Lincoln Electric MULTI-SOURCE IM692 User's Manual
Contents
1. 104 S siu p UO JALLO31OHd TOYLNOD BEKI W3WHOJSNVH L dsva WJ3QT3M LNdNI IVLSOWYSHL HOS AM M x NOILHASNI WO33 SHOLOANNOOD 45913 Yad SIOSWAS WO bat x3 00000 6960 2000 y 9 6 01 9 ges 9 E SC e 3009 91419313 IVNOLLVN Hd GNNOYS WALSAS got NOLLO3NNOO ASLb 08E 57100 ASVWIHd OL Q O QV31 038 ege 2101 NOLLO3NNOO Id 10 1 02 2 irs N kee ch eech EN c EN CIN lt LW 9N lt e lt 9N lt o SW lt lt SIV YALA LNdLNO TE Vv CES oh 1331 9 vv vez Lo sez gt A oez DH ve M L YAWYOASNVEL 092 804 NOLLO3NNOO AGZS 0SS 2 ae NONI HONN ULI uvas ue 2 ZOE LN 1OH1LNO9 162 0 0 is HOLIMS2. doremi e dein ae A 2 LOCATION EM A 2 SLACKING Em A 2 Input and Grounding Connections A 2 Output Cable Connections and Limitations A 3 Recommended Equipment and Processes AAA A 3 A 3 Recommended Equipment Interface A 3 Equipment Limitations oec crea de dee nro ae tin A 3 Distribution BOX L A 3 Pig Tail Leads and Connections ss A 3 ecu Section Additional Safety Precautions B 1 General Description sise B 1 Design Features All Models nennen nennen nnne 1 Specifications Design Features and Achyamtages B 1 ucc ln Section C Factory Installed Options Accessories C 1 Field Installed Options Accessories C 1 Maintenance Section 0 Safety Precautions 1 D 1 Routine and Periodic D 1 Machine Calibration Specification TroubleShooting mmee Safety ee redit ita et ba d een ERR LED How to Use Troubleshooting
3. Ss ool Gaul FAS AAT ETS BEHE alal d aul d al Gail guet agil g Ca L LINCOLN 5 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
4. M October 2000 For use with machines Code 10668 Safety Depends on You Lincoln arc welding equipment is designed and built with safety in mind However your overall safety can be increased by proper instal lation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful Date of Purchase Serial Number Code Number Model Where Purchased BS OPERATOR S MANUAL 2 42 2 4 ES EE LI NCOLN Copyright 2000 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJ
5. 36kW 50Hz 80VDC buss power source K1752 1 is recommended for use in the Multi Weld system The number of Multi Weld Converters that may be connected to a single Multi Source Power Source is determined by the following formula Power Source Volts x Amps capacity gt 1 1 x Sum of Converters Volts x Amps arcs RECOMMENDED EQUIPMENT INTERFACE The Multi Weld 350 K1752 1 is the recommended means by which to control the Multi Source power supply 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 manual and semi automatic processes When a wire feeder is required an LN 25 K449 is recommended EQUIPMENT LIMITATIONS 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 50 2 watt rating of the Multi Source supply The machine is IP 23S rated and is designed for outdoor applications DISTRIBUTION BOX The Multi Weld Distribution Box K1736 1 is avail able 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 distribution or daisy chain inter connection to other boxes Four pig tail leads see below are incl
6. 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 voltage supplied determines the position required for the reconnect panel jumper The three ranges on the standard 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 Technical Specification Section A 1 are per the 1999 National Electrical Code The sizes are in American Wire Gauge and the next largest standard metric size in 2 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 Technical Specification Section A 1 They are also called inverse time or thermal magnetic circuit breakers Use of fuses or circuit breakers with a lower amp rat ing than recommended can result in nuisance tripping caused by inrush current even when machine is not being used for welding at high output currents Machines may be paralleled for increased output 520428 Paralleling Kit permits paralleling of two Multi Source power supplies for supplying currents of up to 1000 amps 100 duty cycle MULTI SOURCE LINCOLN 5
7. 3 INSTALLATION A 3 OUTPUT CABLES CONNECTIONS AND LIMITATIONS The Multi Source has two parallel connected output studs for positive and negative connections Each one is rated to carry the full output current For its maxi mum rated current at 100 duty cycle a minimum size of 4 0 AWG 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 output 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 RECOMMENDED EQUIPMENT AND 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 50 2 output Its output is stable with a wide range of inductive resistive and capacitive loads 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 MULTI SOURCE The Multi Source 40kW
8. Contactor power circuit has an open lead Broken power lead T2 internal thermal breaker open Defective POWER ON OFF Switch S1 Control circuit diode bridge open Transformer iron rear thermostat open Open input contactor coil Defective Control Board Contactor moving iron binding Electrode or work lead loose or broken Open main transformer T1 pri mary or secondary circuit Firing P C board not connected or is faulty Firing board not getting enable signal One input fuse blown 2 One phase of main transformer T1 open Faulty Control or Firing P C boards Faulty SCR bridge Input voltage too low Machine has either an internal or external short circuit on the output Faulty Control PC board Output voltage peaks are too high because input voltage too high Output voltage peaks are too high because output filter circuit not working Output voltage peaks are too high because control circuit isn t sensing output voltage Control board faulty Output SCR shorted Machine is overloaded If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Se
9. Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE CONTENTS Page 5 Aen Section Technical Specifications A 1 Installation
10. Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra o REPORTA ELE EE LATE MLMPT APSSAPRBS NTUSHIELTFSU e SR ER ER 945 MIER d TH ecran SSE RE S sup ole e AXE HZA ole AMI W o e Quali Ye 3 puni ag gh la uae AU DUA dan ule Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos CRAP TU THEW ein Jo ALD a gll pis e Sug Wu AI uie Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und perschutz Use prote o para a vista ouvido e corpo EROS SCRHBREUCF aU RRR DESSSSRSHSR ez 12 59 s ESSAI didi due de Lily putes cl gal e A d READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y E
11. Guide E 1 Troubleshooting 2 ss E 2 E 3 PC Board Troubleshooting Guide P C Board E 4 E 5 Wirmg DIA mn Section F 1 Dimension Pritt mc Section F 2 Parts RT CN P367 Series vi 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS Multi Source K1752 1 INPUT THREE PHASE ONLY Standard Voltage Frequency Input Current at Rated Output 100 Duty Cycle 380 415 50 400 60 440 50 460 60 550 50 575 60 RATED OUTPUT 60 Hz 40 kw Volts at Rated Amperes Duty Cycle 75 100 Duty Cycle 50 C 122 F Volts at Rated Amperes 75 8 CURRENT RANGE INPUT HERTZ VOLTAGE COPPER WIRE IN 380 415 460 575 PHYSICAL DIMENSIONS HEIGHT DEPTH NET WEIGHT 30 8 in 2i 41 in 992 Ibs 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 C 40 to 85 C MULTI SOURCE LINCOLN 5 2 INSTALLATION A 2 A WARNING e ELECTRIC SHOCK can Hill 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 be used if the green Safe Output light is not lit The machine is designed to open its input contactor if output volt age peaks exceed the limits set by certain approval agencies If the Saf
12. cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations SAFETY PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce
13. sont sous tension quand la machine a souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer
14. un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie NS LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel donc REDRESSEUR a Utiliser un bon masque avec
15. un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel 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 TRANSFORMATEUR ET 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 Mar 93 LINCOLN 5 V for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln
16. with low pressure compressed air to insure that all cooling pas sages are open and that conductive foreign material has not built up inside MACHINE CALIBRATION SPECIFICATION The Multi Source digital display is controlled by a cur rent sensing circuit on the Control board The display reads 100 when machine output is a little over 40 kW To recalibrate the display the machine output may loaded with Multi Weld welders or resistive grids or a combination of both to obtain an output of 533 Adc as read by a calibrated standard ammeter Trimmer resistor R49 may be adjusted to cause the display to read 100 MULTI SOURCE LINCOLN 5 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the ma
17. 0 amps and sends a sig nal to turn the cooling fan on If LEDS is on but the fan is not there could be a problem with the fan motor or the fan motor drive circuit see LED6 LED4 says that some signal either thermostat out put current or output over current is calling for the fan to operate 05 tells us that the current signal from the shunt is too high If LEDS is lit for 5 8 seconds the enable signal to the Firing board is made high to shut off the output SCRs In the case of a short duration current overload LED5 may only be briefly lit because in normal operation the machine output immediately goes to zero Once disabled the out put will remain off for about 75 seconds 7 LED6 indicates that the input to the fan motor opto triac driver has been energized LED6 should be on as long as the fan motor runs LED6 and the fan motor will be on for about 5 minutes after LED4 goes off LED7 will light when the shorted SCR circuit acti vates A positive voltage on the negative output stud AC instead of DC on the output studs will activate a circuit causing the input contactor to open This circuit is active only when the enable signal to the Firing board is high the output is off The contactor will remain open and the white Power light will remain on until the Power switch is turned off or the input power to the machine is oth erwise removed for about 1 second and then turned on again The green Sa
18. H3MOd 206 JIYNOS ILTNN AIGWASSV LNdNI ALON MULTI SOURCE LINCOLN E DIAGRAMS F 2 F 2 88S6IW V 107 ie SU 62 200 n 56 2 5 692 Y ore 69 02 90 eet LNldd NOISN3MWIG 394NOS ILINN MULTI SOURCE LINCOLN E 5 LINCOLN 5 5 LINCOLN 5 Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the Americ
19. NTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n 0 aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRcocuc 9 fsPBHEICTASSUCFEU e zc EUR E fE FEES aH e SH7IAE gayet 247 75747 S7lE AHBSMAS oe lue e Gal bacs d e ll ge gaal ses us Turn power off before servicing Desconectar el cable de ali me
20. Read Shop Drawings 34350 H Educational Video Information Incentive Management 500 5299 New Approach to Industrial Economics 500 NA Lames Lincoln Arc Welding The American Century of John 5500 AC Foundation Book Information JFLF 515 ex ate MA LE Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 Welding Preheat Calculator 390 woe __ 1 Pipe Welding Chats 9450 es som Shipping Costs tr any 77 TOTALCOSI Le M M M Name Address Telephone Signature as it appears on Charge Card WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes 0 los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder
21. URY 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 copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O 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 3 Sem MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing 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 fume
22. an Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of funda
23. can 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 5 CYLINDER may explode 72 s if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or
24. chine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MULTI SOURCE LINCOLN 5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Machine input contactor does not operate White Power light off White Power light on Machine input contactor operates but no output when trying to weld Machine does not have maximum output Machine has output only momentarily after contactor closes Output returns momentarily every 75 seconds Machine has output only momen tarily contactor opens immediately after closing Green Safe Output light off Machine output doesn t stay on Amber Thermal light on fan run ning digital Output display reads greater than 100 Supply line fuse is blown
25. e Output light is on the output voltage is within it designed operating range 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 material that can be drawn into the welder should be kept at a minimum Failure to observe these precau tions can result in excessive operating temperatures and nuisance shut downs STACKING A 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 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 INPUT AND GROUNDING CONNETIONS 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
26. ect 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 insula tion 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 circuit breaker protecting the fan auxiliary against short cir cuits DESIGN FEATURES ALL MODELS SPECIFICATIONS DESIGN FEATURES AND ADVANTAGES Case parts are predominantly stainless steel the PC boards are potted in trays the controls are sealed all machine coils are copper and the whole transformer is varnish dipped to maximize environmental withstand capability The coils are all conservatively rated for long life The Multi Source output regulates against wide changes in output loading and input line voltage varia tions to supply a consistently stable voltage high enough to allow the Multi Welds to provide good man ual electrode capability MULTI SOURCE LINCOLN 5 1 ACCESSORIES C 1 FACTORY INSTALLED OPTIONS FIELD INSTALLED OPTIONS ACCESSORIES ACCESSORIES There are no factory installed options K1735 1 Multi Weld 350 Multi process controll
27. er K857 K857 1 Remote Control Control Multi Weld remotely 25 or 100 ft 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 520428 Paralleling Kit Allows two machines to equally share double load MULTI SOURCE LINCOLN 5 1 MAINTENANCE D 1 SAFETY PRECAUTIONS A WARNING Have qualified personnel do the maintenance work Always use the greatest care when working near moving parts If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill Do not touch electrically live parts or 9 electrode with skin or wet clothing e insulate yourself from work ground Always wear dry insulating gloves EXPLODING PARTS can cause injury Failed parts can explode or cause other 7 parts to explode when power is RZ applied RYE Always wear a face shield and long sleeves when servicing See additional warning information throughout this operator s manual ROUTINE MAINTENANCE The Multi Source needs no routine maintenance The fan bearings are sealed units PERIODIC MAINTENANCE Periodically the machine may be cleaned
28. erial 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 SAFETY WELDING SPARKS can gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard 249 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the Ameri
29. es detailed throughout this manual PC BOARD TROUBLESHOOTING GUIDE FIRING P C BOARD 1 LEDs 1 through 9 must be lit when the Multi Source is turned on and the Control board is sending an enable signal to the Firing board pin 7 in P8 is low in reference to common at pin 12 in P5 2 LEDs 7 8 and 9 indicate AC power being supplied to the P C board from auxiliary windings on the main transformer T1 If a LED is not on turn the machine off and unplug P8 from the firing board Turn the machine back on and check the following voltages 3 If all voltages are present turn power off and plug P5 back into J5 Turn power back on If LEDs 7 8 or 9 are still not lit replace Firing PCB A If voltages were not present check the circuit back through the external dropping resistors to the auxil iary windings for a possible open resistor or wire 5 LEDs 1 through 6 indicate gate signals are being sent to the main SCRs 1 through 6 respectively If LED2 on the Control board is bright along with LEDs 7 8 and 9 on Firing board and LEDs 1 through 6 are unequal in brightness check to make sure lead 231 between Control board and Firing board is not broken If lead 231 is removed while the machine output is at open circuit the output voltage peaks may be unregulated and cause the over voltage protection circuit to open the input contactor The over voltage protection circuit may disabled by disconnecting lead 222D at the nega
30. fe Output light on the control panel when the machine output voltage is present and safe It lights when the machine output is between 40 and 113 volts peak 10 The yellow Thermal light on the front panel lights when the open thermostat signal is sent to the fan control and output disable circuits CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MULTI SOURCE LINCOLN DIAGRAMS 1 epoo jueuudinbe eu 10 jueunredeg si au sjeued y euo uo episul pejsed s Jenoryed 10 jenueui siy Aq je 104 eq jou 3 YI 804 406 904 504 voc 202 YOLSISSY OO OM e lt j f x or vez SNOILOANNOO ONMATIVEVd 8 T NO 00 9 S v E L 300819319 e 90 906 8 262 MO0 906 51444 V 008 09 5 LAdLNO
31. g and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating 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 mat
32. lder 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 LINCOLN ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 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 screenin
33. mentals 700 00 is a 10 discount on all orders of 50 00 or more for shipment at one time to one location Orders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value up to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment IMETHOD OF PAYMENT Sorry No C O D Orders CHECK ONE Please Invoice only if order is over 50 00 Check or Money Order Enclosed U S Funds only I Credit Card m Laccount lise THIS FORM TO ORDER Books OR FREE INFORMATIVE CATALOGS li incoin Welding School Titles Price Code Quantity Cost ED 80 New Lessons in Arc Welding 500 L Seminar Information Procedure Handbook Twelfth Edition 15 00 PH ___ ED 45 How to
34. ntaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas e X7TTL2A 9 U ACWRUPD PRE gt e RK SHA AGS HEAS Aie Aly ltd Qd dg ghil Do not operate with panel open or guards off No operar con panel abierto 0 guardas quitadas e N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas EX CRRRIARRARS Ro e 20 Sel dos Asal L t Cols Vil gall lu Qai ye WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese it ie BR LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR PRMOX A NHERBEE lt RA tL THHORAMEI ETF SU RA ET MEL BE RH ND RES
35. put 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 trans former auxiliary windings power the firing circuit and fan motor The control auxiliary transformer has a sin gle wide range primary and is not reconnectable The Fan As Needed feature is activated by an output current of 20 Adc or a thermostat on the main trans former 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 within the safe operating range Other indicator lights include the amber Thermal light that signals when the long term output current limit has been exceeded This limit is determined by a ther mostat 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 prot
36. rvice Facility for technical troubleshooting assistance before you proceed MULTI SOURCE LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Machine output doesn t stay on Amber Thermal light on fan run ning digital Output display never reads greater than 100 Machine output doesn t stay on Amber Thermal light on fan not running digital Output display never reads over 100 Machine will not shut off Cooling air blocked or limited Faulty output lead thermostat SCR heat sink thermostat or connecting leads Ambient cooling air too hot Faulty cooling fan or wiring Faulty wiring in shunt circuit Digital Output display reads near zero Faulty Control board 115 Vac winding on main trans former not providing voltage Fan circuit breaker on front con trol panel is tripped Input contactor contacts are frozen Defective POWER switch S1 If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MULTI SOURCE LINCOLN 4 TROUBLESHOOTING E 4 Observe all Safety Guidelin
37. s have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 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 position and in good 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 In some cases it may be necessary to remove safety mis 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 tape 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 governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your bod
38. tive output stud or at pin 1 of P2 NOTE The machine may not be used for welding with the pro tection circuit disabled 6 If one or more of LEDs 1 through 6 are off LEDs 7 8 and 9 are on and the voltage on lead 231 from the Control board 13 P5 to pin 12 P5 is 3 to 13Vdc replace the Firing PCB LED that was off Check AC voltage between Voltage should be approximately CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed MULTI SOURCE LINCOLN 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual PC BOARD TROUBLESHOOTING GUIDE CONTROL P C BOARD The white Power light on the machine control panel indicates that the Control board power supply is being supplied by rectified secondary voltage from the Control transformer T2 by way of the Power Switch and transformer iron rear thermostat LED1 indicates machine output voltage At normal output voltages LED1 will be brightly lit LED2 indicates the level of the control signal to the Firing board The brightness of LED2 is inversely proportional to machine output because the control signal increases as the machine output decreases LED3 lights when the current amplifier senses output current over about 1
39. uded with the Box PIG TAIL LEADS AND CONNECTORS Accessory pig tail leads and Twist Mate connectors are available from Lincoln for extra connections to the Muli Weld 350 or the Distribution Box Order No Description CLO12705 22in 56cm long 2 0 70mm cable with O 5in 13mm hole lug and cut off ends K852 70 Twist Mate male insulated plug for 1 0 2 0 50 70mm2 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 95mm cable MULTI SOURCE LINCOLN 5 B 1 OPERATION B 1 SAFETY PRECAUTIONS ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing eInsulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be danger 23 ous Keep your head out of fumes AR Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or ST explosion Keep flammable material away Do not weld on closed containers ARC RAYS can burn eyes and skin Wear eye ear and body protection EZ See additional warning information at front of this operator s manual GENERAL DESCRIPTION The Multi Source is designed to supply power to the Multi Weld welders It has a wide range three phase AC in
40. y 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 X Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder We
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