It is conceivable that the machine could be used as a constant voltage DC power supply up to its rating of 40 000 watts 36 000 watts on 50Hz output Its output is stable with a wide range of inductive resistive and capacitive lo
102. pe when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the idler by pushing on the throttle control rods while the engine is running 2 4 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 4 4 Connect the work cable to the workpiece as close as possible to the area being welded 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 2 d 5 Do not work next to welding power source Mar 95 MULTI SOURCE LINCOLN Return to Master TOC Return to Master TOC 0 iv z o c tc Return 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
103. pique le laitier 6 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 levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES
104. ple over ELECTRICAL INPUT CONNECTIONS Before installing the machine check that the input sup ply voltage phase and frequency are the same as the machine s voltage phase and frequency as specified on the machine s rating plate on the Case Front Assembly Control Panel Connect input power supply by removing the rear access panel and connecting to the three line terminals on the input panel See Figure A 2 for location of the machine s input cable entry opening and reconnect panel assembly for dual volt age machines Rear Panel 09 KO KO FIGURE A2 Input Power Supply Connection MULTI SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC E 515 818 5 2 1 Return to Section Return to Master TOC Return to Master TOC A 4 A 4 INSTALLATION FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the page of this manual for the machine being used They are also called inverse time or ther mal magnetic circuit breakers DO NOT use fuses or circuit breakers with a lower amp rating than recommended This can result in nuisance tripping caused by inrush current even when machine is not being used for welding at high output currents Use input and grounding wire sizes that meet local electrical code
105. r 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 tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD TEST DESCRIPTION This procedure will aid the technician in checking and calibrating the meter display MATERIALS NEEDED DC ammeter and meter grade shunt 196 accuracy Resistive load bank and or Multi Weld machines This procedure takes approximately 30 minutes to perform MULTI SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 40 F 40 TROUBLESHOOTING amp REPAIR MULTI SOURCE METER ACCURACY CHECK Continued METER ACCURACY CHECK 1 With power off connect a resistive load and the meter grade shunt to the output terminals Use either a resistive grid multisource welders or a combination of both 2 Turn machine on 3 Adjust the resistive load to approximately 533 amps DC as read by the DC ammeter via the meter grade shunt 4 The Multi Source digital display should read approximately 100 5 f the res
106. s or see the Technical Specifications page in this manual INPUT AND GROUNDING CONNECTIONS Note A qualified electrician should connect the input power supply leads Input conductor is brought into the machine input box area through a hole in the rear panel sized to accom modate 2 trade size conduit and fittings This is more than adequate for the largest conductors required Conductors must be lugged to attach to the three 3 8 studs on the input reconnect panel and the 5 16 ground stud marked with the symbol The input volt age supplied determines the position required for the reconnect panel jumper The three ranges on the stan dard machine are 380 415 440 460 and 550 575 The machine is rated for 50 and 60 Hz operation See the Input Connection Diagram located on the inside of Case Back Input Access Door The conductor and fuse sizes in the Specification Section are per the National Electrical Code The sizes are in American Wire Gauge and the next largest standard metric size National and local codes must be consulted before connecting a machine Protect the input circuit with the super lag fuses or delay type circuit breakers listed in the Specification Section They are also called inverse time or thermal magnetic circuit breakers RECONNECT PROCEDURE Multiple voltage machines are shipped connected to the highest input voltage listed on the machine s rating plate Before installing
107. ster TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 31 F 31 TROUBLESHOOTING amp REPAIR CONTROL BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD TEST DESCRIPTION This test will determine if the control board is receiving the correct voltages and feedback signals MATERIALS NEEDED Volt Ohm Meter Multimeter MULTI SOURCE wiring diagrams See Electrical Diagram Section of Manual This procedure takes approximately 45 minutes to perform MULTI SOURCE LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 D
108. ster TOC Return to Section TOC Return to Master TOC 515 818 5 2 1 Return to Section Return to Master TOC B 4 B 4 OPERATION RECOMMENDED EQUIPMENT CONNECTIONS The Multi weld 350 K1735 1 is the recommended means by which to control the MULTI SOURCE power supply Connections between the MULTI SOURCE and the Multi weld may be easily made using Twist Mate male and female connectors and the K1736 1 Distribution box Twist Mate Male Connector K852 70 For 1 0 Cable Twist Mate Female Connector Mate Female Connector K1759 70 Twist Mate Male Connector K852 90 For 3 0 Cable Twist Mate Female Connector Mate Female Connector K1759 90 The Multi weld 350 has multi process and may be used in manual and semi automatic processes When a wire feeder is required an LN 25 K449 is recommended The number of Multi Weld 3505 the procedures used and the combined duty cycle of the arcs are only limited by the 40 000 watt 36 000 watts on 50 Hz rating of the Multi Source supply The machine is IP 23S rated and is designed for outdoor applications CONTROLS AND SETTINGS All operator controls and adjustments are located on the Case Front Assembly of the MULTI SOURCE See Figure B 1 below for the location of each control o Output Thermal Power FIGURE B 1 CONTROL PANEL 1 ON OFF
109. t The Multi Source operates but does NOT have maximum welding output 40 000 watts on 60 Hz 36 000 watts on 50HZ Check all three phases of the input voltage at the Multi Source machine Make sure the input voltages are present and match the machine s rat ing and reconnect panel con figuration Check for loose or faulty weld ing cables 1 Perform the Main Transformer T1 Test 2 Perform the SCR Rectifier Bridge Test 3 Perform the Input Contactor Test 4 Perform the Firing Board Test 5 Perform the Control Board Test 6 The output shunt may be faulty See Calibration Procedure CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 MULTI SOURCE LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 z F 6 F 6 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE OUTPUT PROBLEMS SYMPTOMS The Multi Source has only momentary output after the input contactor activates Output returns momentarily approximately every 75 seconds Observe Sa
110. t time the SCR will turn on and conduct cur rent The amount of ON timer versus OFF time determines the output of the machine SCR A capacitor filter and resistor are connected across the output leads on the Multi Source This is required to reduce and limit the output voltage peaks The capac itor ripple current greatest with light resistive loads is limited by the resistor 515 gt 818 2 1 Return to Section Return to Master TOC MULTI SOURCE LINCOLN amp E 5 TROUBLESHOOTING amp REPAIR PROTECTION DEVICES AND CIR CUITS Several thermostats protect the Multi Source from over temperature and or excessive loading High transformer watts could cause the main transformer to over heat so the cooling fan is activated if a thermo stat located on the front of the main transformer iron should open Return to Section TOC Return to Master TOC Two additional thermostats connected in series pro tect the machine in case of fan failure or blocked air flow at normal output loads The opening of either the secondary or SCR heat sink thermostat s will disable the machine s output and cause the amber thermal light to glow The thermostat located at the rear of the main trans former iron senses the lamination temperature and thus the coil insulation temperature and will interrupt power to the control board causing the input conta
111. tegories Output Problems and Function 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 wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points components terminal strips etc can be found on the referenced 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 contact the Lincoln Electric Service Department for electri
112. ter TOC o 5 B Return to Section TOC Return to Master TOC 2 2 5 F 14 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST Continued FIGURE F 3 INPUT CONTACTOR CONNECTIONS 240 CONTACTOR 241 COIL Disconnect the main input supply power to the machine With the 3 8 nut driver remove the case top and the left case side Locate the two leads connected to the input contactor coil 240 and 241 See Figure F3 for location Note The discon nects may be located inside the loom lead covering Connect a DC ammeter to either lead 240 or 4241 WARNING 0 Electric Shock can kill With the input power on there are high voltages inside the machine Do not reach into the machine or touch any internal part of the machine while the power is on High voltage is present at terminals 5 Carefully apply the correct voltage to the machine and turn the power switch S1 ON CONTACTOR 1CR CONTACTS CONTACTOR COVER 6 Check for approximately 1 amp of current flow at the contactor coil This current is supplied by the Control Board NOTE The pull in coil current is designed to be about 5 amps for 100ms occurring about one second after the power switch is closed Without this current pulse the contactor will not activate If the current is present and t
113. the machine check that the Reconnect Panel in the Input Box Assembly is con nected for the proper voltage A CAUTION Failure to follow these instructions can cause immedi ate failure of components within the machine To reconnect a multiple voltage machine to a different voltage remove input power and follow the input Connection Diagram located on the inside of the Case Back Input Access Door This connection diagram is shown below FIGURE A 3 Input Connection Diagram 550 575V Connection A WARNING All input power must be electrically discon nected before touching reconnect panel Mount the movable reconnect bar to the stationary reconnect panel as shown and secure firmly with the three hex nuts provided Connect L1 L2 and L3 input supply lines to the input side of the recon nect panel as shown Connect terminal marked to ground per national electrode code MULTI SOURCE LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 INSTALLATION OUTPUT CONNECTIONS The Multi Source has two parallel connected output studs for positive and negative connections Each one is rated to carry the full output current For its maximum rated current at 100 duty cycle a minimum size of 4 0
114. turn to Master TOC E 3 E 3 TROUBLESHOOTING amp REPAIR FIGURE MAIN TRANSFORMER CONTROL BOARD COOLING FAN MOTOR amp LEDs SURGE NOISE FILTER INPUT CONTACTOR CONTROL TRANSFORMER THERMOSTAT SWITCH CONTROL FAN VOLTAGE BOX RECTIFIER CONTACTOR MAIN TRANSFORMER CONTROL BOARD COOLING FAN MOTOR DIGITAL METER AND INDICATOR LIGHTS LEDs The main transformer changes the high voltage low current input power to a lower voltage higher current output The finishes or neutrals of the main sec ondary coils are connected together and the six starts of the secondary windings are connected to the SCR output rectifier assembly In addition the main trans former has an isolated 120VAC nominal winding the supplies 120VAC via the control board to operate the cooling fan motor The three isolated 32VAC nominal phase angle windings are also housed in the main transformer assembly These windings provide power and timing information to the firing board The control board receives a widely varying DC volt age from the control box rectifier The switching power supplies that are housed on the control board supply DC current to the control circuits and the input contactor The control board receives current feed back information from the output shunt voltage feed back information from the output terminals and tem perature information from s
115. turn to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section Return to Master TOC 2 2 5 F 21 F 21 TROUBLESHOOTING amp REPAIR STATIC SCR TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 800 833 9353 WELD TEST DESCRIPTION The Static SCR Test is a quick check to determine if an SCR is shorted or leaky See machine waveform section for normal and abnormal output waveforms MATERIALS NEEDED Analog Volt Ohm Meter Multimeter MULTI SOURCE wiring diagrams See Electrical Diagram Section of Manual 3 8 Nut Driver 9 16 Wrench This procedure takes approximately 45 minutes to perform MULTI SOURCE LINCOLN F 22 F 22 TROUBLESHOOTING amp REPAIR STATIC SCR TEST
116. ult is satisfactory the the test is over and the machine may be reassembled If the required results are not obtained proceed to the next sec tion PROCEDURE TO RECALIBRATE IF METER IS OUT OF RANGE If the measured current is within the acceptable cur rent range approximately 533 amps DC and the Multi Source digital display does not read approxi mately 100 then the meter must be recalibrated The Multi Source digital display is controlled by a current sensing circuit on the Control board The display should read 100 when the machine output is a little over 40 kW To adjust the digital meter trimmer resis tor R49 on the Control board may be adjusted See Figure F 18 for location of R49 trimmer If the meter can not be calibrated using this procedure then the Control board or the output shunt may be faulty See the Wiring Diagram Note The output shunt is rated at 50 mv Q 800 A FIGURE F 18 R49 TRIMMER as as as J as s ER s P ER gt P SR P J Control Board MULTI SOURCE LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BS 5 8 Return to Section 2 2 5 Return to Master
117. unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 Return to Section TOC Return to Master TOC MULTI SOURCE LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Et 8 Return to Section Return to Master TOC 9 2 5 z F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE OUTPUT PROBLEMS SYMPTOMS The white power light is lit and the input contactor activates but there is no welding output The amber thermal light is NOT lit Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Check the welding cables for loose or faulty connections Make certain the Multi Weld s are connected and operating properly Check at the output terminals of the Multi Source for approximately 75 80VDC open circuit voltage If this voltage is present the problem is most likely external to the Multi Source machine RECOMMENDED COURSE OF ACTION 1 Perform the Firing Board Test 2 Perform the Control Board Test 3 Perform the SCR Rectifier Bridge Test 4 Perform the Main Transformer T1 Test 5 Perform the Input Contactor Tes
118. vidual 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 5 gt 818 5 2 1 Return to Section TOC Return 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 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

Lincoln Electric MULTI-SOURCE SVM155-A User's Manual

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