Download Lincoln Electric INVERTEC SVM158-A User's Manual
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View Safety Info PS LTS A Return to Master TOC View Safety Info ad nt na Lo ed dosuumm no ng er du t ag it,t, ci tu ci eliel eeet ipips m m is te tin orrem dia ree ip ut lalaore lolor ec Lo ed do ad nt t it,t, ns mod eleli eeet er du co is tu ci orre lalao et eu erat te tin bh m ec od t am ns si y ni ua co ism r iq lo mm al et eu at er do nu num na t am bh m m ni ag su no m r si y iqua ip am lo m al m di lore do umm n na re ed do m nu Lo it, t su no mag el ee ip am re or la rem di lo ed do Lo it, t el ee or la View Safety Info ! ng ci is ip ut ing sc ipi ad t ut er un g tu cid ining te tin iscsc ec ipipi ns od ad t ut co ism un et eu at tuer g cid ining am bhh er te tin iscsc ninib amm ec sit ipipi r ns od y lolor m iqquua co ad t ut ism do umm alali et un ing eu at tuer nnu na m iscsc cid am bhh er te suum no ipipi tin ipips m mag sit ninib m ec ad t ut m didiaam ree lolorr my quuaam ns od er un iq co re lolor m tu cid ism Lo ed do do nnuum alali et m t, eu at te tin t na am bhh er ec eli eeet suum no ag ninib amm ns od orre ipips m m sit co ism r y la m didiaam e lao lolor m iqquua g re et lor ining do umm alaliam h eu erat Lo ed do iscsc nnu na bh it,t, et um no ipipi ninib m sit eliel r re ips ag y uaam ad t ut amm mlolor m iqqu lao m er un didia reedo umm alali tu cid re g lolor nnu na te ining Lo ed doum no tin ec ag t it,t, iscsc ns od eleli eeet ips amm m ipipi co ism ad t ut orrem didia ree g lolor lalaore ed ining et eu at er un Lo iscsc t, t do am bhh er tetu cid ipipi eli eeet tin ninib amm sit ec ad t ut r orre y g lolor m iqquua ns od lalao er un ining tu cid co ism do umm alali iscsc te et eu at nnu na m ipipi tin ec suum no ad t ut am bhh er ns od ipips m mag er un ninib amm sit co ism m didiaam e r tu cid y et eu at te re lolor m iqquua lor tin Lo ed do do umm alali am h er ec t it,t, nnu na nib am ns od sit eliel eeet suumm no co ism y orre ipips m mag lor m iqu quet la lao eu at do umm alali m dia ree ng er re nnu na am bhh m lolor ci ninib am sit Lo ed do suum no is y ipips m maglolorr t it,t, qu ip ut eleli eeet m didiaam ree do mm alaliiqu re orre lolor nnuum la lao y do lor m iqquua co ism ing do umm alali et eu at iscsc nnu na am h ipipi m er ad t ut suum no ipips m mag r sit y nib amm er un m dia ree lolor m iqquua tu cid re te lolor do umm alali tin ec Lo ed do m nnu na t um it,t, ns od eliel eeet ipipssu m no ag co ism am m orre et eu at la rem didia e lao lor am bhh er Lo ed do ninib m sit t it,t, eleli eeet orre lalao ER W PO ! et re lao +8 +1 CR 0 ISP +6 -1 SO 0 FT ed Return to Master TOC ! it,t, eleli Copyright © 2002 Lincoln Global Inc. • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Return to Master TOC ! Lo 6 0 -2 -4 8 0 +2 -6 9 10 +4 E M OT RE 7 1 NG NI 5 3 TE R LD UT VO V W WA ARN IN RN G IN G g ining sc ipi ad t ut er un tu cid ing te tin iscsc ec ipipi ns od ad t ut co ism un et eu at tuer g cid ining am bhh er te tin iscsc ninib am ec sit ipipi r y ns od lolor m iqu qu co ad t ut ism do umm alali et un eu at tuer nnu na m cid am er te suum no bhh g tin ipips m mag sit ninib m ec ining m didiaam ree lolorr my quuaam ns od iscsc iq co re ipipi lolor m ism Lo ed do do nnuum alali et ad t ut m eu at t na it,t, er un am bhh er eleli eeet suum no ag tu cid ninib am orre ipips m m sit te y lalao m didiaam ree tin g ec lor m qu re ining lolor ns od do umm ali Lo ed do iscsc co ism t, nnu na t m ipipi eli eeet suum no et eu at ad t ut orre ipips m mag am h er er un g am lalao m ining tu cid nib amm sit didia ree re te r y lolor iscsc tin lolor m iqquua Lo ed do ec ipipi t it,t, do umm alali ns od ad t ut eliel eeet nnu na m co ism er un orre suum no et eu at tu cid lalao ipips m mag am bhh er ecte tin m didiaam ree re ninib amm ns od sit lolor ed do Lo it, t el ee or la ad nt am r y ng er du lolor m iqquua ci tu ci do umm alali is te tin nnu na ip ut um no ec ad nt ips m mag ns mod m didiaam ree er du re co is lolor tu ci Lo ed do et eu erat te tin it,t, et eliel bh m ec od re t am ns lao si y ni ua co ism r iq lo mm al et eu at er do nu num na t am bh m m ni ag su no m r si y iqua ip am lo m al m di lore do umm n na re ed do m nu Lo it, t su no mag el ee ip am re or la rem di lo CC SE LE CT HO TS TA RT 4 WE TP OU MIN ALS -STI CK CC -STI 7018 CK TIG 60 10 GTA W CVWIR E CVFL UX CO RED AR CC ON TR OL 2 SE LE CT W AR AM A -8 ON O FF 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. A A T PR VIS TEN EC O D TIO AU E N CIO N Safety Depends on You INVERTEC V350-PRO For use with machine code numbers 10873, 10874, 10876 View Safety Info April, 2002 Return to Master TOC SVM158-A RETURN TO MAIN INDEX SERVICE MANUAL Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com Return to Master TOC i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Return to Master TOC Return to Master TOC Return to Master TOC Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” 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.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ____________________________________________________ 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 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. ____________________________________________________ 1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment. ____________________________________________________ 1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts. ___________________________________________________ 1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running. ELECTRIC AND MAGNETIC FIELDS may be dangerous 2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines 2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding. 2.c. Exposure to EMF fields in welding may have other health effects which are now not known. 2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 2.d.1. Route the electrode and work cables together - Secure them with tape when possible. 2.d.2. Never coil the electrode lead around your body. 2.d.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.d.4. Connect the work cable to the workpiece as close as possible to the area being welded. ___________________________________________________ 1.g. 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 Return to Master TOC Return to Master TOC ii ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 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. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays. In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment: • Semiautomatic DC Constant Voltage (Wire) Welder. • DC Manual (Stick) Welder. • AC Welder with Reduced Voltage Control. 4.c. 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. 3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”. 3.d. 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. 3.e. Ground the work or metal to be welded to a good electrical (earth) ground. 3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation. Return to Master TOC ii SAFETY 3.g. Never dip the electrode in water for cooling. 3.h. 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. 3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock. 3.j. Also see Items 6.c. and 8. 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. 5.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products. 5.c. 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. 5.d. 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. Return to Master TOC 5.e. Also see item 1.b. Mar ‘95 Return to Master TOC iii SAFETY WELDING SPARKS can cause fire or explosion. Return to Master TOC CYLINDER may explode if damaged. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b. 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. 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. 7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support. 7.c. Cylinders should be located: • Away from areas where they may be struck or subjected to physical damage. 6.c. 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. 6.d. 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). 6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode. 6.f. 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. Return to Master TOC iii 6.g. 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. • A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame. 7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder. 7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. 7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use. 7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “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. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. Return to Master TOC Mar ‘95 V350-PRO Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie. Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains. b. Faire trés 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 couché pour lesquelles une grande partie du corps peut être en contact avec la masse. c. Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement. d.Ne jamais plonger le porte-électrode dans l’eau pour le refroidir. e. Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines. f. Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage. 2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps. 8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent. 9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques. 10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants. 11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974. PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR 3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc: a. Utiliser un bon masque avec un verre filtrant approprié ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc. b. Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de l‘arc. c. Protéger l’autre personnel travaillant à proximité au soudage à l’aide d’écrans appropriés et non-inflammables. 4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes. 1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre. 2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié. 3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles. 4. Garder tous les couvercles et dispositifs de sûreté à leur place. 5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. V350-PRO Mar. ‘93 v v MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Safety.................................................................................................................................................i-iv Installation .............................................................................................................................Section A Operation...............................................................................................................................Section B Accessories...........................................................................................................................Section C Maintenance .........................................................................................................................Section D Theory of Operation .............................................................................................................Section E Troubleshooting and Repair.................................................................................................Section F How to Use Troubleshooting Guide............................................................................................F-2 Troubleshooting Guide ................................................................................................................F-4 Test Procedures ........................................................................................................................F-15 Replacement Procedures .........................................................................................................F-51 Electrical Diagrams ..............................................................................................................Section G Parts Manual ....................................................................................................................P-401 Series V350-PRO Return to Master TOC SectionA-1 Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION Installation Technical Specifications .............................................................................................................A-2 Safety Precautions......................................................................................................................A-3 Stacking ......................................................................................................................................A-3 Tilting ..........................................................................................................................................A-3 Input Grounding Connections ....................................................................................................A-3 Power Cord Connection .............................................................................................................A-3 Cobramatic Connection Instructions..........................................................................................A-4 Parallel Operation .......................................................................................................................A-5 Return to Master TOC Return to Master TOC Return to Master TOC Connection of Wire Feeders................................................................................................A-3/A-4 V350-PRO Return to Master TOC Return to Section TOC A-2 TECHNICAL SPECIFICATIONS - INVERTEC V350-PRO INPUT AC VOLTAGE & DC OUTPUT Product Ordering Input AC Name Information Voltage Return to Section TOC Return to Master TOC Return to Master TOC Rated DC Output Amps/Volt /Duty Cycle Output Range (continuous) Weight with Cord K1728-5 Construction Invertec V350PRO 60/50 Hz Return to Section TOC A-2 INSTALLATION 200 208-230/ 380-400/ 415-460/ K1728-7 575 Advanced 1& 3 Phase Process 60/50 Hz Construction (81.0 lbs.) (36.7 kg.) 350A / 34V / 60% K1728-6 Factory AMPS 5-425 Factory (81.0 lbs.) (36.7 kg.) 300A / 32V /100% Dimensions HxWxD Voltage Open Circuit 14.8” x 13.3” x 27.8”* (373 x 338 x 706*)mm 80 VDC Advanced Process (81.5 lbs.) (37.0 kg.) * Overall Length Including Handle, 27.8” (706mm) V350-PRO INPUT CURRENT Recommemded Fuse Sizes Base On The U.S. National Electrical Code And Maximum Machine Outputs Input 50/60 Hz Output Recommended Notes Voltage Phases 300Amps @ 350Amps @ Fuse size Line Cord 32Volts(100%) 34Volts(60%) AWG Note 1 200 1 Not Not --Recommended Recommended Note 2 208 1 76 94 125A 2 Note 2 230 1 69 85 125A 4 Note 1 380 1 Not Not --Recommended Recommended Note 1 400 1 Not Not ----Recommended Recommended Note 2 415 1 41 64 80A 6 460 1 36 42 70A 8 575 1 31 37 50A 8 200 208 230 380 400 415 460 575 3 3 3 3 3 3 3 3 41 39 36 23 22 22 19 16 50 50 42 28 27 26 23 18 8 6 8 8 8 8 8 8 Note 2 Note 2 80A 80A 70A 50A 50A 50A 50A 35A Note 1. Not rated is indicated by 4-x’s in the box on the rating plate. Note 2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger. Return to Master TOC Return to Section TOC OUTPUT CABLES, CONNECTIONS AND LIMITATIONS Select The output cable size based upon the following chart. Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated: DUTY CYCLE LENGTH UP TO 200FT.(61m) CURRENT 100% 1/0 300 60% 1/0 350 V350-PRO 200-250 FT. (61-76m) 1/0 2/0 Return to Master TOC Return to Section TOC A-3 INSTALLATION SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH BEFORE ATTEMPTING TO CONNECT OR DISCONNECT INPUT POWER LINES, OUTPUT CABLES, OR CONTROL CABLES. • Only qualified personnel should perform this installation. • Connect the green/yellow lead of the power cord to ground per U.S.National Electrical Code. ---------------------------------------------------------------------- ing laoreet ! dolore ing adipisc ut nt conse at laoreet euismerat er ctetu tincid amet m od sit y nibh conse at mm aliqua euismerat er dolor umm a amet m nonu non sit y nibh magn ipsum e mm aliqua diam dolor umm a ed dolor nonu non Lorem et magn ipsum elit, e diam laore ed dolor Lorem et elit, laore ing tetuer tincidu d adipisc ut consec nt euismo at ing amet ererat tetuer tincidu nibh sit d y m adipisc ut consec nt dolor ummy aliquam ing euismo at amet ererat tetuer non nonum tincidu magna sit y nibh adipisc ut d nt m dolor ummy aliquam consec euismo at tetuer tincidu non nonum amet ererat d ipsum magna sit nibh consec y diam m euismo at ing dolore dolor ummy aliquam amet ererat non nonum sit y nibh adipisc ut ipsum magna m nt laoreet diam dolor ummy aliquam tetuer ing Lorem ed dolore non tincidu nonum d ipsum magna elit, consec diam adipisc ut ing nt laoreet ed Lorem euismo at dolore amet ererat tetuer elit, tincidu nibh sit adipisc ut d nt y ing laoreet m dolor ummy aliquam consec tetuer tincidu euismo at d adipisc ut non nonum amet ererat nt ipsum magna sit consec nibh y diam euismo at tetuer tincidu m Lorem ed dolore dolor ummy aliquam amet ererat d nibh sit elit, consec y non nonum m ipsum magna laoreet dolor ummy aliquam euismo at amet ererat diam cing nibh non nonum sit Lorem ed dolore y ipsum magna m ut elit, diam dolor ummy aliquam adipis laoreet Lorem ed dolore non nonum er unt cing ipsum elit, magna diam ut ctetu tincid laoreet Lorem ed dolore adipis od elit, er unt Lorem ed elit, laoreet ! AT AV TE PR ISO NT EC DE IO N AU CIO N ipsum diam Lorem ed elit, cing ut adipis er unt cing dolor ummy aliquam ut ctetu tincid non nonum adipis od magna er unt conse at euismerat dolore er ctetu tincid amet m od laoreet sit y nibh conse at mm aliqua euismerat er dolor umm a amet m nonu non sit y nibh magn ipsum e mm aliqua diam dolor umm a ed dolor nonu non Lorem et magn ipsum elit, e diam laore ed dolor Lorem et elit, laore ipsum diam Lorem ed elit, INPUT AND GROUNDING CONNECTIONS • Only a qualified electrician should connect the Invertec V350-PRO. Installation should be made in accordance with the appropriate National Electrical Code, all local codes and the information detailed below. • When received directly from the factory, multiple voltage machines are internally connected for 460VAC. If 460VAC is the desired input, then the machine may be connected to the power system without any setup required inside the machine. adipisc ut nt TILTING Place the machine directly on a secure, level surface or on a recommended undercarriage. The machine may topple over if this procedure is not followed. ing STACKING V350-PRO cannot be stacked. adipisc ut nt Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not less than 5.90”(150mm) beyond the equipment on all sides. tetuer tincidu d • Dirt and dust that can be drawn into the machine should be kept to a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown. consec A WA RN WA ING RN ING euismo at ing amet ererat tetuer tincidu nibh sit d y m adipisc ut consec nt dolor ummy aliquam euismo at amet ererat tetuer non nonum tincidu ing magna sit y nibh d m dolor ummy aliquam consec dolore adipisc ut euismo at nt non nonum amet ererat ipsum magna sit nibh tetuer y tincidu diam m d ing dolore dolor ummy aliquam consec non nonum adipisc ut euismo at ipsum nt magna amet ererat laoreet ing diam sit nibh tetuer y tincidu Lorem ed dolore m d dolor ummy aliquam adipisc ut elit, nt consec nonum laoreet ipsum non euismo at tetuer magna amet ererat tincidu diam d nibh sit y Lorem ed dolore consec ing m dolor ummy aliquam euismo at elit, amet ererat non nonum sit adipisc ut laoreet nibh nt ipsum magna y m diam tetuer dolor ummy aliquam tincidu Lorem ed dolore d non nonum elit, ipsum consec magna diam laoreet euismo at amet ererat Lorem ed dolore nibh sit y elit, m Lorem ed elit, Return to Master TOC ! ! laoreet Return to Master TOC •Incorrect connection may result in equipment damage. ----------------------------------------------------------------------BLACK GREEN RED WHITE OR BROWN AMP S V CAUTION Return to Master TOC CAUTION VOL TS A • The machine must be located where there is free circulation of clean air such that air movement in the back, out the sides and bottom will not be restricted. • Keep machine dry. Shelter from rain and snow. Do not place on wet ground or in puddles. • DO NOT MOUNT OVER COMBUSTIBLE SURFACES. Return to Section TOC POWER CORD CONNECTION A 10 ft. power cord is provided and wired into the machine. Follow the power cord connection instructions. ipsum diam The Invertec V350-PRO will operate in harsh environments. Even so, it is important that simple preventative measures are followed in order to assure long life and reliable operation. • Initial 200VAC - 415VAC and 575VAC operation will require an Input voltage panel setup. • Open the access panel on the rear of the machine. • For 200 or 230: Position the large switch to 200230. For higher voltages: Position the large switch to 380-575. • Move the "A" lead to the appropriate terminal. Lorem ed elit, Return to Section TOC SELECT SUITABLE LOCATION Return to Section TOC A-3 OUT PUT LIN CO ELE LN CTR WELD TERM INALS IC WARNI NG IN REMOT E SELE VE CT RT EC V3 50 -P RO POWER ON OFF Single Phase Input Connect green lead to ground per National Electrical Code. Connect black and white leads to power. Wrap red lead with tape to provide 600V insulation. Three Phase Input Connect green lead to ground per National Electric Code. Connect black, red and white leads to power. CONNECTIONS OF WIRE FEEDERS TO V350-PRO LN-25 Connection Instructions (Factory, Construction & Advanced Process versions can be connected.-Not recommended for Pulse Welding with the Advanced Process Model). • Turn the Invertec power switch "off". • Connect the electrode cable to the output terminal of polarity required by electrode. Connect the work lead to the other terminal. • LN-25 with Remote Control options can be used with the Factory Advanced Process version of the V350. The 6-Pin (K444-1) and 14-pin (K444-2) remotes can be connected directly to the 6-pin & 14-pin MS-style connectors. The 42 Volt Remote Voltage and Output Control (K624-1) Kit can be connected to the V350’s 14-pin MS-style connector using Remote Control Cable assembly K627- [ ]. LN-25s with a K431-1 remote kit can be connected to the V350’s 14-pin MS-style connector using a K432 cable and K876 adapter. (See connection diagram S19899). Or the K432 cable could be modified with a K867 Universal Adapter Plug (See connection diagram S19405) to connect it to the V350’s 14-pin MS-style connector. V350-PRO Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC A-4 A-4 INSTALLATION LN-7 Connection Instructions An LN-7 can only be used with the “Factory” & “Advanced Process” versions of the 350-Pro. • Turn the Invertec power switch "off". • Connect the K480 control cable from the LN-7 to the 14-pin MS-style connector. • Connect the electrode cable to the output terminal of the polarity required by electrode. Connect the work lead to the other terminal. • Set the meter polarity switch on the front of the Invertec to coincide with wire feeder polarity used. The wire feeder will now display the welding voltage. • If K480 is not available, see connection diagram S19404 for modification of K291 or K404 LN-7 input cable with K867 Universal Adapter Plug. • If a remote control such as K857 is to be used with the LN-7, the remote can be connected directly to the 6-pin MS-style connector on the front of the Invertec or use a K864 adapter to connect the LN-7 and the remote to the 14-pin MS-style connector. (See connection diagram S19901) LN-10 Connection Instructions An LN-10 can only be used with the “Factory” & “Advanced Process” versions of the 350-Pro. • Turn the Invertec power switch "off" • Connect the K1505 control cable from the LN-10 to the 14-pin MS-style connector. • Connect the electrode cable to the output terminal of polarity required by the electrode. Connect the work lead to the other terminal. • Set the meter polarity switch on the front of the Invertec to coincide with wire feeder polarity used. • See the LN-10 manual for details on accessing Control DIP Switch LN-742 Connection Instructions An LN-742 can only be used with the “Factory” & “Advanced Process” versions of the 350-Pro. • Turn the Invertec power switch "off" • Either a K591 or a K593 Input cable assembly is required to connect the LN-742 to the Invertec. • Connect the control cable from the LN-742 to the 14-pin MS-style connector. • Connect the electrode cable to the output terminal of the polarity required by electrode. Connect the work lead to the other terminal. • Set the meter polarity switch on the front of the Invertec to coincide with wire feeder polarity used. The wire feeder will now display the welding voltage. • If a remote control such as K857 is to be used with the LN-742, the remote can be connected directly to the 6-pin MS-style connector on the front of the Invertec or use a K864 adapter to connect the LN-742 and the remote to the 14-pin MS-style connector. Cobramatic Connection Instructions A Cobramatic can only be used with the “Factory” & “Advanced Process” versions of the 350-Pro. • Turn the Invertec power switch "off" • Connect the control cable from the Cobramatic to the 14-pin MS-style connector. • Connect the electrode cable to the output terminal of the polarity required by electrode. Connect the work lead to the other terminal. • Set the meter polarity switch on the front of the Invertec to coincide with wire feeder polarity used. • If a remote control such as K857 is to be used with the Cobramatic, the remote can be connected directly to the 6-pin MS-style connector on the front of the Invertec or use a K864 adapter to connect the cobramatic and the remote to the 14-pin MSstyle connector. TIG Module K930-2 The TIG Module connects to the Factory and Advanced Process V350-Pro versions with a K936-1 (9-14 pin) control cable. Connect the K936-1 to the MS-style connector. The TIG Module can also be used with the V350-Pro Construction version. A K936-4 control cable is required to supply 115VAC to the TIG Module from an external 115VAC supply. General Instructions for Connection of Wire Feeders to V350-Pro Wire feeders other than those listed above may be used provided that the auxiliary power supply rating of the V350-Pro is not exceeded. K867 universal adapter plug is required. See connection diagram S24985 on page F-4. REMOTE CONTROL OF INVERTEC Remote Control K857, Hand Amptrol K963 and Foot Amptrol K870. UNDERCARRIAGE MOUNTINGS MOUNTING HOLE LOCATIONS NOTE: MOUNTING SCREWS CA N NOT PROTRUDE MORE THAN 0.5 INCHES INSIDE THE MACHINE. V350-PRO 3.50 1/4-20 NUT (4 PLACES) 5.50 10.00 11.84 4/01 M19527 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC A-5 INSTALLATION PARALLEL OPERATION The V350-Pro can be paralleled in CC mode. For best results, the currents of each machine should be reasonably well shared. As an example, with two machines set up in parallel for a 400 amp procedure, each machine should be set to deliver approximately 200 amps, not 300 amps from one and 100 amps from the other. This will minimize nuisance shutdown conditions. In general, more than two machines in parallel will not be effective due to the voltage requirements of procedures in that power range. To set machine outputs, start with output control pots and arc control pots in identical positions. Use the output control pots to balance the currents and maintain the desired current. The arc control pots should be kept identical on the two machines. V350-PRO A-5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC A-6 NOTES V350-PRO A-6 Return to Master TOC Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION Operation...............................................................................................................................Section B Safety Precautions......................................................................................................................B-2 General Description..............................................................................................................B-2 Duty Cycle ............................................................................................................................B-2 Operational Features and Controls ............................................................................................B-2 Weld Mode Select.......................................................................................................................B-3 CC-Stick Soft..................................................................................................................B-3 CC-Stick Crisp................................................................................................................B-3 Return to Master TOC TIG GTAW .......................................................................................................................B-4 CV-Wire ...........................................................................................................................B-4 CV-Innersheild.................................................................................................................B-4 Advanced Process Panel............................................................................................................B-5 Controls ......................................................................................................................................B-6 Electrode Material.......................................................................................................................B-6 Hot Start & Arc Control...............................................................................................................B-6 Weld Mode Details......................................................................................................................B-7 Pulse Programs ..........................................................................................................................B-8 Lower Case Front .......................................................................................................................B-9 CV Modes.............................................................................................................................B-9 Return to Master TOC Return to Master TOC TIG Mode .............................................................................................................................B-9 CC-Stick Modes...................................................................................................................B-9 Types of Remote Output Control................................................................................................B-9 Types of Remote Weld Terminal Control ....................................................................................B-9 Auxiliary Power .........................................................................................................................B-10 Limitations.................................................................................................................................B-10 Recommended Processes........................................................................................................B-10 Descriptions of Special Welding Processes Available on this Machine...................................B-11 V350-PRO Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-2 OPERATION SAFETY PRECAUTIONS DUTY CYCLE WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. -----------------------------------------------------------------------FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes from breathing zone. -----------------------------------------------------------------------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 protection. ------------------------------------------------------------ Return to Master TOC Return to Section TOC See additional warning information at front of this operators manual. ----------------------------------------------------------- GENERAL DESCRIPTION The Invertec V350-Pro offers multi-process CV, CC, and DC welding and is rated 350 amps, 34 volts at a 60% duty cycle. The V350-Pro is available in either a Construction version (no wire feeder connection and auxiliary power) and a Factory & Advanced Process versions (includes wire feeder connection and related power) . • The factory model is the construction model with the addition of the Wire Feeder/Remote Adapter. Return to Master TOC • In this form, the V350-Pro provides the hardware to power and connect to 24, 42 or 115 VAC wire feeders. Return to Section TOC B-2 • The advanced process model is the factory model with an advanced process panel installed in place of the standard mode panel. In this form, the V350-Pro provides access to the 5 standard weld modes (Stick Soft, Stick Crisp, TIG, CV-Wire, CV-Innershield), gouge, constant power and pulse MIG weld modes. The V350-Pro is rated at 350 amps, 60% duty cycle (based on a 10 minute cycle). It is also rated at 300 amps, 100% duty cycle. OPERATIONAL FEATURES and CONTROLS: UPPER CONTROL PANEL 1. AMPS Meter • Prior to STICK or TIG operation (current flow), the meter displays preset current value (+/- 2 amps or +/- 3%, whichever is greater). • Prior to CV operation, the meter displays four dashes indicating non-presettable AMPS. • During welding, this meter displays actual average amps. • After welding, the meter holds the actual current value for 5 seconds. Output adjustment while in the "hold" period results in the "prior to operation" characteristics stated above. The displays blink indicating that the machine is in the "Hold" period. 2. VOLT METER • Prior to CV operation (current flow), the meter displays desired preset voltage value (+/- .5V). • Prior to STICK or TIG operation, the meter displays the Open Circuit Voltage of the Power Source or four dashes if the output has not been turned on. • During welding, this meter displays actual average volts. • After welding, the meter holds the actual voltage value for 5 seconds. The displays blink indicating that the machine is in the "Hold" period. • Output adjustment while in the "hold" period results in the "prior to operation" characteristics stated above. 3. OUTPUT CONTROL • Output control is conducted via a single turn potentiometer. • Adjustment is indicated by the meters as stated above. • When in TIG modes, this control sets the maximum welding current. Full depression of a foot or hand Amptrol results in the preset level of current. 4. WELD TERMINALS-REMOTE / ON • Two status lights indicate the location of trigger control as determined by the "WELD TERMINALS" push button. • If trigger control is local "weld terminals on", the ON display will be lit. • If trigger control is remote "weld terminals remotely controlled", the REMOTE display will be lit. V350-PRO Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-3 OPERATION 7. WELD MODE SELECT - FACTORY AND CONSTRUCTION (See Figure B.1) The Mode Control button selects from the following welding modes. • The unit will power up in "pre-determined preferred" trigger modes. STICK = ON CV = REMOTE TIG = REMOTE if remote output controls are attached to the machine. TIG = 0N if remote output controls are not attached to the machine. For all versions, these trigger modes can be over-ridden (switched) with the WELD TERMINALS push button. When changed, the unit will power up in the configuration it was in when it was last powered down. CC-STICK SOFT: The Stick Soft process features continuous control ranging from 5 to 425 amps. This mode was intended for most SMAW applications, and Arc Gouging. • Arc Gouging: Setting the output of the Stick Soft mode to 425 amps will enable the arc-gouging mode. The actual output current will depend on the size of carbon used. The recommended maximum size carbon is 5/16". • The Hot Start control regulates the starting current at arc initiation. Hot Start can be adjusted from minimum (0), with no additional current added at arc start, to maximum (10), with double the preset current or 425 amps (max of machine) added for the first second after arc initiation. • The Arc Control regulates the Arc Force to adjust the short circuit current. The minimum setting (-10) will produce a "soft" arc and will produce minimal spatter. The maximum setting (+10) will produce a "crisp" arc and will minimize electrode sticking. 5. THERMAL • This status light indicates when the power source has been driven into thermal overload. If the output terminals were "ON", the "ON" light will blink indicating that the output will be turned back on once the unit cools down to an acceptable temperature level. If the unit was operating in the "REMOTE" mode, the trigger will need to be opened before or after the thermal has cleared and closed after the machine has cooled down to an acceptable temperature to establish output. 6. CONTROL-REMOTE / LOCAL • Two status lights indicate the location of output control as pre-determined by the power sources auto-configure system. • The LOCAL display will be lit when control is at the power source. • The REMOTE display will be lit when a remote pot/control is detected. These Output Control configurations can be overridden (switched) with the CONTROL push button. When changed, the unit will power up in the configuration it was in when it was last powered down. CC-STICK CRISP:The Stick Crisp mode features continuous control from 5 to 425 amps. This mode was intended primarily for pipe welding applications. • The Hot Start control regulates the starting current at arc initiation. Hot Start can adjust starting current up or down by 25% of the preset value. The recommended setting for Hot Start is 5 where the initial current is equal to the preset current. Hidden Middle Control Panel – Mode Panel FIGURE B.1. 2 1 5 6 A MPS 3 V OLTS CONTROL WELD TERMINALS REMOTE REMOTE LOCAL 4 REMOTE REMOTE ON OUTPUT SELECT 7 SELECT HOT HO T STAR START CC-STICK SOFT 7018 ARC CONTROL CONTROL 6 -2 8 1 SELECT 9 0 10 11 0 +2 -4 +4 -8 +8 7 2 CV-WIRE CV-WIRE CV-FLUX CV -FLUX CORED 5 4 3 CC-STICK CRISP 6010 TIG GT GTAW Return to Master TOC Return to Section TOC B-3 -6 +6 -10 SOFT +10 CRISP 8 9 12 10 V350-PRO Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-4 OPERATION • The Arc Control regulates the Arc Force to adjust the short circuit current. The minimum setting (-10) will produce a "soft" arc and will produce minimal spatter. The maximum setting (+10) will produce a "crisp" arc and will minimize electrode sticking. TIG GTAW: The TIG mode features continuous control from 5 to 425 amps. The TIG mode can be run in either the TIG touch start or high frequency (optional equipment required) assisted start mode. • The Hot Start control selects the starting mode desired. A setting of less than 5, the TIG lift start mode is selected. The OCV is controlled below 10v and the short circuit "TIG touch" current is maintained at 25 amps independent of the preset current. When the tungsten is lifted, an arc is initiated and the output is regulated at the preset value. Hot start settings between 0 and 5 regulate the arc initiation current. A setting of 5 results in the most positive arc initiation. A setting of 0 reduces hot start. • Hot Start settings between 5 and 10, select high frequency assisted starting TIG mode. In this range, the OCV of the machine is controlled between 50 and 70 volts. If using the Lincoln K930-1 TIG Module, set the Hot start to 10 for maximum OCV. CV-WIRE: The CV-WIRE mode features continuous control from 10 to 40 volts. The mode was intended for most GMAW, FCAW, and MCAW applications. • The Hot Start control is not used in the CV-WIRE mode. • The Arc Control regulates pinch effect. At the minimum setting (-10), minimizes pinch and results in a soft arc. Low pinch settings are preferable for welding with gas mixes containing mostly inert gases. At the maximum setting (+10), maximizes pinch effect and results in a crisp arc. High pinch settings are preferable for welding FCAW and GMAW with CO2. CV-INNERSHEILD: The CV-INNERSHEILD mode features continuous control from 10 to 45 volts. This mode was designed for self-shielded flux cored wires that require tight voltage control. • The Hot Start control is not active in the CV-FLUX CORED mode. • The Arc Control regulates pinch effect. At the minimum setting (-10), minimizes pinch and results in a soft arc. At the maximum setting (+10), maximizes pinch effect and results in a crisp arc. Most selfshielded wires work well at an Arc Control setting of 5. • The Arc Control is not used in the TIG mode. Return to Section TOC Return to Master TOC Return to Master TOC TIG SOLENOID OPTION Return to Section TOC B-4 The Solenoid only operates when the V350 is in the TIG mode. If the Weld Terminals are in “Remote” then the solenoid will open when the arc start switch is closed. The solenoid will close after the arc switch has been opened and the post flow time expired. If the Weld Terminals are turned “ON”, then the solenoid will open when the electrode is touched to the work. The electrode needs to remain in contact with the work to allow for gas coverage before attempting to start the arc. The solenoid will close after the arc has been broken and the post flow time expired. V350-PRO Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-5 B-5 OPERATION • Pulsed Modes In Pulse Modes; The work point will be in the Amps window and should be set close to the wire feed speed of the wire feeder in inches per minute. The Volts window will have SPd displayed indicating Wire Feed Speed. Once current starts flowing and during the 5 second “Hold” feature the displays will show amps and volts. 7A. ADVANCED PROCESS PANEL (See Figure B.2) To program Welding modes. SELECT knob is used to Scroll through all Welding modes. The MEMORY button is used to store and access Welding modes into locations M1 thru M8. Modes: In addition to the 5 welding modes described in SECTION 7, the Advanced Process Panel allows you to select the Following additional modes. Pulse Mode features that are displayed while selecting a Welding pulse mode are listed below; Steel - .030, .035, .045, .052 – Argon Blends Stainless Steel - .030, .035, .045 – Argon Blends & Helium/Argon Blends Aluminum - .035, 3/64, 1/16 – 4043 & 5356 Metal Core - .045, .052 – Argon Blends Nickel - .035, .045 – Argon/Helium blends • Power Mode In the Power Mode; The work point will be in the Volts window. The Amp window will have CP displayed indicating Constant Power. Once current starts flowing and during the 5 second “Hold” feature the displays will show Volts and Amps respectively. Refer to the detailed explanation at the end of this section. Refer to the detailed explanation at the end of this section. • Gouge Air Carbon Arc Cutting (CAC-A) is a physical means of removing base metal or weld metal by using a carbon electrode, an electric arc and compressed air. ADVANCED PROCESS PANEL VERSION FIGURE B.2 Return to Master TOC Return to Section TOC OUTPUT KNOB A MPS V OLTS CONTROL WELD TERMINALS REMOTE LOCAL OUTPUT SELECT MEMORY 7A REMOTE ON SELECT SELECT SELECT ADJUST Return to Master TOC Return to Section TOC MEMORY BUTTON (M1 THRU M8) ADJUST KNOB (0 THRU 10-HOT START) (-10 THRU 0 AND 0 THRU +10-ARC CONTROL) SELECT KNOB (SCOLLS WELDING PROCESSES) SELECT BUTTON ON (HOT START OR ARC CONTROL) V350-PRO Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-6 OPERATION CONTROLS: (See Figure B.2.) The MEMORY button and SELECT knob are used together to select a welding process and store it in memory (M1 thru M8). The SELECT knob scrolls through the, welding process modes and memory M1 thru M8. The MEMORY button stores the welding process in memory. • SELECT button" (The right button) selects between the "Hot Start" or "Arc Control". The < will indicate the active feature shown below. Right Digital Window "Hot Start" (-10 to 0 +10) "Arc Control" (0 to 10) < • The ADJUST knob adjusts the desired settings for the Hot Start or Arc Control feature that is active. WELDING PROCESS MODES AVAILABLE Stick SMAW, TIG GTAW Gouge CAG, CV MIG GMAW CV Flux Core, Pulse MIG ELECTRODE MATERIAL Steel, Metal Core, Stainless, Aluminum, Nickel The following example is how to select Pulse MIG using .035 steel and store it into memory. Return to Master TOC 5. After all adjustments have been made press and hold the Memory button until the display changes. The right and the left window will display what memory to save in, lets say M1. To store in M1 push the Memory button again to save the Pulse Mig mode to memory M1. 6. The display in the digital windows will read as follows: M1 Pulse MIG Argon Blends Steel .035 Arc Cntrl 1.2 7. Saving or entering a second welding mode to a memory, M2. Turn the Select knob until the desired welding process mode is displayed in right digital window. Then follow steps 1 thru 6. Press the Memory button till the digital window reads, Save to MEM M2 Press the Memory button again and the New Welding process is saved in M2. 8. Adjust the output control to the correct wire feed setting and the V350-PRO is ready to weld again. (Note: The wire feed speed setting is not stored in memory and will need to be reset.) EXAMPLE OF SAVING WELDING MODES TO MEMORY Return to Section TOC B-6 1. Turn the Select knob until welding process is displayed. LEFT WINDOW RIGHT WINDOW Pulse MIG Argon Blends Steel .035 2. Wait two seconds and the right window will display Arc Control on the second line on the right side. Pulse MIG Argon Blends Steel .035 Arc Cntrl ### < 9. Adjust the Arc Control and note that the M1 goes away indicating that the V350-PRO settings no longer match what is stored in memory. Going back to the original settings will not bring the M1 back. You will need to push the Memory button to recall the original settings in M1. Note: After all memory’s M1 thru M8 are used and the welder needs to store another welding process, a new welding process will overwrite what was originally in the memory and will read, Save to MEM M1 Overwrite M1 which stored Pulse Mig is Overwritten with the new welding process. LN-10/DH-10 Wire Feeder Compatibility Note: Return to Master TOC Return to Section TOC 3. SPd is displayed in the upper right Volts window. The left Amps window matches the desired wire feed speed that is set on the wire feeder. Adjust the Output knob until desired number is displayed. 4. Start welding. If the arc length is too short turn the Output knob up. If the arc length is too long turn the Output knob down. The Arc Control which is displayed in the right digital window can be used to fine-tune the arc length and characteristics. The LN-10 and DH-10 feeders can be used to pulse weld and in the power mode with the panel. The displays on the LN-10 & DH-10 do not show the wire feed speed or power. 8. HOT START and ARC CONTROL features have different functions depending on the welding Mode that is active. Each feature is described under the welding mode heading. (See Item 7 or 7.A for specified Mode Operations) (See Figure B.1 or B.2) V350-PRO Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-7 OPERATION B-7 WELD MODE DETAILS: Mode Range Comments Stick Soft 5 - 425 amps The stick soft mode is the best selection for general stick applications. Arc Control = Arc Force Hot Start = Initial hot start current (min = start a match set amps, Max. = greatest hot start current) During hot start, arc force is set at high and is fast response. For gouging applications: Turn current up to 425 amps. Stick Crisp 5 - 425 amps The stick crisp mode features an aggressive arc force routine well suited for Exx10, Exx11 series electrodes. Arc Control = Arc Force Hot Start = Initial hot start current (Mid range = welding current and will vary up and down with knobcontrol.) During hot start, arc force is set at high and is fast response. For gouging applications: Turn current up to 425 amps. GTAW (Tig mode) 5 - 425 amps The tig mode produces a soft, steady constant current waveform for either touch start or high frequency assisted start DC GTAW applications. Hot Start = Min to Mid range = Touch start with low OCV Mid to Max range = High frequency assistedstarting with adjustable OCV up to 70 volts. GMAW - CV 10 - 45 volts The GMAW - CV mode is the best selection for general MIG welding, Metal core, and gas shielded applications. Arc Control = Pinch (Min = min pinch, softest arc), (Max = max pinch, crispest arc) FCAW-SS 10 - 45 volts The FCAW-SS mode is designed for Self Shielded Innershield products that require tight voltage control. For example; the NR 203 series or NR 207) Arc Control = Pinch (Min = min pinch, softest arc), (Max = max pinch, crispest arc, ) ADVANCED PULSE PANEL WELDING PROGRAMS Gouging GMAW - Power 60 - 425 amps The gouging mode is a low power version of other Lincoln welding equipment gouging programs, for example a PowerWave 455. 1 - 18 (No Units) Refer to the detailed explanation at the end of this section. Return to Master TOC Return to Section TOC This mode does not allow preset voltage. In the short arc GMAW mode, the set KW will not equal the actual Volts * Amps. The set power is regulated only when an arc is present. During shorting, the output is allowed to increase to clear the short. V350-PRO Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-8 OPERATION B-8 PULSE PROGRAMS: MODE .030 Steel .035 Steel .045 Steel .052 Steel .045 Metal Core .052 Metal Core .030 Stainless Ar Blends .030 Stainless He Ar CO2 .035 Stainless Ar Blends .035 Stainless He Ar CO2 .045 Stainless Ar Blends .045 Stainless He Ar CO2 .035 Aluminum 4043 .035 Aluminum 5356 3/64 Aluminum 4043 3/64 Aluminum 5356 1/16 Aluminum 4043 1/16 Aluminum 5356 Range (IPM*) 65 - 1200 55 - 800 50 - 700 75 - 550 50 - 650 50 - 500 85 - 770 110 - 770 65 - 770 75 - 770 50 - 600 50 - 600 100 - 700 115 - 740 80 - 550 85 - 700 75 - 325 75 - 450 COMMENTS The V350 pulse programs are non-synergic and allow independent control of the wire feed speed (at the wire feeder) and the arc length. The Output Control Knob on the V350, adjusts an "SPD" value. Similar to trim, the "SPD" value indicates the relative arc length setting. The "SPD" value displayed on the V350 may not match the actual wire feed speed! The value of "SPD" is meant to be a point at which to set the arc length relative to the wire feed speed and should be set the same as actual speed for a starting point. Depending on the application, the "SPD" value can be adjusted to obtain the desired arc length. Refer to the detailed explanation at the end of this section. The operation of the Arc Control knob on the V350 is similar to the PowerWave series. As Arc Control is increased, the frequency is increased and the background reduced. Decreasing Arc Control will reduce frequency and increase background current. Arc Control acts to fine tune the arc plasma to the specific application. Preferred gas selections: Steel Argon Blends = Argon with CO2 additions from 2 to 20 % or Oxygen additions from 2 to 5%. Stainless Argon Blends = Argon with Oxygen additions up to 2%. 2% Stainless He Ar CO2 = ~ 90% Helium, 7 1/2 % Argon 2 1/2 CO2 Aluminum 100% Argon Return to Master TOC Return to Section TOC .035 Nickel Alloys (Non Adaptive) .045 Nickel Alloys (Non Adaptive) 80 - 700 75 - 550 The Nickel Alloy pulse programs are non adaptive. The operator sets the output control knob to deliver the correct arc length at desired wire feed speed and stick out. While welding, the operator manipulates the stick out to maintain the correct arc length. This method of operation produces very stable arc performance considering the nature of nickel alloys. Preferred gas: Argon/Helium Blends = for the best results add helium to the argon base from 0-25%. PULSE ON PULSE .035 3/64 .035 3/64 4043 4043 5356 5356 (4x (4x (5x (5x Pulse Pulse Pulse Pulse on on on on Pulse) 120 - 600 Pulse) 85 - 400 Pulse) 130 - 700 Pulse) 100 - 550 Arc Control = Pulse on Pulse frequency. For faster travel speed welds, the arc control should be increased. For larger puddle, slower travel speeds, the arc control should be decreased. Refer to the detailed explanation at the end of this section. Return to Master TOC Return to Section TOC *IPM (INCHES PER MINUTE) V350-PRO Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC B-9 OPERATION LOWER CASE PANEL The output studs, line switch and remote connector are located on the lower case front. 9. Both terminals are "Twist-Mate" connectors. The Negative terminal is configured to accept the pass through gas system. 10. The METER POLARITY switch is located above the output connectors. The switch provides a work connection for wire feeder voltmeters. Place the switch in the position of the electrode polarity indicated by the decal. The switch does not change the welding polarity. 11. 6-pin MS-style connector for remote control. 12. 14-pin MS-style connector for wire feeder connection and remote control. REMOTE CONTROL of the OUTPUT CONTROL and WELD TERMINALS The Invertec V350-Pro has auto sensing of remote output controls. If after connecting or removing a remote, the Invertec V350-Pro did not configure the way you would like the local or remote control settings can be changed by pushing the OUTPUT CONTROL or WELD TERMINAL button. (A user cannot select between the 6 and 14 pin MS-style connectors.) CV modes • The remote will default to the 14-pin MS-style connector if a remote is connected. If no remote is connected to the 14-pin MS-style connector then the remote will default to the 6-pin MS-style connector if a remote is connected to it. • In all of the CV modes, the WELD TERMINAL control will default to REMOTE. TIG mode • The remote will default to the 6-pin MS-style if a remote control is connected to the 6-pin MS-style and to the 14-pin MS-style connector. If a remote is not connected to the 6-pin MS-style connector then the remote will default to the 14-pin MS-style connector if a remote is connected. • If a remote control is connected to any of the MSstyle connectors the WELD TERMINAL control will default to REMOTE. If there are not any remote control devices attached the WELD TERMINAL control will default to ON. CC-Stick modes • The remote will default to only the 6-pin MS-style connector if a remote is connected to it. • The WELD TERMINAL control will default to ON with or without a remote connected. B-9 Types of Remote OUTPUT CONTROL • The Invertec V350-Pro’s Output Control can be controlled by either a potentiometer connected between 77 & 75 with the wiper connected to 76 or a 0V to 10V DC supply connected between 76 & 75. (76 needs to be positive) • 14-Pin Ms-style connector lead 75 is pin G, lead 76 is pin F and lead 77 is pin E. • 6-Pin Ms-style connector lead 75 is pin C, lead 76 is pin B and lead 77 is pin A. Potentiometer Control • The total resistance should be between 2000 ohms (2K) and 10,000 ohms (10K) • The machine output will be at minimum when lead 76 (wiper) is at the end of the potentiometer that is connected to 75. The machine’s output will increase as the wiper of the potentiometer is moved to the end that is connected to 77. (Note: In TIG mode, moving the lead 76 (wiper) to lead 77 would produce the current that has been set by the Invertec V350-Pro’s front panel Output Control.) • Remotes of this type offered by Lincoln Electric are the K857, K812 and K870. Voltage Control • The supply must be an isolated supply. (Not referenced to earth ground, any auxiliary power from the Invertec V350-Pro or the welding output) The supply should be capable of supplying at least 20mA. • 0 volts supplied to 76 will set the Invertec V350-Pro to minimum output for the mode that has been selected while 10 volts supplied to 76 will set the Invertec V350-Pro to the maximum output for the mode. (Note: In TIG mode, 10 volts supplied to lead 76 would produce the current that has been set by the Invertec V350-Pro’s front panel Output Control.) Types of Remote WELD TERMINAL Control • The Invertec V350-Pro’s Weld Terminals can be controlled from each of the MS-style connectors. The circuit has a nominal OCV of 15VDC and requires a dry contact closure (less than 100 ohms) to activate the output of the Invertec V350-Pro. • 14-Pin MS-style connector, the Weld Terminals are controlled from pin C (lead 2) and pin D (lead 4). Pin C is positive. • 6-Pin MS-style connector, the Weld Terminals are controlled from pin D (lead 2) and pin E (lead 4). In the 6-pin MS-style connector pin D is positive. V350-PRO Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC B-10 OPERATION AUXILIARY POWER • 115VAC, 42VAC and 24VAC power is available from the 14-pin MS-style connector. The Construction model of the Invertec V350-Pro does not have the 14-pin MS-style connector) These supplies are intended to supply power for auxiliary equipment like wire feeders and the TIG Module. • 115VAC supply is rated at 2 amps and is protected by a 3.5 amp breaker. • 42 VAC supply is rated at 5.5 amps and is protected by a 6 amp breaker. • 24 VAC supply is rated at 5.5 amps and is protected by a 6 amp breaker. LIMITATIONS • The V350-Pro is not recommended for processes other than those listed. • The V350-Pro can only be used with the recommended equipment and options. RECOMMENDED PROCESSES Properly equipped, the Invertec V350-Pro supports GMAW-P, FCAW, SMAW, GTAW and CAC-A processes for a variety of materials, including mild steel, stainless steel, cored wires, and aluminum. V350-PRO B-10 Return to Master TOC Return to Section TOC B-11 B-11 OPERATION SPECIAL WELDING PROCESSES AVAILABLE ON THIS MACHINE • For steel, use 75/25 Ar/CO2 shield gas. POWER MODE™ • For Aluminum, use 100% Ar. • For Stainless, select a Helium blend Tri-Mix. The Power Mode™ process was developed by Lincoln to maintain a stable and smooth arc at low procedure settings which are needed to weld thin metal without pop-outs or burning-through. For Aluminum welding, it provides excellent control and the ability to maintain constant arc length. This results in improved welding performance in two primary types of applications. Start by setting the wire feed speed based upon material thickness and appropriate travel speed. Then adjust the Output knob as follows: • For steel, listen for the traditional “frying egg” sound of a good short-arc MIG procedure to know you have the process set correctly. • Short Arc MIG at low procedure settings. • For aluminum, simply adjust the Output knob until the desired arc length is obtained. Return to Master TOC Return to Section TOC • Aluminum MIG welding. Note the Volts display is simply a relative number and DOES NOT correspond to voltage. Power Mode™ is a method of high speed regulation of the output power whenever an arc is established. It provides a fast response to changes in the arc. The higher the Power Mode Setting, the longer the arc. If a welding procedure is not established, the best way to determine the Power Mode Setting is by experimentation until the desired output result is established. Some procedure recommendations appear in the table below. In the Power Mode variables need to be set: Setting up a Power Mode procedure is similar to setting a CV MIG procedure. Select a shielding gas appropriate for a short arc process. Recommended Welding Procedures for Power Mode Aluminum 4043 Aluminum 5356 Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Stainless Steel Stainless Steel WIRE E4043 E5356 L56 L56 L56 L56 L56 L56 E308L E308L WIRE SIZE 0.035 0.035 0.025 0.025 0.030 0.030 0.035 0.035 0.030 0.035 GAS 100% Ar. 100% Ar. 100% CO2 75/25% Ar/CO2 100% CO2 75/25% Ar/CO2 100% CO2 75/25% Ar/CO2 Tri-mix Tri-mix WFS / POWER MODE SETTING MATERIAL MATERIAL THICKNESS Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC • Wire Feed Speed • Output • Arc Control 22 ga. 125 / 2.25 125 / 1.75 Not Recommended 100 / 0.8 Not Recommended 90 / 1.0 20 ga. 150 / 2.5 150 / 2.3 120 / 1.0 120 / 1.0 100 / 0.7 100 / 1.0 80 / 1.5 50 / 0.5 18 ga. 200 / 3.75 200 / 3.0 140 / 1.7 140 / 1.5 110 / 1.5 110 / 1.5 100 / 2.5 100 / 2.5 110 / 2.0 110 / 2.0 16 ga. 300 / 7.75 300 / 6.85 190 / 2.0 190 / 2.0 125 / 2.0 125 / 2.0 125 / 3.0 125 / 3.0 140 / 2.5 130 / 2.7 14 ga. 400 / 9.0 400 / 7.5 260 / 3.0 260 / 3.0 160 / 2.3 160 / 2.3 160 / 3.8 160 / 3.5 210 / 3.0 190 / 3.5 12 ga. 450 / 9.5 450 / 8.0 330 / 5.0 330 / 4.5 230 / 3.5 230 / 3.5 200 / 5.0 200 / 4.5 270 / 5.0 230 / 6.0 10 ga. 500 / 10.0 500 / 8.5 300 / 6.0 300 / 6.0 240 / 6.5 240 / 7.0 325 / 6.5 300 / 7.0 3/16 600 / 11.25 600 / 9.5 400 / 7.5 400 / 7.0 1/4 700 / 11 V350-PRO B-12 OPERATION PULSE WELDING (GMAW-P) The pulsed-arc process is, by definition, a spray transfer process wherein spray transfer occurs in pulses at regularly spaced intervals. In the time between pulses, the welding current is reduced and no metal transfer occurs. Pulsed-arc transfer is obtained by operating a power source between low and high current levels. The high current level or “pulse” forces an electrode drop to the workpiece. The low current level or “background” maintains the arc between pulses. (See Figure below). Pulsed MIG is an advanced form of welding that takes the best of all the other forms of transfer while minimizing or eliminating their disadvantages. Unlike short circuit, pulsed MIG does not create spatter or run the risk of cold lapping. The welding positions in pulsed MIG are not limited as they are with globular or spray and its wire use is definitely more efficient. Unlike the spray arc process, pulsing offers controlled heat input that allows better welding on thin materials, lower wire feed speeds and leads to less distortion and improved overall quality and appearance. This is especially important with stainless, nickel and other alloys that are sensitive to heat input. In GMAW-P mode, arc control adjusts the background current and frequency of the wave. When arc control goes up, the frequency increases thus increasing the droplet transfer. EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL PEAK AMPS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-12 FREQUENCY Return to Master TOC Return to Section TOC SPRAY TRANSITION CURRENT V350-PRO Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-13 B-13 OPERATION When Arc Control is used in the Pulse on Pulse modes, it does the same things it does in the other pulsed modes: decreasing the Arc Control decreases the droplet transfer and weld deposition rate. Increasing the Arc Control increases the droplet transfer and weld deposition rate. Since Arc Control varies weld droplet transfer rate, the Arc Control can be used to vary the ripple spacing in the weld bead. PULSE-ON-PULSE™ (GMAW-PP) Pulse on Pulse™ is a Lincoln process specifically designed for use in welding relatively thin (less than 1/4" thick) aluminum (See the table below). It gives weld beads with very consistent uniform ripple. In Pulse on Pulse modes, two distinct pulse types are used, instead of the single pulse type normally used in GMAW-P. A number of high energy pulses are used to obtain spray transfer and transfer metal across the arc. Such pulses are shown in the figure below. After a number "N" of such pulses, depending on the wire feed speed used, an identical number "N" of low energy pulses are performed. These low energy pulses, shown in the figure below, do not transfer any filler metal across the arc and help to cool the arc and keep the heat input low. BENEFITS OF PULSE ON PULSE FROM LINCOLN ELECTRIC • Excellent appearance of the weld bead • Improved cleaning action • Reduced porosity "N" PULSES Table B.2 shows WFS and Trim settings for common aluminum types and wire sizes when welding with Pulse-on-Pulse. The welds made to obtain the values in the table were fillet welds in the flat position. The values in the table can be helpful as a starting point to establish a welding procedure. From there, adjustments need to be made to set the proper procedure for each specific application (out-of-position, other types of joints, etc.). "N" PULSES HIGH HEAT PULSES LOW HEAT PULSES PEAK AMPS BACKGROUND AMPS TIME The Peak Current, Background Current, and Frequency are identical for the high energy and low energy pulses. In addition to cooling the weld down, the major effect of the low energy pulses is that they form a weld ripple. Since they occur at very regular time intervals, the weld bead obtained is very uniform with a very consistent ripple pattern. In fact, the bead has its best appearance if no oscillation of the welding gun ("whipping") is used.(See the figure below) The comments on the table below show values of WFS below which it is not recommended to weld. The reason is, that below these values the weld transfer will change from a spray arc to a short-arc, which is not advisable when welding aluminum. Aluminum 4043 Aluminum 5356 Aluminum 5356 100% Ar. 100% Ar. 100% Ar. 100% Ar. WIRE E4043 E4043 E5356 E5356 WIRE SIZE 0.035 3/64 0.035 3/64 250 / 0 200 / 0 230 / 0 225 / 0 10 ga. 400 / 0 280 / 0 425 / 0 400 / 0 3/16 550 / 0 340 / 0 670 / 0 500 / 0 1/4 600 / 0 400 / 0 700 / 0 550 / 0 WFS / ARC CONTROL Aluminum 4043 GAS MATERIAL THICKNESS Return to Master TOC Return to Section TOC WELDING PROCEDURES FOR PULSE-ON-PULSE MATERIAL 14 ga. COMMENTS Not Recommended below 200 WFS Not Recommended below 100 WFS V350-PRO Not Recommended below 200 WFS Not Recommended below 200 WFS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC B-14 NOTES V350-PRO B-14 Return to Master TOC C-1 C-1 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories...........................................................................................................................Section C Cobramatic & Tig Module Connection Instructions ...................................................................C-2 Options/Accessories...................................................................................................................C-2 Quick Disconnect Plugs .............................................................................................................C-3 Connection of Lincoln Electric Wire Feeders............................................................C-4 Thru C-11 V350-PRO/LN-25 with Optional 6 Pin K441-1 Remote.......................................................C-4 V350-PRO/LN-25 with Optional 6 Pin K857 Remote ..........................................................C-5 V350-PRO/LN-25 with K867 Adapter ..................................................................................C-7 V350-PRO/LN-7 with K480 Control Cable ..........................................................................C-8 V350-PRO/LN-7 with K867 Adapter ....................................................................................C-9 V350-PRO/LN-742 .............................................................................................................C-10 V350-PRO/LN-10 with K1505 Control Cable ....................................................................C-11 Return to Master TOC Return to Master TOC Return to Master TOC LN-25 with K431 Remote Option.........................................................................................C-6 V350-PRO Return to Master TOC Return to Section TOC C-2 ACCESSORIES "CE" Version – K1728-3 Cobramatic Connection Instructions A Cobramatic can only be used with a Factory or "CE" version of the V350 1. Turn the Invertec power switch "off" 2. Connect the control cable from the Cobramatic to the 24/42 VAC 14-pin wire feeder amphenol on the rear of the Invertec. 3. Connect the electrode cable to the output terminal of the polarity required by electrode. Connect the work lead to the other terminal. Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 4. Set the meter polarity switch on the front of the Invertec to coincide with wire feeder polarity used. 5. If a remote control such as K857 is to be used with the Cobramatic, the remote can be connected directly to the 6pin amphenol on the front of the Invertec or use a K864 adapter to connect the cobramatic and the remote to the 24/42VAC 14pin wire feeder amphenol connector on the rear of the Invertec. TIG Module K930-2 The TIG Module connects to the V350-Pro Factory or CE versions with a K936-1 (9-14 pin) control cable. Connect the K936-1 to the 115VAC Wire Feeder Amphenol on the rear of the V350-Pro. The TIG Module can also be used with the V350 Construction version. A K936-4 control cable is required to supply 115VAC to the TIG Module from an external 115VAC supply. General Instructions for Connection of Wire Feeders to V350-Pro Wire feeders other than LN-7 and LN-25 may be used provided that the auxiliary power supply capacity of the V350-Pro is not exceeded. K867 universal adapter plug is required. See connection diagram S19406 and S19386 at the back of this manual for more information. Remote Control of Invertec Remote Control K857, Hand Amptrol K963 and Foot Amptrol K870. Return to Master TOC OPTIONS / ACCESSORIES Return to Section TOC C-2 • The "CE" version is the Factory version with the addition of power line filtering allowing the machine to comply with the European and Australian EMC emission requirements. Field Installed Options/Accessories Two versions of the V350-Pro are available from the factory for both the CE and ROW versions. Options for K1728-1 Factory and K1728-3 "CE" V350’s • TIG Gas Control Kit – K1762-2 • Advanced Process Panel – K1763-1 Options for all models of V350-PRO • Undercarriage – K1764-1 • Valet Style Undercarriage - K1838-1 Welding Cable Connectors: • K852-70 1/0-2/0 cable • K852-95 2/0-3/0 cable FACTORY VERSION and ADVANCED PROCESS VERSION K857 Remote Output Control K814 Arc Start Switch K812 Hand Operated Amptrol K870 Foot Operated Amptrol Note: All of the above remote controls connect directly to the 6-pin MS-style connector, with either a K864 or K876 adapter and connect it to the 14 pin wire feeder MS-style connector. (See Diagram in Section F-1) K930-[ ] TIG Module K428, K446, K449 LN-25 * K617 (-1 or -2) K618 (-1 or -2) LN-742 K440 (-1), K567-1 LN-7 GMA K1559-1, K1564-1 LN-10 K1499-1, K1521-1 DH-10 K1587-1 Cobramatic *Not recommended for pulse welding Construction Version – K1728-2 • All welding modes for this model run with local output control and weld terminals ON (e.g. Stick, TIG, LN25 off the arc). K930-1 TIG Module K428,K446, K449 LN-25(Off the Arc) V350-PRO Return to Master TOC Return to Section TOC C-3 ACCESSORIES QUICK DISCONNECT PLUGS A quick disconnect system is used for the welding cable connections. The K852-70 is designed to accept a welding cable size of 1/0 to 2/0. 1. Remove 25mm (1 in.) of welding cable insulation. 2. Slide rubber boot onto cable end. The boot end may be trimmed to match the cable diameter. Soap or other lubricant will help to slide the boot over the cable. BOOT Return to Master TOC Return to Section TOC WELDING CABLE 25 mm TRIM 1 in. 3. Slide the copper tube into the brass plug. 4. Insert cable into copper tube. SET SCREW BRASS PLUG Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC COPPER TUBE 5. Tighten set screw to collapse copper tube. Screw must apply pressure against welding cable. The top of the set screw will be well below the surface of the brass plug after tightening. 6. Slide rubber boot over brass plug. The rubber boot must be positioned to completely cover all electrical surfaces after the plug is locked into the receptacle. V350-PRO C-3 Return to Master TOC Return to Section TOC C-4 C-4 ACCESSORIES CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS CONNECTION OF THE LN-25 TO THE V350-PRO “ACROSS THE ARC” WITH OPTIONAL 6 PIN K441-1 REMOTE CONTROL. 4. Set the voltmeter switch to the electrode polarity chosen. 5. Set “CONTROL SELECT” to “REMOTE”. 6. Set the “MODE” to the “CV-WIRE” position. 7. Set “WELD TERMINALS SELECT” to the “ON” CAUTION Return to Master TOC Return to Section TOC 1. Remove input power to the V350-PRO. 2. Connect the electrode cable to the output terminal of polarity required by the electrode. Connect the work lead to the other terminal. Welding cable must be sized for current and duty cycle of the application. 3. Attach the single lead from the LN-25 control box to the work using the spring clip on the end of the lead. This is only a control lead - it carries no welding current. position. If you are using an LN-25 without an internal contactor, the electrode will be “HOT” when the V350PRO is energized. 8. Set the “ARC CONTROL” to the “O” position and then adjust to suit. Return to Master TOC Return to Section TOC Figure C.1 V350-PRO/LN-25 ACROSS THE ARC CONNECTION DIAGRAM 6 pin Amphenol Optional K444-1 Remote Control + LN-25 Wire Feeder - Work Clip Lead To Work To Work Return to Master TOC Return to Section TOC Electrode Cable NOTE: Illustration shows electrode connected for negative polarity. V350-PRO Return to Master TOC Return to Section TOC C-5 ACCESSORIES CONNECTION OF THE LN-25 TO THE V350-PRO “ACROSS THE ARC” WITH OPTIONAL 6 PIN K857 REMOTE CONTROL. Return to Master TOC 5. Set the voltmeter switch to the electrode polarity chosen. 6. Set “CONTROL SELECT” to “REMOTE”. 7. Set the “MODE” to the “CV-WIRE” position. 1. Remove input power to the V350-PRO. 2. Connect the electrode cable to the output terminal of polarity required by the electrode. Connect the work lead to the other terminal. Welding cable must be sized for current and duty cycle of the application. 3. Connect the K857 remote control to the 6-pin amphenol on the V350-PRO. Return to Section TOC C-5 4. Attach the single lead from the LN-25 control box to the work using the spring clip on the end of the lead. This is only a control lead - it carries no welding current. 8. Set “WELD TERMINALS SELECT” to the “ON” position. CAUTION If you are using an LN-25 without an internal contactor, the electrode will be “HOT” when the V350PRO is energized. 9. Set the “ARC CONTROL” to the “O” position and then adjust to suit. Return to Master TOC Return to Section TOC Figure C.2 V350-PRO/LN-25 ACROSS THE ARC CONNECTION DIAGRAM WITH K857 REMOTE CONTROL K857 Remote Control 6 pin Amphenol + LN-25 Wire Feeder - Work Clip Lead To Work To Work Return to Master TOC Return to Section TOC Electrode Cable NOTE: Illustration shows electrode connected for negative polarity. V350-PRO Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC C-6 C-6 ACCESSORIES CONNECTION OF THE LN-25 WITH K431 REMOTE OPTION TO THE V350-PRO. NOTE: AN LN-25 CAN ONLY BE USED WITH A FACTORY OR “CE” VERSION OF THE V350-PRO. 6. Set the “MODE” to the “CV-WIRE” position. 7. Set “WELD TERMINALS “REMOTE” position. SELECT” to 8. Set the “ARC CONTROL” to the “O” position and then adjust to suit. 1. Remove input power to the V350-PRO. 2. Connect the electrode cable to the output terminal of polarity required by the electrode. Connect the work lead to the other terminal. Welding cable must be sized for current and duty cycle of the application. 3. Attach the single lead from the LN-25 control box to the work using the spring clip on the end of the lead. This is only a control lead - it carries no welding current. 9. Connect the K432 remote control cable to the LN25. 10. Connect the K876 adapter to the K432 and to the 24/42VAC 14-pin amphenol located at the rear of the V350-PRO. 11. Adjust the wire feed speed and voltage at the LN25. 4. Set the voltmeter switch to the electrode polarity chosen. NOTE: See Figure C.4 for connection Using K867 adapter. 5. Set “CONTROL SELECT” to “REMOTE”. Figure C.3 LN-25 with K431 Remote Option to the V350-PRO Return to Master TOC Return to Section TOC ELECTRODE CABLE TO LN-25 TO WORK 14 PIN (24/42VAC) AMPHENOL 6 PIN AMPHENOL LN-25 WITH K431 OPTION + K876 ADAPTER K432 REMOTE CONTROL CABLE INVERTEC POWER SOURCE Return to Master TOC NOTE: Illustration shows electrode connected for positive polarity. Return to Section TOC the V350-PRO Return to Master TOC Return to Section TOC C-7 C-7 ACCESSORIES CONNECTION OF THE K867 ADAPTER FOR USE WITH LN-25 WITH K431 OPTION/V350-PRO. 1. Insulate each unused lead individually. 2. Remove 6 pin plug from K432 cable in order to connect K867 adapter. 3. Label each lead (A thru F) as they are removed from the 6 pin plug. Return to Master TOC Return to Section TOC 4. Splice leads and insulate. Figure C.4 Connection of LN-25 to V350-PRO using K867 adapter. 21 82 81 42 ELECTRODE CABLE TO LN-25 TO WORK 14 PIN (24/42VAC) 31 32 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC K867 ADAPTER LN-25 WITH K431 OPTION GND AMPHENOL + 1 41 2 E 4 F SPARE D 75 A 76 B 77 C INVERTEC 4 POWER SOURCE V350-PRO K432 REMOTE CONTROL CABLE Return to Master TOC Return to Section TOC C-8 C-8 ACCESSORIES CONNECTION OF THE LN-7 TO THE V350PRO USING K480 CONTROL CABLE (SEE FIGURE C.5) 3. Connect the input cable from the K480 control cable to the (115VAC) 14 pin amphenol on the V350-PRO and the input cable plug on the LN-7. NOTE: AN LN-7 CAN ONLY BE USED WITH A FACTORY OR “CE” VERSION OF THE V350-PRO. IF YOUR LN-7 COMES EQUIPPED WITH A K291 OR K404 INPUT CABLE, REFER TO THE CONNECTION OF THE LN-7 USING K867 UNIVERSAL ADAPTER. 4. Set the “VOLTMETER” switch to “+” or “-” depending on the polarity chosen. 5. Set “CONTROL SELECT” to “REMOTE”. 6. Set the “MODE” to the “CV-WIRE” position. 1. Remove input power to the V350-PRO. Return to Master TOC Return to Section TOC 2. Connect the electrode cable from the K480 control cable to the “+” terminal of the welder and to the LN-7 wire feeder. Connect the work cable to the “-” terminal of the welder. NOTE: Figure C.5 shows the electrode connected for positive polarity. To change polarity, shut the welder off and reverse the electrode and work cables at the output terminals. 7. Place the “WELD TERMINALS SELECT” in the “REMOTE” position. 8. Adjust wire feed speed at the LN-7 and adjust the welding voltage with the optional remote control if used. 9. Set the “ARC” control at “0” initially and adjust to suit. NOTE: Welding cable must be sized for current and duty cycle of application. Figure C.5 V350-PRO/LN-7 with K480 Control Cable Connection Diagram Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TO LN-7 INPUT 14 PIN AMPHENOL (115VAC) AT REAR OF MACHINE CABLE PLUG OPTIONAL K857 REMOTE CONTROL - + K480 CONTROL CABLE 6 PIN AMPHENOL ELECTRODE CABLE TO WIRE FEED UNIT TO WORK V350-PRO Return to Master TOC Return to Section TOC C-9 C-9 ACCESSORIES CONNECTION OF THE K867 ADAPTER FOR USE WITH THE K291 OR K404 INPUT CABLES AND LN-7. 1. Insulate each unused lead individually. 2. Splice leads and insulate. Return to Master TOC Return to Section TOC Figure C.6 Connection of LN-7 to V350-PRO using K867 adapter. SPARE 82 ELECTRODE CABLE TO LN-7 TO WORK 81 14 PIN(115VAC) AMPHENOL + INVERTEC POWER SOURCE K867 UNIVERSAL ADAPTER PLUG BOX 42 41 31 31 32 32 2 2 4 4 21 21 GND GND 75 75 76 76 77 77 GREEN Return to Section TOC Return to Master TOC Return to Master TOC 2 Return to Section TOC LN-7 CONTROL 1 V350-PRO K291 OR K404 INPUT CABLE K775 OPTIONAL REMOTE CONTROL Return to Master TOC Return to Section TOC C-10 ACCESSORIES CONNECTION OF THE LN-742 TO THE V350-PRO (SEE FIGURE C.7) NOTE: AN LN-7 CAN ONLY BE USED WITH A FACTORY OR “CE” VERSION OF THE V350-PRO. Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC 4. Set the “VOLTMETER” switch to “+” or “-” depending on the polarity chosen. 5. Set the “MODE” to the “CV-WIRE” position.. 2. Connect the electrode cable from the LN-742 to the “+” terminal of the welder. Connect the work cable to the “-” terminal of the welder. NOTE: Welding cable must be sized for current and duty cycle of application. 6. Set “CONTROL SELECT” to “LOCAL”. 7. Place the “WELD TERMINALS SELECT” in the “REMOTE” position. 8. Adjust wire feed speed at the LN-742. 9. Set the “ARC” control at “0” initially and adjust to suit. Figure C.7 V350-PRO/LN-742 Connection Diagram TO LN-742 INPUT 14 PIN AMPHENOL (24/42VAC) AT REAR OF MACHINE Return to Section TOC 3. Connect the K591 control cable to the 24/42VAC 14 pin amphenol on the back of the V350-PRO and the input cable plug on the LN-742. 1. Remove input power to the V350-PRO. NOTE: Figure C.7 shows the electrode connected for positive polarity. To change polarity, shut the welder off and reverse the electrode and work cables at the output terminals. Return to Section TOC C-10 CABLE PLUG + - K591 CONTROL CABLE ELECTRODE CABLE TO WIRE FEED UNIT TO WORK V350-PRO Return to Master TOC Return to Section TOC C-11 ACCESSORIES CONNECTION OF THE LN-10 TO THE V350-PRO USING THE K1505 CONTROL CABLE. NOTE: AN LN-10 CAN ONLY BE USED WITH A FACTORY OR “CE” VERSION OF THE V350-PRO. 1. Remove input power to the V350-PRO. 2. Connect the K1505 control cable from the LN-10 to the Invertec 24/42VAC 14 pin amphenol connecter on the rear of the V350-PRO. Return to Master TOC 3. Connect the electrode cable to the output terminal of polarity required by the electrode. Connect the work lead to the other terminal. Return to Section TOC C-11 8. Set the “ARC CONTROL” to the “0” position and then adjust to suit. 9. Set wire feed speed and voltage at the LN-10. NOTE: The voltage set point displayed on the V350-PRO should be ignored when operating in the remote control mode with the LN-10. 10. See the LN-10 manual for details on accessing the control DIP switch. 11. The control DIP switch inside the LN-10 should be set per the instructions in the LN-10 manual. 4. Set the meter polarity switch on the front of the V350-PRO to coincide with wire feeder polarity used. 5. Set “CONTROL SELECT” to “REMOTE”. 6. Set the “MODE” to the “CV-WIRE” position.. 7. Set the “WELD TERMINALS SELECT” to the “REMOTE” position. Return to Master TOC Return to Section TOC Figure C.8 LN-10 V350-PRO TO LN-10 14 PIN AMPHENOL (24/42VAC) AT REAR OF MACHINE + - K1505 TO WORK Return to Master TOC Return to Section TOC ELECTRODE CABLE TO LN-10 V350-PRO Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC C-12 NOTES V350-PRO C-12 Return to Master TOC Section D-1 Section D-1 TABLE OF CONTENTS -MAINTENANCEMaintenance .........................................................................................................................Section D Capacitor Discharge Procedure .................................................................................................D-2 Visual Inspection.........................................................................................................................D-2 Routine Maintenance..................................................................................................................D-2 Periodic Maintenance .................................................................................................................D-2 Return to Master TOC Return to Master TOC Return to Master TOC Major Component Locations .....................................................................................................D-3 V350-PRO Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC D-2 MAINTENANCE D-2 VISUAL INSPECTION WARNING Have qualified personnel do the maintenance work. Always use the greatest care when working near moving parts. Do not put your hands near the cooling blower fan. 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 electrode with skin or wet clothing. • Insulate yourself from work and ground • Always wear dry insulating gloves. ------------------------------------------------------------------------ EXPLODING PARTS can cause injury. • Failed parts can explode or cause other parts to explode when power is applied. • Always wear a face shield and long sleeves when servicing. ------------------------------------------------------------------------ See additional warning information throughout this Operator’s Manual. Clean interior of machine with a low pressure air stream. Make a thorough inspection of all components. Look for signs of overheating, broken leads or other obvious problems. Many problems can be uncovered with a good visual inspection. ROUTINE MAINTENANCE 1. Every 6 months or so the machine should be cleaned with a low pressure airstream. Keeping the machine clean will result in cooler operation and higher reliability. Be sure to clean these areas: • • • • • • • All printed circuit boards Power switch Main transformer Input rectifier Auxiliary Transformer Reconnect Switch Area Fan (Blow air through the rear louvers) 2. Examine the sheet metal case for dents or breakage. Repair the case as required. Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained. All external sheet metal screws must be in place to insure case strength and electrical ground continuity. ------------------------------------------------------------------------ Return to Master TOC Return to Section TOC PERIODIC MAINTENANCE CAPACITOR DISCHARGE PROCEDURE 1. Obtain a power resistor (25 ohms, 25 watts). 2. Hold resistor body with electrically insulated glove. DO NOT TOUCH TERMINALS. Connect the resistor terminals across the two studs in the position shown. Hold in each position for 1 second. Repeat for all four capacitors. Return to Master TOC Return to Section TOC RESISTOR CAPACITOR TERMINALS 3. Use a DC voltmeter to check that voltage is not present across the terminals on all four capacitors. Overload Protection The machine is electrically protected from producing high output currents. Should the output current exceed 430A, an electronic protection circuit will reduce the current to approximately 100A. The machine will continue to produce this low current until the protection circuit is reset. Reset occurs when the output load is removed. Thermal Protection Thermostats protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating. If excessive operating temperature should occur, the thermostat will prevent output voltage or current. The meter will remain energized during this time. Thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the Power Switch may be left on and the reset should occur within a 15 minute period. V350-PRO HO F OF VO LTS PS S C CO +8 +1 CR 0 ISP +6 -10 SO FT 0 L -2 -8 RO +4 Return to Master TOC 4 Return to Master TOC V R WE PO V350-PRO Return to Master TOC 6 +2 -6 9 -4 8 0 NT 1 1 A 3 Return to Section TOC y qu co ism t lor mm ali et eu do nu a am h era gn am um no sit y nib qu ma ips m e lor ali dia lor do mm a nu gn rem ed do Lo t, t um no ma eli ree ips m e lao rem dia lor ed do Lo t, t eli ree lao SE LE CT T ST AR T 4 D TE RM INAL UT A A T PR VIS TEN EC O D TIO AU E N CIO N Return to Section TOC ! W WA ARN IN RN G IN G ! g cin pis ut adi nt er g idu tetu cin tinc pis sec od ut adi con sm nt er t et eui idu g am h era tetu tinc cin nib sit sec od pis uam or my ut adi con sm g nt dol um aliq et t er eui cin idu um non gna am h era tetu pis tinc ips m ma sit nib ut adi uam sec od nt em dia ore or my er con sm idu Lor , ed dol dol um aliq et t tetu eui t um tinc non gna am h erasec elit od ree ips m ma nib sit lao em dia uamcon sm g t ore or my et eui dol um aliq Lor , ed dol cin am h era t pis um non gnasit nib elit ut ree ips uam adi m maor my nt lao er em dia oredol um aliq idu g tetu Lor , ed dolum non gna tinc cin t ips m sec od pis ma elit ut ree con sm adi em dia ore g nt lao ed t et eui er cin Lor , idu t dol am h era tetu pis elit tinc ut nib sit ree adi uam sec od g nt or my lao er cin idu dol um aliq con sm g tetu t et eui pis tinc um non gna ut cin sec od am h era adi nt ips m ma pis nib er sit con sm ut idu adi uam em dia ore or my t tetu et eui nt er tinc Lor , ed dol dol um aliq g am h erasec idu t od tetu cin nib sit elit um tinc non gna ree uamcon sm pis or my sec od ips m ma t et ut lao adi dol um aliq h eui con sm nt em dia ore am era ing er t et eui um non gnasit idu nib g Lor , ed dol sc am h era tetu tinc t uam ips m maor my cin ipi ut elit nib sit sec od ree pis em dia ore dol um aliq ad t uam or my ut lao adi r un con sm Lor , ed dolum non gna nt ing dol aliq t t er et um ue cid ips m ma eui idu elit sc um non gna am h ree era tetu tet tin g em dia ore ipi ut tinc ips m ma sit nib lao cin ec Lor , ed dol uam sec od ad t em dia ore or my t pis r un ns od con sm elit ut Lor , ed dol dol um aliq et adi ree t co ism t ue cid eui nt t um er lao non gna am h era elit et eu era tet tin idu ree ips m ma nib h sit tetu ec od tinc lao am g uam dia em sec od ore or my am ns cin sit y nib qu co ism t dol um aliq Lor , ed dol con sm pis t um non gna ut t et eui lor mm ali et eu elit adi ree ips nt am h era m ma do nu a am h era er g lao idu nib sit gn em dia ore cin nib am tetu uam um no or my sit y qu tinc pis Lor , ed dol ma sec od ut t dol um aliq ips m e lor adi ali elit nt con ree sm er um non gna dia lor do mm a idu t et eui nu gn lao ips m ma rem ed do am h era tetu tinc Lo t, t um no ma em dia ore sec od nib sit g uamcon sm eli ree ips m e Lor , ed dol or my t cin t dol um aliq et eui elit lao rem dia lor pis ree era ut um non gna am h ed do adi lao nib Lo t, t nt ips m ma sit er uam or my idu eli ree em dia ore dol tetu um aliq tinc Lor , ed dol lao sec od t um non gna ing elit con sm ree ips m ma sc t et eui lao em dia ore ipi ut am h era Lor , ed dol ad t nib sit t r un elit uam or my ing ree ue cid dol um aliq sc lao tet tin ipi ut um non gna ec od ad t ips m ma r un ns em dia ore co ism t ue cid Lor , ed dol et eu era tet tin t h elit ec od ree am nib am ns lao sit 5 3 AR 2 SE LE CT 10 TE MO RE WEL TP OU CC -ST ICK CC 70 -ST 18 ICK TIG 60 10 GT AW CV -W IRE CV -FL UX CO RE D 7 ING RN WA AM A 2 Return to Section TOC Center Panel Base Assembly Case Back Case Front Case Wraparound FIGURE D.1 – MAJOR COMPONENT LOCATIONS Return to Section TOC Return to Master TOC 1. 2. 3. 4. 5. ! D-3 MAINTENANCE D-3 5 ! ON Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC D-4 NOTES V350-PRO D-4 Return to Master TOC Section E-1 Section E-1 TABLE OF CONTENTS -THEORY OF OPERATION SECTIONTheory of Operation .............................................................................................................Section E General Description ....................................................................................................................E-2 Input Line Voltage, Auxiliary Transformer and Precharge...........................................................E-2 Switch Board and Main Transformer ..........................................................................................E-3 Power board, Control Board, and SPI Communications............................................................E-4 Output Rectifier and Choke ........................................................................................................E-5 Thermal Protection .....................................................................................................................E-6 Protection Circuits ......................................................................................................................E-6 Return to Master TOC Over current Protection ........................................................................................................E-6 Under/Over Voltage Protection ............................................................................................E-6 Insulated Gate Bipolar Transistor (IGBT) Operation ...................................................................E-7 Pulse Width Modulation..............................................................................................................E-8 Minimum/Maximum Output..................................................................................................E-8 FIGURE E.1 – V350-PRO BLOCK LOGIC DIAGRAM To Control Board Main Switch Board Current Feedback Positive Output Terminal Primary Current Sensor Choke Primary Current Sensor Fan Fan Control 115VAC Fan Supply Auxiliary 115VAC, 42VAC Transformer 24VAC Primary Current Feedback Input Relay Control Soft Start Control V/F Capacitor Feedback (2) Negative Output Terminal Output Voltage Sense Reconnect Switch IGBT Drive Signal Return to Master TOC Input switch Input Rectifier Machine Control Supply +15VDC, -15VDC, +5VDC Power Board 28VAC 14 Pin Amphenol 40VDC SPI Supply +15VDC +5VDC Control Board RS232 Supply +5VDC RS232 Remote Control & Trigger Mode Panel Remote Board (Not used if APP is in place) 12 VDC Return to Master TOC SPI Communications 6 Pin Amphenol Output Control Weld Terminals Optional Solenoid Output Potentiometer V350-PRO & +15VDC, +5VDC Supply Display Panel Advanced Process Panel THEORY OF OPERATION FIGURE E.2 – INPUT VOLTAGE AND PRECHARGE To Control Board Main Switch Board Input switch Input Rectifier Positive Output Terminal Primary Current Sensor Choke Reconnect Switch Primary Current Sensor Fan Return to Master TOC Fan Control Soft Start Control V/F Capacitor Feedback (2) Machine Control Supply +15VDC, -15VDC, +5VDC Power Board 28VAC 40VDC SPI Supply +15VDC +5VDC Control Board RS232 Supply +5VDC 14 Pin Amphenol RS232 SPI Communications Remote Control & Trigger Mode Panel Remote Board (Not used if APP is in place) & +15VDC, +5VDC Supply Display Panel Advanced Process Panel 12 VDC Return to Section TOC Auxiliary 115VAC, 42VAC Transformer 24VAC Primary Current Feedback Input Relay Control IGBT Drive Signal 115VAC Fan Supply Negative Output Terminal Output Voltage Sense Return to Master TOC E-2 Current Feedback Return to Section TOC E-2 6 Pin Amphenol Output Control Weld Terminals Optional Solenoid Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Output Potentiometer GENERAL DESCRIPTION is rectified and the resultant 40VDC is applied to the power board. The Invertec V350-Pro is an inverter based welding power source that offers multi mode constant voltage (CV) and constant current (CC) welding and is rated at 350 amps 34VDC at a 60% duty cycle. The Invertec V350-Pro is available in a construction version (no wire feeder connection or auxiliary power ), a factory version that includes a wire feeder connection and related power, an advanced process version and a rack version. The input voltage is rectified by the input rectifier and the resultant DC voltage is applied to the switch board through the reconnect switch assembly located at the rear of the machine. The reconnect switch connect the two pairs of input capacitors either in a parallel (lower voltage) or series (higher voltage) configuration to accommodate the applied input voltage. During the precharge time the DC input voltage is to the input capacitors through a current limitINPUT LINE VOLTAGE, AUXILIARY applied ing circuit. The input capacitors are charged slowly TRANSFORMER, & PRECHARGE and current limited. A voltage to frequency converter circuit located on the switch board monitors the The Invertec V350-Pro can be connected for a variety capacitor voltages. This signal is coupled to the conof three-phase or single-phase input voltages. The initrol board (measure frequency, not voltage to check tial power is applied to the V350 through a line switch signal). When the input capacitors have charged to an located on the front of the machine. Two phases of the acceptable level, the control board energizes the input input voltage are applied to the auxiliary transformer. relays, that are located on the switch board, making all The auxiliary transformer develops four different secof the input power, without current limiting, available ondary voltages. The 115VAC is used to power the fan to the input capacitors. If the capacitors become motor and also is applied to the 14 pin amphenol type under or over voltage the control board will de-enerconnector for wirefeeder operation. The 24VAC and gize the input relays and the V350 output will be dis42VAC voltages are also applied to the 14 pin ampheabled. Other possible faults may also cause the input nol type connector to power wirefeeders. The 28VAC relays to drop out. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. V350-PRO THEORY OF OPERATION FIGURE E.3 – SWITCH BOARD & MAIN TRANSFORMER To Control Board Main Switch Board Input switch Input Rectifier Positive Output Terminal Primary Current Sensor Choke Primary Current Sensor Fan Fan Control Soft Start Control V/F Capacitor Feedback (2) Machine Control Supply +15VDC, -15VDC, +5VDC Power Board 28VAC 40VDC 14 Pin Amphenol SPI Supply +15VDC +5VDC Control Board RS232 Supply +5VDC RS232 SPI Communications Remote Control & Trigger Remote Board Mode Panel (Not used if APP is in place) & +15VDC, +5VDC Supply Display Panel Advanced Process Panel 12 VDC Return to Master TOC Auxiliary 115VAC, 42VAC Transformer 24VAC Primary Current Feedback Input Relay Control IGBT Drive Signal 115VAC Fan Supply Return to Section TOC Negative Output Terminal Reconnect Switch Output Voltage Sense Return to Master TOC E-3 Current Feedback Return to Section TOC E-3 6 Pin Amphenol Output Control Weld Terminals Optional Solenoid Output Potentiometer Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC SWITCH BOARD & MAIN TRANSFORMER There is one switch board in the Invertec V350-Pro. This board incorporates two pairs of input capacitors, two insulated gate bipolar transistor (IGBT) switching circuits, a fan motor drive circuit, and a voltage/frequency capacitor feedback circuit. The two capacitors in a pair are always in series with each other. When the reconnect switch is in the lower voltage position the capacitor pairs are in parallel . Thus two series capacitors in parallel with two series capacitors. When the reconnect switch is in the high voltage position the two capacitor pairs are in series. Thus four capacitors in series. This is required to accommodate the higher input voltages. When the input capacitors are fully charged they act as power supplies for the IGBT switching circuits. When welding output is required the Insulated Gate Bipolar Transistors switch the DC power from the input capacitors, "on and off" thus supplying a pulsed DC current to the main transformer primary windings. See IGBT Operation Discussion and Diagrams in this section. Each IGBT switching circuit feeds current to a separate, oppositely wound primary winding in the main transformer. The reverse directions of current flow through the main transformer primaries and the offset timing of the IGBT switching circuits induce an AC square wave output signal at the secondary of the main transformer. The two current transformers (CT) located on the switch board monitor these primary currents. If the primary currents become abnormally high the control board will shut off the IGBTs, thus disabling the machine output. The DC current flow through each primary winding is clamped back to each respective input capacitor when the IGBTs are turned off. This is needed due to the inductance of the transformer primary winding. The firing of the two switch boards occurs during halves of a 50 microsecond interval, creating a constant 20 KHZ output. In some low open circuit Tig modes the firing frequency is reduced to 5KHZ. The Invertec V350-Pro has a F.A.N. fan as needed circuit. The fan operates when the welding output terminals are energized or when a thermal over temperature condition exists. Once the fan is activated it will remain on for a minimum of five minutes. The fan driver circuit is housed on the switch board but it is activated from a control board signal. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. V350-PRO Return to Master TOC E-4 THEORY OF OPERATION FIGURE E.4 – POWER BOARD, CONTROL BOARD AND SERIAL PERIPHERAL INTERFACE (SPI) COMMUNICATIONS To Control Board Main Switch Board Current Feedback Return to Section TOC E-4 Input switch Input Rectifier Positive Output Terminal Primary Current Sensor Choke Primary Current Sensor Fan Fan Control Return to Master TOC Return to Section TOC Auxiliary 115VAC, 42VAC Transformer 24VAC Primary Current Feedback Input Relay Control Soft Start Control V/F Capacitor Feedback (2) IGBT Drive Signal 115VAC Fan Supply Negative Output Terminal Output Voltage Sense Reconnect Switch Machine Control Supply +15VDC, -15VDC, +5VDC Power Board 28VAC 40VDC 14 Pin Amphenol SPI Supply +15VDC +5VDC Control Board RS232 Supply +5VDC RS232 SPI Communications Remote Control & Trigger Remote Board Mode Panel (Not used if APP is in place) & +15VDC, +5VDC Supply Display Panel Advanced Process Panel 12 VDC 6 Pin Amphenol Output Control Weld Terminals Optional Solenoid Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Output Potentiometer POWER BOARD, CONTROL BOARD AND SERIAL PERIPHERAL INTERFACE (SPI) COMMUNICATIONS POWER BOARD The 28VAC auxiliary is rectified and filtered and applied to the power board. The power board, utilizing a switching power supply, processes the 40VDC input and develops several regulated positive and negative DC supplies. Three DC supplies are fed to the control board for machine control supplies. Two positive DC voltages are coupled to the control board for the Serial Peripheral Communications (SPI) supplies. A +5VDC is used for the RS232 connection supply. An over or under input voltage detection and shutdown circuit is also part of the power board’s circuitry. The optional 12VDC gas solenoid is powered by the remote board. CONTROL BOARD the V350 machine. The control board sends and receives command signals from the mode or advanced process panel, the display panel and the remote panel. These communications are processed through a digital network called a Serial Peripheral Interface (SPI). This network digitally communicates to and from the control board the user’s commands and various machine status messages. The software that is contained within the control board processes and compares these commands with the voltage and current feedback information it receives from the output current sensor and the output voltage sensing leads. The appropriate pulse width modulation (PWM) signals (See Pulse Width Modulation in this section) are sent to the switch board IGBTs. In this manner, the digitally controlled high-speed welding waveform is created and regulated. The control board also monitors the thermostats, the main transformer primary currents and the input capacitor voltages. The control board performs the primary interfacing functions to establish and maintain output control of NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. V350-PRO THEORY OF OPERATION FIGURE E.5 – OUTPUT RECTIFIER AND CHOKE To Control Board Main Switch Board Input switch Input Rectifier Positive Output Terminal Primary Current Sensor Choke Reconnect Switch Primary Current Sensor Fan Return to Master TOC Return to Section TOC Fan Control Auxiliary 115VAC, 42VAC Transformer 24VAC Primary Current Feedback Input Relay Control Soft Start Control V/F Capacitor Feedback (2) IGBT Drive Signal 115VAC Fan Supply Machine Control Supply +15VDC, -15VDC, +5VDC Power Board 28VAC 14 Pin Amphenol 40VDC SPI Supply +15VDC +5VDC Control Board RS232 Supply +5VDC RS232 SPI Communications Remote Control & Trigger Remote Board Mode Panel (Not used if APP is in place) & +15VDC, +5VDC Supply Display Panel Advanced Process Panel 12 VDC 6 Pin Amphenol Output Control Weld Terminals Optional Solenoid Return to Section TOC Return to Master TOC Return to Master TOC Output Potentiometer Return to Section TOC Negative Output Terminal Output Voltage Sense Return to Master TOC E-5 Current Feedback Return to Section TOC E-5 OUTPUT RECTIFIER AND CHOKE The output rectifier receives the AC output from the main transformer secondary and rectifies it to a DC voltage level. Since the output choke is in series with the negative leg of the output rectifier and also in series with the welding load, a filtered DC output is applied to the machine’s output terminals. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion. V350-PRO Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC E-6 THEORY OF OPERATION OVER CURRENT PROTECTION THERMAL PROTECTION Two normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are connected to the control board. One of the thermostats is located on the heat sink of the switch board and the other is located on the output choke. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond its duty cycle or output rating. If excessive operating temperatures should occur, the thermostats will prevent output from the machine. The yellow thermal light, located on the front of the machine, will be illuminated. The thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the power switch may be left on and the reset should occur within a 15-minute period. If the average current exceeds 450 amps for one second, then the output will be limited to 100 amps until the load is removed. If the peak current exceeds 600 amps for 150 ms, the output will be limited to 100 amps until the load is removed. UNDER/OVER VOLTAGE PROTECTION Protective circuits are included on the switch and control boards to monitor the voltage across the input capacitors. In the event that a capacitor pair voltage is too high, or too low, the machine output will be disabled. The protection circuits will prevent output if any of the following conditions exist. 1. Voltage across a capacitor pair exceeds 467 volts. (High line surges or improper input voltage connections.) PROTECTIVE CIRCUITS Protective circuits are designed into the V350-PRO to sense trouble and shut down the machine before damage occurs to the machine's internal components. 2. Voltage across a capacitor pair is under 190 volts. (Due to improper input voltage connections.) Return to Section TOC Return to Master TOC Return to Master TOC 3. Internal component damage. Return to Section TOC E-6 V350-PRO Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC E-7 E-7 THEORY OF OPERATION INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION An IGBT is a type of transistor. IGBT are semiconductors well suited for high frequency switching and high current applications. capable of conducting current. A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to the circuit components coupled to the source. Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present. This is similar to turning ON a light switch. Example A in Figure E.6 shows an IGBT in passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow. The drain terminal of the IGBT may be connected to a voltage supply; but since there is no conduction, the circuit will not supply current to components connected to the source. The circuit is turned OFF like a light switch. Example B shows the IGBT in an active mode. When the gate signal , a positive DC voltage relative to the source, is applied to the gate terminal of the IGBT, it is FIGURE E.6 – IGBT POSITIVE VOLTAGE APPLIED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC SOURCE n+ GATE SOURCE n+ n+ GATE n+ p BODY REGION p BODY REGION n- DRAIN DRIFT REGION n- DRAIN DRIFT REGION n+ BUFFER LAYER n+ BUFFER LAYER p+ INJECTING LAYER p+ INJECTING LAYER DRAIN DRAIN B. ACTIVE A. PASSIVE V350-PRO Return to Master TOC Return to Section TOC E-8 E-8 THEORY OF OPERATION FIGURE E.7 — TYPICAL IGBT OUTPUTS. sec 48 50 sec sec sec Return to Master TOC Return to Section TOC MINIMUM OUTPUT 24 sec 24 sec 2 sec 50 sec MAXIMUM OUTPUT MAXIMUM OUTPUT Return to Master TOC Return to Section TOC PULSE WIDTH MODULATION The term Pulse Width Modulation is used to describe how much time is devoted to conduction in the positive and negative portions of the cycle. Changing the pulse width is known as modulation. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine. MINIMUM OUTPUT By holding the gate signal on for 24 microseconds each, and allowing only two microseconds of dwell time (off time) during the 50-microsecond cycle, the output is maximized. The darkened area under the top curve can be compared to the area under the bottom curve. The more dark area that is under the curve indicates that more power is present. 1An IGBT group modules feeding winding. Return to Master TOC Return to Section TOC By controlling the duration of the gate signal, the IGBT is turned on and off for different durations during the cycle. The top drawing in Figure E.7 shows the minimum output signal possible over a 50-microsecond time period. The positive portion of the signal represents one IGBT group1 conducting for one microsecond. The negative portion is the other IGBT group1. The dwell time (off time) is 48 microseconds (both IGBT groups off). Since only two microseconds of the 50-microsecond time period is devoted to conducting, the output power is minimized. V350-PRO consists of two IGBT one transformer primary Section F-1 TABLE OF CONTENTS TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section .................................................................................Section F How to Use Troubleshooting Guide ....................................................................................F-2 PC Board Troubleshooting Procedures and Replacement .................................................F-3 Troubleshooting Guide ........................................................................................................F-4 Test Procedures Input Filter Capacitor Discharge Procedure .................................................................F-15 Main Switch Board Test ................................................................................................F-17 Input Rectifier Test ........................................................................................................F-21 Power Board Test..........................................................................................................F-25 Output Diode Modules Test ..........................................................................................F-29 Auxiliary Transformer Test .............................................................................................F-33 Current Transducer Test ................................................................................................F-37 Fan Control and Motor Test ..........................................................................................F-41 SPI Cable Resistance and Voltage Test........................................................................F-45 Voltage and Current Calibration Procedure ..................................................................F-47 Replacement Procedures Control Board Removal and Replacement ...................................................................F-51 Display Board Removal and Replacement ...................................................................F-55 Main Switch Board Removal and Replacement ...........................................................F-59 Advanced Process Panel Removal and Replacement .................................................F-63 Remote Board Removal and Replacement ..................................................................F-69 Snubber Board Removal and Replacement .................................................................F-73 Power Board Removal and Replacement.....................................................................F-75 Input Rectifier Removal and Replacement ...................................................................F-79 Output Rectifier Modules Removal and Replacement .................................................F-83 Current Transducer Removal and Replacement ...........................................................F-87 Retest after Repair ........................................................................................................F-92 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 V350-PRO Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-2 TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE CAUTION Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into three main categories: Output Problems, Function Problems, and LED Function Problems. Step 2. PERFORM EXTERNAL TESTS. The second column, labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)”, lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap-around cover. Step 3. PERFORM COMPONENT TESTS. The last column, labeled “Recommended Course of Action” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem. All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the referred to test points, components, terminal strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram. Return to Master TOC Return to Section TOC CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353.(WELD) V350-PRO F-2 TROUBLESHOOTING & REPAIR 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. Return to Master TOC Return to Section TOC CAUTION Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom. 2. Check for loose connections at the PC board to assure that the PC board is properly connected. Return to Master TOC Return to Master TOC Return to Section TOC 3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures: Return to Section TOC F-3 PC BOARD TROUBLESHOOTING PROCEDURES Return to Master TOC Return to Section TOC F-3 - Remove the PC board from the static-shielding bag and place it directly into the equipment. Don’t set the PC board on or near paper, plastic or cloth which could have a static charge. If the PC board can’t be installed immediately, put it back in the static-shielding bag. - If the PC board uses protective shorting jumpers, don’t remove them until installation is complete. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis. 4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board. NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting. NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature. 5. Remove the replacement PC board and substitute it with the original PC board to recreate the original problem. a. If the original problem does not reappear by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips. PC board can be damaged by static electricity. ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations - Remove your body’s static charge before opening the staticshielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame. - If you don’t have a wrist strap, touch an un-painted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time. b. If the original problem is recreated by the substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine. 6. Always indicate that this procedure was followed when warranty reports are to be submitted. NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims. - Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative. V350-PRO Return to Master TOC Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS RECOMMENDED COURSE OF ACTION Major physical or electrical damage is evident when the sheet metal cover is removed. 1. Contact your local authorized Lincoln Electric Field Service Facility for technical assistance. 1. Contact the Lincoln Electric Service Department, The machine is dead—no output— no displays. 1. Make sure the input line/breaker switch is in the ON position. 1. Perform the Transformer Test. 2. Check the 3.5 amp circuit breaker (CB3). Reset if tripped. 2. Perform the Power Board Test. 3. Check the main input line fuses. If open , replace. 3. The control rectifier and or associated filter capacitor (C5) may be faulty. Check and replace as necessary. 4. Check the 3.5 amp circuit breaker (CB2). Reset if tripped. 5. Check the 6 amp circuit breaker (CB1). Reset if tripped. 6. Make sure the reconnect switch and jumper lead is configured correctly for the applied input voltage. Return to Master TOC 1-800-833-9353(WELD). Auxiliary 4. Perform The SPI Cable Resistance and Voltage Test. 5. The Control Board may be faulty. 7. If the machine is being operated with single phase input voltage make sure the red lead is not connected. See the Installation Section. The main input fuses (or breaker) repeatedly fail. 1. Make certain the fuses or breakers are sized properly. 2. Make sure the reconnect switch and jumper lead is configured correctly for the applied input voltage. 3. The welding procedure may be drawing too much input current or the duty cycle may be too high. Reduce the welding current and /or reduce the duty cycle. Return to Section TOC F-4 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-4 1. Check the reconnect switches and associated wiring. See the Wiring Diagram. 2. Perform the Input Rectifier Test. 3. Perform the Main Switch Board Test. 4. Perform the Module Test. Output Diode 5. The Input Filter Capacitors may be faulty. Check, and if any are faulty replace all four. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353(WELD). V350-PRO Return to Master TOC TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) The V350-Pro does not have welding output. The displays are lit. Return to Master TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Make sure the reconnect switch is configured correctly for the input voltage applied. 2. Make sure the Weld Terminals Select is ON. If the problem is solved the remote control device or associated circuitry may be faulty. See the wiring diagram. 3. Put the Control Select in the Local position. If the problem is solved the remote control device or associated circuitry may be faulty. 4. If an error code is displayed see Fault Code Explanations. The V350-Pro will not produce full output. 1. The input voltage may be too low, limiting the output capability of the machine. Make certain the input voltage is correct for the machine and the reconnect switch and jumper lead configuration. 2. The welding current may be too high . The machine will fold back to 100 amps if the welding current exceeds 450 amps. Return to Master TOC 3. Make sure the machine is in "Local" output control.. If the problem is resolved the Remote control board or the external remote control unit may be faulty. Return to Section TOC F-5 RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Return to Master TOC Return to Section TOC Return to Section TOC F-5 1. Check the reconnect switch and associated leads for loose or faulty connections. See the wiring diagram. 2. Perform the Main Switch Board Test. 3. Perform the Power Board Test. 4. Perform the Output Diode Module Test. 5. The control board may be faulty. 6. The input filter capacitors may be faulty. Check and replace if necessary. 7. The remote board may be faulty. 1. Perform the Output Rectifier Test. 2. Perform the Main Switch Board Test. 3. Perform the Power Board Test. 4. Perform the Current Transducer Test. 5. If the preset function is not performing properly the status panel board or the output control may be faulty. 6. The control board may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353(WELD). V350-PRO Return to Master TOC Return to Section TOC F-6 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) The machine regularly overheats and the yellow thermal light is ON indicating a thermal overload. 1. Check the 3.5 amp circuit breaker (CB2). Reset if tripped. 3. Dirt and dust may have clogged the cooling channels inside the machine. Return to Master TOC Return to Master TOC Return to Section TOC RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS 2. The welding application may be exceeding the recommended duty cycle of the V350-Pro. Return to Section TOC F-6 TROUBLESHOOTING & REPAIR 4. Air intake and exhaust louvers may be blocked due to inadequate clearance around the machine. 5. Make certain the fan as needed (F.A.N.) is operating properly. The fan should operate when welding voltage is present and/or when there is an over temperature condition. An attached wire feeder function correctly. will not 1. Make certain the wire feeder control cable is connected to the correct 14-pin amphenol type plug (115VAC or 24/42VAC) for the wire feeder being used. See the connection diagram. If wirefeeder has DIP switch, be sure it is set correctly. 1. The 115VAC fan motor is controlled by the control board via the main switch board. Perform the Fan Motor And Control Test. 1. A thermostat or associated circuitry may be faulty. See the wiring diagram. One normally closed thermostat is located on the output choke and the other is located on the main switch board heat sink. See the wiring diagram. Note: The Main Switch Board Removal Procedure will be required to gain access to the heat sink thermostat. 1. Perform the Transformer Test. Auxiliary 2. Check the leads between the 14-pin amphenol type plugs and the auxiliary transformer for loose or faulty connections. 2. Check the two circuit breakers located at the rear of the machine. Reset if tripped. Return to Master TOC Return to Section TOC 3. The wire feeder or control cable may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353(WELD). V350-PRO Return to Master TOC F-7 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT(S) FUNCTION PROBLEMS The machine’s welding output is very high and uncontrollable. 1. Put the Control Select in the Local position. If the problem is solved the remote control device or associated circuitry may be faulty. 2. Check for proper current and voltage calibration. Return to Master TOC Return to Section TOC Return to Section TOC F-7 1. Perform the Transducer Test. Current 2. If the output is normal when the Control Select is in the Local position but the output is very high in the Remote position the remote board may be faulty. Perform The SPI Cable Resistance and Voltage Test. 3. The control board may be faulty. The Weld Mode Select does not function properly. 1. Refer to Operation Section of this manual for normal operation characteristics. NOTE: The mode panel is not present if the advanced process panel is installed. 1. Check for loose or faulty plug connections between the control board and the mode select panel. See the wiring diagram. 2. Perform the SPI Cable Resistance and Voltage Test. Return to Master TOC Return to Section TOC 3. The Mode Select Panel board may be faulty. 4. The control board may be faulty. The output control and/or Weld Terminals Select functions do not operate properly. 1. Refer to Operation Section of this manual for normal operation characteristics. 2. Check for proper current and voltage calibration. 1. Check for loose or faulty plug connections between the remote board and the weld/output controls. See the wiring diagram. 2. The Remote Board may be faulty. Return to Master TOC Return to Section TOC 3. The control board may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353(WELD). V350-PRO Return to Master TOC Return to Section TOC F-8 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT(S) FUNCTION PROBLEMS The display is not functioning properly. 1. Refer to the Operation Section of this manual for normal operation characteristics. 2. Check for proper current and voltage calibration. 1. Check for loose or faulty plug connections between the Display board and the control board. See the wiring diagram. 2. The display board may be faulty. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 3. The control board may be faulty. A fault or error code is displayed. 1. See the Fault Explanations. Code For no apparent reason the welding characteristics have change. 1. Check the welding cables for loose or faulty connection. 2. Make sure the machine’s mode and output are set correctly for the process being used. (CV, CC,TIG etc.) Return to Master TOC 3. If Mig welding make sure the shielding gas and wire speed are correct for the process being used. 4. Check for proper current and voltage calibration. Return to Section TOC F-8 TROUBLESHOOTING & REPAIR 1. See Fault Code Explanations. 1. Perform the Current Procedure. Voltage and Calibration 2. Perform the Transducer Test. Current 3. Perform the Output Diode Module Test 4. The control board may be faulty. 5. The advanced process panel (If used) may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353(WELD). V350-PRO Return to Master TOC Return to Section TOC F-9 F-9 TROUBLESHOOTING & REPAIR FAULT CODES 31 DESCRIPTION/ CORRECTIVE DEFINITION ACTION Main transformer primary over current Turn the machine off and back on to reset the machine. If condition persists, contact an authorized Lincoln Field Service Facility. SERVICE FACILITY CORRECTIVE ACTION Perform the Main Switch Board Test. Perform the Power Board Test. The control board may be faulty. Return to Master TOC Return to Section TOC There may be a problem with the primary current sensors (CT) located on the main switch board. See the Wiring diagram Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 32 Capacitor bank “A” (lower) is under voltage Make sure the reconnect switches are configured for the input voltage being applied to the machine. The machine is self clearing when condition ceases. There may be a problem with the V/F signals from the main switch board to the control board. Perform the Main Switch Board Test. Perform the Power Board Test. The control board may be faulty. NOTE: If more than one fault message is being displayed, perform all the checks for the faults before replacing the printed circuit board V350-PRO Return to Master TOC Return to Section TOC F-10 F-10 TROUBLESHOOTING & REPAIR FAULT CODES 33 DESCRIPTION/ CORRECTIVE DEFINITION ACTION Capacitor bank "B"(upper) is under voltage. Make sure the reconnect switches are configured for the input voltage being applied to the machine. The machine is self-clearing when condition ceases. SERVICE FACILITY CORRECTIVE ACTION There may be a problem with the V/F signals from the main switch board to the control board. Perform the Main Switch Board Test. The control board may be faulty. Return to Master TOC Return to Section TOC Perform the Power Board Test. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 34 Capacitor bank "A"(lower) is over voltage. Make sure the reconnect switches are configured for the input voltage being applied to the machine. The machine is self-clearing when condition ceases. There may be a problem with the V/F signals from the main switch board to the control board. Perform the Main Switch Board Test. Perform the Power Board Test. The control board may be faulty. NOTE: If more than one fault message is being displayed, perform all the checks for the faults before replacing the printed circuit board V350-PRO Return to Master TOC Return to Section TOC F-11 F-11 TROUBLESHOOTING & REPAIR FAULT CODES 35 DESCRIPTION/ CORRECTIVE DEFINITION ACTION Capacitor bank "B"(lower) is over voltage. Make sure the reconnect switches are configured for the input voltage being applied to the machine. The machine is self-clearing when condition ceases. SERVICE FACILITY CORRECTIVE ACTION There may be a problem with the V/F signals from the main switch board to the control board. Perform the Main Switch Board Test. The control board may be faulty. Return to Master TOC Return to Section TOC Perform the Power Board Test. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 37 The soft start function failed. Turn the machine off and back on to reset the machine. There may be a problem with the V/F signals from the main switch board to the control board. Perform the Main Switch Board Test. Perform the Power Board Test. The control board may be faulty. NOTE: If more than one fault message is being displayed, perform all the checks for the faults before replacing the printed circuit board V350-PRO Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-12 F-12 TROUBLESHOOTING & REPAIR FAULT CODES 39 DESCRIPTION/ CORRECTIVE DEFINITION ACTION Electrical "glitch" on the primary over current fault detector circuit. Possibly caused by an external electrical "noise" or signal level. Make sure the V350-Pro is grounded correctly. The machine is self clearing when condition ceases. SERVICE FACILITY CORRECTIVE ACTION Perform the Main Switch Board Test. Perform the Power Board Test. There may be a problem with the primary current sensors (CT) located on the main switch board. See the wiring diagram. The control board may be faulty. 43 Capacitor banks "A" (lower) and "B"(upper) are not balanced. Make sure the reconnect switches are configured for the input voltage being applied to the machine. The machine is self-clearing when condition ceases. There may be a problem with the V/F signals from the main switch board to the control board. Perform the Main Switch Board Test. The capacitor(s) may be faulty. Check and replace if necessary. 44 The machine has detected a fault in the central processing unit (CPU). Make sure the V350-Pro is grounded correctly. The machine is self clearing when condition ceases. Perform the Power Board Test. The control board or associated wiring may be faulty. See the wiring diagram. NOTE: If more than one fault message is being displayed, perform all the checks for the faults before replacing the printed circuit board V350-PRO Return to Master TOC Return to Section TOC F-13 F-13 TROUBLESHOOTING & REPAIR FAULT CODES 47 DESCRIPTION/ CORRECTIVE DEFINITION ACTION Electrical "glitch" on the V/F signals from the main switch board to the control board. Possibly caused by an external electrical "noise" or signal level. Make sure the V350-Pro is grounded correctly. The machine is self clearing when condition ceases. SERVICE FACILITY CORRECTIVE ACTION There may be a problem with the V/F signals from the main switch board to the control board. Perform the Main Switch Board Test. The control board may be faulty. Return to Master TOC Return to Section TOC Perform the Power Board Test. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC “bad node” “####” The selected weld mode Press the Mode Select does not exist in the weld button to select a table that is presently different welding mode. loaded in the machine. If new software was just installed, try reinstalling the software or put the original software back. Perform the Power Board Test. Perform the SPI Cable Resistance and Voltage Test. The control board may be faulty. NOTE: If more than one fault message is being displayed, perform all the checks for the faults before replacing the printed circuit board V350-PRO Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-14 NOTES V350-PRO F-14 Return to Master TOC Return to Section TOC F-15 TROUBLESHOOTING & REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION This procedure will drain off any charge stored in the four large capacitors that are part of the switch board assembly. This procedure MUST be performed, as a safety precaution, before conducting any test or repair procedure that requires you to touch internal components of the machine. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC MATERIALS NEEDED 5/16” Nut Driver Insulated Pliers Insulated Gloves High Wattage Resistor (25-1000 ohms and 25 watts minimum) DC Volt Meter This procedure takes approximately 20 minutes to perform. V350-PRO F-15 Return to Master TOC Return to Section TOC F-16 TROUBLESHOOTING & REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued) 4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This resistor is not with the machine. NEVER USE A SHORTING STRAP FOR THIS PROCEDURE. 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. Return to Master TOC • Do not touch electrically hot parts. Return to Section TOC F-16 • Prior to performing preventative maintenance, perform the following capacitor discharge procedure to avoid electric shock. 5. Locate the eight capacitor terminals shown in figure F.1. 6. Using electrically insulated gloves and pliers, hold the body of the resistor with the pliers and connect the resistor leads across the two capacitor terminals. Hold the resistor in place for 10 seconds. DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS. 7. Repeat the discharge procedure for the other three capacitors. DISCHARGE PROCEDURE 1. Remove the input power to the V350-PRO. 2. Using the 5/16” wrench remove the screws from the case wraparound cover. 3. Be careful not to make contact with the capacitor terminals located at the top and bottom of the switch board. 8. Check the voltage across the terminals of all capacitors with a DC voltmeter. Polarity of the capacitor terminals is marked on the PC board above the terminals. Voltage should be zero. If any voltage remains, repeat this capacitor discharge procedure. Return to Master TOC Return to Section TOC FIGURE F.1 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS EIGHT CAPACITOR TERMINALS - + - + Return to Master TOC Return to Section TOC INSULATED PLIERS - + + INSULATED GLOVES POWER RESISTOR V350-PRO TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-17 MAIN SWITCH BOARD TEST WARNING Return to Master TOC Return to Section TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION This test will help determine if the “power section” of the switch boards are functioning correctly. This test will NOT indicate if the entire PC board is functional. This resistance test is preferable to a voltage test with the machine energized because this board can be damaged easily. In addition, it is dangerous to work on this board with the machine energized. Return to Master TOC Return to Section TOC MATERIALS NEEDED Analog Volt/Ohmmeter 5/16 in. Wrench 7/16 in. Wrench Return to Master TOC Return to Section TOC This procedure takes approximately 30 minutes to perform. V350-PRO F-17 F-18 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-18 MAIN SWITCH BOARD TEST (continued) FIGURE F.2 MAIN SWITCH BOARD LEAD LOCATIONS 202 207 J22 Return to Master TOC Return to Section TOC - + - 201 + 209 204 205 208 J21 J20 Return to Master TOC Return to Section TOC - + - 206 203 TEST PROCEDURE 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver, remove the case wraparound. Return to Master TOC 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. Return to Section TOC + 4. Using a 7/16” wrench locate, label and remove leads 201, 202, 203, 204, 205, 206, 207 and 208 from the switch board. Note lead and washer placement for reassembly. Clear leads. 5. Using the Analog ohmmeter, perform the resistance tests detailed in Table F.1. Refer to figure F.2 for test point locations. Note: Test using an Analog ohmmeter on the Rx1 range. Make sure the test probes are making electrical contact with the conductor surfaces on the PC board. V350-PRO Return to Master TOC Return to Section TOC F-19 TROUBLESHOOTING & REPAIR F-19 MAIN SWITCH BOARD TEST (continued) 6. If any test fails replace the switch board. See Main Switch Board Removal and Replacement. 7. If the switch board resistance tests are OK, check connections on plugs J20, J21, J22 and all associated wiring. See wiring diagram. 8. Reconnect leads 201, 202, 203, 204, 205, 206, 207, and 208 to the switch board. Ensure that the leads are installed in their proper locations. PreTorque all leads nuts to 25 inch lbs. before tightening them to 44 inch lbs. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 9. Replace the case wraparound cover using a 5/16” nut driver. TABLE F.1. SWITCH BOARD RESISTANCE TEST APPLY POSITIVE TEST PROBE TO TERMINAL APPLY NEGATIVE TEST PROBE TO TERMINAL NORMAL RESISTANCE READING +206 +208 +202 +201 +205 +203 +204 +207 -205 -203 -204 -207 -206 -208 -202 -201 Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms Less than 100 ohms V350-PRO Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-20 NOTES V350-PRO F-20 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-21 INPUT RECTIFIER TEST WARNING Return to Master TOC Return to Section TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION This test will help determine if the input rectifier has “shorted” or “open” diodes. Return to Master TOC Return to Section TOC MATERIALS NEEDED Analog Voltmeter/Ohmmeter (Multimeter) 5/16” Nut Driver Phillips Head Screwdriver Wiring Diagram Return to Master TOC Return to Section TOC This procedure takes approximately 25 minutes to perform. V350-PRO F-21 Return to Master TOC Return to Section TOC F-22 F-22 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (CONTINUED) TEST PROCEDURE 1. Remove input power to the V350-PRO machine. 2. Using a 5/16” nut driver, remove the case wraparound cover. 3. Perform the Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the input rectifier and associated leads. See Figure F.3. 6. Using a phillips head screwdriver, remove leads 207, 207A, and 209 from the input rectifier. 7. Use the analog ohmmeter to perform the tests detailed in Table F.2. See the Wiring Diagram. 8. Visually inspect the three MOV’S for damage (TP1,TP2,TP3). Replace if necessary. Return to Master TOC Return to Section TOC 5. Carefully remove the silicone sealant from leads 207, 207A, and 209. Figure F.3 Input Rectifier Small Lead "H1" To Auxiliary Transformer 3/16" ALLEN BOLTS C #207 Return to Master TOC Return to Section TOC B #207A Return to Master TOC Return to Section TOC A #209 FRONT REAR V350-PRO Small Lead "A" To Circuit Breaker Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-23 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (CONTINUED) Table F.2 Input Rectifier Test Points Return to Master TOC ANALOG METER X10 RANGE TEST POINT TERMINALS + PROBE - PROBE Acceptable Meter Readings A B C 207 207 207 Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms A B C 207A 207A 207A Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms A B C 209 209 209 Less than 100 ohms Less than 100 ohms Less than 100 ohms 207 207 207 A B C Less than 100 ohms Less than 100 ohms Less than 100 ohms 207A 207A 207A A B C Less than 100 ohms Less than 100 ohms Less than 100 ohms 209 209 209 A B C Greater than 1000 ohms Greater than 1000 ohms Greater than 1000 ohms 9. If the input rectifier does not meet the acceptable readings outlined in Table F.2 the component may be faulty. Replace Return to Section TOC F-23 Note: Before replacing the input rectifier, check the input power switch and perform the Main Switch Board Test. Also check for leaky or faulty filter capacitors. 11. If the input rectifier is faulty, see the Input Rectifier Bridge Removal & Replacement procedure. 12. Replace the case wraparound cover. 10. If the input rectifier is good, be sure to reconnect leads 207, 207A, and 209 to the correct terminals and torque to 31 inch lbs. Apply silicone sealant. V350-PRO Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-24 NOTES V350-PRO F-24 F-25 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-25 POWER BOARD TEST WARNING Return to Master TOC Return to Section TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION This test will help determine if the power board is receiving the correct voltages and also if the power board is regulating and producing the correct DC voltages. Return to Master TOC Return to Section TOC MATERIALS NEEDED Volt-Ohmmeter 5/16” Nut Driver Wiring Diagram Return to Master TOC Return to Section TOC This procedure takes approximately 30 minutes to perform. V350-PRO Return to Master TOC Return to Section TOC F-26 TROUBLESHOOTING & REPAIR POWER BOARD TEST (CONTINUED) TEST PROCEDURE 1. Remove input power to the V350-PRO machine. 2. Using a 5/16” nut driver, remove the case wraparound cover. 3. Perform the Capacitor Discharge Procedure detailed earlier in this section. Return to Master TOC Return to Section TOC 4. Locate the power board and plugs J41, J42 and J43. Do not remove plugs from the power board. See Figure F.4. 5. Carefully apply the correct input voltage to the V350-PRO. Return to Section TOC Return to Master TOC Return to Master TOC 8. If any of the DC voltages are low, or not present at plugs J42 or J43, the power board may be faulty. 9. Remove the input power to the V350-PRO. 10. Replace the case wraparound cover using a 5/16” nut driver. 6. Carefully test for the correct voltages at the power board. See Table F.3. Figure F.4 Power Board Plug Location J42 Return to Section TOC 7. If the 40VDC is low, or not present at plug J41, check the rectifier bridge and C5 filter capacitor. See Wiring Diagram. Also perform the Auxiliary Transformer Test. J41 V350-PRO J43 F-26 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-27 Return to Master TOC TROUBLESHOOTING & REPAIR POWER BOARD TEST (CONTINUED) Table F.3 Power Board Voltage Checks CHECK POINT LOCATION TEST DESCRIPTION CONNECTOR PLUG PIN NO. POWER PC BOARD CONNECTOR PLUG J41 CHECK 40VDC SUPPLY FROM RECT. BRIDGE TO POWER BD. 2(+) 1(-) POWER PC BOARD CONNECTOR PLUG J42 CHECK +15VDC SUPPLY FROM POWER PC BOARD 1(+) 5(-) POWER PC BOARD CONNECTOR PLUG J42 CHECK +5VDC SUPPLY FROM POWER PC BOARD 3(+) 5(-) POWER PC BOARD CONNECTOR PLUG J42 CHECK -15VDC SUPPLY FROM POWER PC BOARD POWER PC BOARD CONNECTOR PLUG J43 CHECK +5VDC “SPI” SUPPLY FROM POWER PC BOARD POWER PC BOARD CONNECTOR PLUG J43 CHECK +5VDC “RS232” SUPPLY FROM POWER PC BOARD LEAD NO. OR IDENTITY NORMAL ACCEPTABLE VOLTAGE READING 65 (+) 66 (-) 38-42 VDC 412 (+) 410 (-) 15 VDC 410 408 (+) 410 (-) 5 VDC 410 411 (+) 410 (-) -15 VDC 403 (+) 401 (-) 5 VDC 406 (+) 405 (-) 5 VDC 402 (+) 401 (-) 15 VDC 65 66 410 412 408 2(+) 5(-) 411 401 3(+) 12(-) 403 POWER PC BOARD CONNECTOR PLUG J43 Return to Section TOC F-27 CHECK +15VDC “SPI” SUPPLY FROM POWER PC BOARD 4(+) 9(-) 405 406 401 6(+) 12(-) 402 V350-PRO Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-28 NOTES V350-PRO F-28 Return to Master TOC TROUBLESHOOTING & REPAIR OUTPUT DIODE MODULES TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). Return to Master TOC Return to Section TOC Return to Section TOC F-29 DESCRIPTION This test will help determine if any of the output diodes are “shorted”. MATERIALS NEEDED Return to Master TOC Return to Section TOC Analog Voltmeter/Ohmmeter Wiring Diagram Return to Master TOC Return to Section TOC This procedure takes approximately 20 minutes to perform. V350-PRO F-29 Return to Master TOC Return to Section TOC F-30 TROUBLESHOOTING & REPAIR OUTPUT DIODE MODULES TEST (continued) FIGURE F.5 Machine Output Terminals A MPS V OLTS CONTROL WELD TERMINALS REMOTE LOCAL OUTPUT REMOTE ON Return to Master TOC Return to Section TOC SELECT SELECT SELECT ATTRIBUTE TTRIBUTE MEMORY BUTT MEMOR BUTTON ON SELECT KNOB Return to Master TOC Return to Section TOC _ ADJUST ATTRIBUTE TTRIBUTE + POSITIVE OUTPUT TERMINAL NEGATIVE OUTPUT TERMINAL TEST PROCEDURE 1. Remove input power to the V350-PRO. 2. Locate the output terminals on the front panel of the machine. See Figure F.5. 3. Remove any output cables and load from the output terminals. 4. Using the analog ohmmeter test for more than 200 ohms resistance between positive and negative output terminals. Positive test lead to the positive terminal; Negative test lead to the negative terminal. See Figure F.6. Return to Master TOC Return to Section TOC NOTE: The polarity of the test leads is most important. If the test leads polarity is not correct, the test will have erroneous results. V350-PRO F-30 OBE _ + - PR Return to Master TOC Return to Master TOC Return to Master TOC Figure F.6 Terminal Probes E Return to Section TOC OUTPUT DIODE MODULES TEST (continued) ROB Return to Section TOC TROUBLESHOOTING & REPAIR +P Return to Section TOC F-31 5. If 200 ohms is measured then the output diodes are not “shorted”. NOTE: There is a 250 ohm resistor across the welding output terminals. 6. If less than 200 ohms is measured, one or more diodes or the snubber board may be faulty. 7. Perform the Filter Capacitor Discharge Procedure detailed earlier in this section. Return to Master TOC Return to Section TOC 8. Locate the output diode modules and snubber board. See Figure F.7. 9. Test all output diode modules individually. V350-PRO NOTE: This may require the disassembly of the leads and the snubber board from the diode modules. Refer to the Output Diode Modules Removal and Replacement Procedure for detailed instructions. F-31 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-32 TROUBLESHOOTING & REPAIR OUTPUT DIODE MODULES TEST (continued) Figure F.7 Snubber and Output Diode Locations Output Diode Modules Snubber Board LEFT SIDE V350-PRO F-32 Return to Master TOC TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). Return to Master TOC Return to Section TOC Return to Section TOC F-33 DESCRIPTION This procedure will determine if the correct voltage is being applied to the primary of auxiliary transformer and also if the correct voltage is being induced on the secondary windings of the transformer. MATERIALS NEEDED Volt-ohmmeter (Multimeter) Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5/16” Nut Driver Wiring Diagram This procedure takes approximately 25 minutes to perform. V350-PRO F-33 Return to Master TOC Return to Section TOC F-34 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST (continued) FIGURE F.8 Auxiliary Transformer Auxiliary Transformer Return to Master TOC Return to Section TOC Secondary Lead Plugs P52 A AM PS V VO LTS A OUT CC -ST ICK CC 701 -ST 8 ICK TIG 601 GT 0 AW CV -W IRE CV -FL UX CO RE D PU RM IN AL S CT RN D TE HO SE T ST AR T 4 LE CT 5 3 SE LE WA WEL T 6 AR 2 ING 1 MO TE NT RO 8 0 RE C CO 7 9 10 -4 -2 L 0 +2 -6 +4 -8 -10 SO FT +6 +8 +10 CR ISP PO WE R ON Return to Master TOC Return to Section TOC OF F TEST PROCEDURE 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver, remove the case wraparound cover. 3. Perform the Input Capacitor Discharge Procedure detailed earlier in this section. Return to Master TOC 5. Locate the secondary leads and plug P52. See Figure F.8 and F.9. FIGURE F.9 Plug Lead Connections Viewed From Transformer Lead Side of Plug 532 Return to Section TOC 4. Locate the auxiliary transformer. See Figure F.8. 24 42 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Plug P52 54 31 V350-PRO 541 F-34 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-35 TROUBLESHOOTING & REPAIR F-35 AUXILIARY TRANSFORMER NO.1 TEST (continued) TABLE F.4 LEAD IDENTIFICATION NORMAL EXPECTED VOLTAGE 31 TO 532 115 VAC 42 TO 541 42 VAC 24 TO 541 24 VAC 54 TO 541 28 VAC 7. Carefully apply the correct input voltage to the V350-PRO and check for the correct secondary voltages per table F.4. Make sure the reconnect jumper lead and switch are configured correctly for the input voltage being applied. Make sure circuit breaker (CB3) is functioning properly. NOTE: The secondary voltages will vary if the input line voltage varies. 8. If the correct secondary voltages are present, the auxiliary transformer is functioning properly. If any of the secondary voltages are missing or low, check to make certain the primary is configured correctly for the input voltage applied. See Wiring Diagram. WARNING High voltage is present at primary of Auxiliary Transformer. 9. If the correct input voltage is applied to the primary, and the secondary voltage(s) are not correct, the auxiliary transformer may be faulty. 10. Remove the input power to the V350-PRO. 11. Install the case wraparound cover using a 5/16” nut driver. V350-PRO Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-36 F-36 NOTES V350-PRO Return to Master TOC Return to Section TOC F-37 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION This test will help determine if the current transducer and associated wiring are functioning correctly. MATERIALS NEEDED Volt-ohmmeter 5/16” Nut Driver Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Resistive Load Bank External DC Ammeter This procedure takes approximately 45 minutes to perform. V350-PRO F-37 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-38 TROUBLESHOOTING AND REPAIR F-38 CURRENT TRANSDUCER TEST (continued) FIGURE F.10 Metal Plate Removal & Plug J8 Location A AM PS V VO LTS A OU CC TP -S TIC K 70 -S 18 TIC K 60 TIG 10 GT AW CV -W IRE CV -FL UX CO RE CC S LE CT IN D TE IN AL 4 G SE LE T ST AR T CT 5 3 SE RN WEL RM HO D WA UT 6 AR 2 7 1 8 0 RE MO 10 TE 9 -4 C CO -2 NT RO L 0 +2 -6 +4 -8 -10 SO FT +6 +8 +1 CR 0 ISP PO WE R ON OF F Plug J8 TEST PROCEDURE 6. Check for the correct DC supply voltages to the current transducer at plug J8. See Figure F.11. Return to Master TOC Return to Section TOC 1. Remove input power to the V350-PRO. 2. Using the 5/16” nut driver, remove the case wraparound cover. A. Pin 2 (lead 802+) to pin 6 (lead 806-) should read +15 VDC. 3. Perform the Input Capacitor Discharge Procedure. B. Pin 4 (lead 804+) to pin 6 (lead 806-) should read -15 VDC. 4. Locate plug J8 on the control board. Do not remove the plug from the P.C. Board. 7. If either of the supply voltages are low or missing, the control board may be faulty. 5. Apply the correct input power to the V350PRO. FIGURE F.11. Plug J8 Viewed From Lead Side of Plug 802 804 Return to Master TOC Return to Section TOC 801 Plug J8 806 V350-PRO Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-39 TROUBLESHOOTING AND REPAIR CURRENT TRANSDUCER TEST (continued) TABLE F.5 OUTPUT LOAD CURRENT EXPECTED TRANSDUCER FEEDBACK VOLTAGE 300 2.4 250 2.0 200 1.6 150 1.2 100 0.8 8. Check the feedback voltage from the current transducer using a resistive load bank and with the V350-PRO in mode 200. Mode 200 is a constant current test mode. This mode can be accessed from the front panel of the V350 by pressing and holding the Mode Select button while turning the machine on. NOTE: Machines with an Advanced Process Panels do not have a mode select button. Use the same procedure except hold in the Memory button on the advanced process panel instead of the mode select button. Then, rotate the output knob while still holding the Mode Select button in until the displays read “Mode 200”. Release the Mode Select Button and the machine will be in mode 200. With the V350PRO in mode 200, apply the grid load across the output of the V350-PRO, set machine output to 300 amps and enable WELD TERMINALS. Adjust the grid load to obtain 300 amps on the external ammeter and check feedback voltages per Table F.5. 9. If for any reason the machine cannot be loaded to 300 amps, Table F.5. shows what feedback voltage is produced at various current loads. 10. If the correct supply voltages are applied to the current transducer, and with the machine loaded, the feedback voltage is missing or not correct the current transducer may be faulty. Before replacing the current transducer, check the leads and plugs between the control board (J8) and the current transducer (J90). See The Wiring Diagram. For access to plug J90 and the current transducer refer to: Current Transducer Removal and Replacement Procedure. 11. Remove input power to the V350-PRO. 12. Replace the control box top and any cable ties previously removed. 13. Install the case wraparound cover using the 5/16” nut driver. Return to Master TOC A. Pin 1 (lead 801) to Pin 6 (lead 806) should read 2.4 VDC (machine loaded to 300 amps). Return to Section TOC F-39 V350-PRO Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-40 NOTES V350-PRO F-40 Return to Master TOC Return to Section TOC F-41 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION This test will help determine if the fan motor, control board, switch board, or associated leads and connectors are functioning correctly. MATERIALS NEEDED Voltmeter Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5/16” Nut Driver This procedure takes approximately 40 minutes to perform. V350-PRO F-41 Return to Master TOC Return to Section TOC F-42 F-42 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST (continued) TEST PROCEDURE 1. Remove the input power to the V350-PRO machine. 3. Perform the Input Filter Capacitor Discharge Procedure. 2. Using the 5/16” nut driver, remove the case wraparound cover. 4. Locate plug J22 on the main switch board. Do not remove the plug from the board. See Figure F.12. FIGURE F.12 PLUG J22 LOCATION Return to Master TOC J21 J20 Return to Master TOC 5. Carefully apply the correct input power to the machine. Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC J22 6. Carefully check for 115VAC at plug J22 pin-2 to J22 pin-3. (leads 32A to 31B(C) See Figure F.13. WARNING: HIGH VOLTAGE IS PRESENT AT THE MAIN SWITCH BOARD. FIGURE F.13 PLUG J22 Fan Lead 1 2 Lead 32A Lead 31B(C) 3 4 Fan Lead Plug J22 V350-PRO Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-43 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST (continued) 7. If the 115VAC is low or not present check circuit breaker CB2 located on the front panel. If the circuit breaker is OK, perform The Auxiliary Transformer Test. Check plug J22, circuit breaker CB2 and associated leads for loose or faulty connections. See the Wiring Diagram. 8. Energize the weld output terminals (Select Weld Terminals ON) and carefully check for 115VAC at plug J22 pin-1 to J22 pin-4 (fan leads). See Figure F.13. If the 115VAC is present and the fan is not running then the fan motor may be faulty. Also check the associated leads between plug J22 and the fan motor for loose or faulty connections. See the Wiring Diagram. WARNING: HIGH VOLTAGE IS PRESENT AT THE SWITCH BOARD. 9. If the 115VAC is NOT present in the previous step then proceed to the fan control test. FAN CONTROL TEST PROCEDURE 1. Locate plug J20 on the switch board. Do not remove the plug from the switch board. See Figure F.12 and F.14. 2. Energize the weld output terminals (Select Weld Terminals ON) and carefully check for +15VDC at plug J20 pin-6+ to J20 pin-2(leads 715 to 716). See Figure F.14. If the 15VDC is present and the fan is not running then the switch board may be faulty. If the 15VDC is not present when the weld terminals are energized then the control board may be faulty. Also check plugs J20, J7, and all associated leads for loose or faulty connections. See the Wiring Diagram. WARNING: HIGH VOLTAGE IS PRESENT AT THE SWITCH BOARD. 3. Remove the input power to the V350-PRO. Note: The fan motor may be accessed by the removal of the rear panel detailed in The Current Transducer Removal and Replacement Procedure. 4. Replace the case wrap-around cover. Return to Master TOC Return to Master TOC Return to Section TOC FIGURE F.14 PLUG J20 Return to Section TOC F-43 Lead 716- 1 2 3 4 5 6 7 8 Lead 715+ Plug J20 V350-PRO Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-44 NOTES V350-PRO F-44 F-45 F-45 Return to Master TOC Return to Section TOC TROUBLESHOOTING AND REPAIR SPI CABLE RESISTANCE AND VOLTAGE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION This test will help determine if there is a possible “open” in the SPI cable and also determine if the correct supply voltages are being applied to the boards in the SPI network. MATERIALS NEEDED Volt/Ohmmeter Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5/16” Nut Driver This procedure takes approximately 35 minutes to perform. V350-PRO Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-46 F-46 TROUBLESHOOTING AND REPAIR SPI CABLE RESISTANCE AND VOLTAGE TEST (continued) TEST PROCEDURE 1. Remove the input power to the V350-PRO. 2. Using the 5/16” nut driver, remove the case wraparound cover. 3. Perform the Capacitor Discharge Procedure. 8. Reconnect the plug into the control board and perform the Display Board Replacement Procedure. 9. With plug J3 still removed from the control board, carefully apply the correct input power to V350-PRO. 4. Perform the Display Board Removal Procedure. Do not remove the SPI ribbon cable connecting the display board to the remote/status boards. 10. Turn on the machine. 5. Locate and remove plug J3 from the control board. See Figure F.15. 12. Carefully check for the presence of +5VDC from plug J3 pin -2(+) to plug J3 pin -10(-) at the control board receptacle. See Figure F.15. 6. Check the resistance and continuity of the SPI cable by testing with the ohmmeter from each pin on plug J3 to the corresponding pins on plug J34. See the Wiring Diagram. 7. The resistance reading pin to corresponding pin should be zero ohms or very low resistance. If the resistance reading is high or “open” check the plug connections to the SPI network PC boards. If the connections are OK and the resistance is high or “open” the SPI cable may be faulty. 11. Carefully check for the presence of +15VDC from plug J3 pin -1(+) to plug J3 pin -10(-) at the control board receptacle. See Figure F.15. 13. If either of these voltages are low or not present, the control board may be faulty. Replace. Also Perform the Power Board Test. 14. Remove the input power to the V350-PRO machine. 15. Replace plug J3 into the control board. 16. Replace any cable ties previously removed. 17. Replace the case wrap-around cover. Return to Master TOC Return to Section TOC FIGURE F.15 Plug J3 Pin 1 Pin 2 Plug J3 J3 t Return to Master TOC Return to Section TOC h Rig Pin 10 e Sid V350-PRO Return to Master TOC Return to Section TOC F-47 TROUBLESHOOTING AND REPAIR VOLTAGE AND CURRENT CALIBRATION PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION This test will help determine if the machine is capable of producing welding output and to check and adjust, if necessary, the voltage and or current calibration. MATERIALS NEEDED Resistive Load Bank Calibrated Test Voltmeter Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Calibrated Test Ammeter This procedure takes approximately 20 minutes to perform. V350-PRO F-47 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-48 TROUBLESHOOTING AND REPAIR VOLTAGE AND CURRENT CALIBRATION PROCEDURE (continued) CALIBRATION CHECK VOLTAGE CALIBRATION The calibration of the V350-PRO can be checked using a resistive load bank with the V350-PRO in mode 200. Mode 200 is a constant current test mode. 1. Connect the resistive load band (approximately .087 ohms) and test voltmeter to the welding output terminals. 1. Press and hold in the Mode Select button. 2. Press and hold in the Mode Select/Memory button. 2. Turn on the V350-PRO. 3. Turn on the V350-PRO. 3. Rotate the output knob, while still holding the mode select button in, until the displays read “mode 200”. NOTE: Machines with an Advanced Process Panels do not have a mode select button. Use the same procedure except hold in the Memory button on the advanced process panel instead of the mode select button. 4. Rotate the Output Control knob until the display reads “vol cAL”. 4. Release the Mode Select/Memory button and the machine will be in mode 200. 5. With the machine in mode 200 apply a resistive load to the welding output terminals (approximately .087 ohms) set the machine output to 300 amps and enable the Weld Terminals. (Weld Terminals Select ON). 6. Using the test meters note the output voltage and current. Return to Master TOC Return to Master TOC Return to Section TOC 7. The V350-PRO voltmeter must match the test meter reading to within +/- 1 volt. Return to Section TOC F-48 5. Release the Mode Select/Memory button. 6. Adjust the output control knob until the actual output voltage reading on the test volt meter is 20volts +/- .5 volts. 7. Wait for the machine’s output to be automatically turned off and then back on. 8. Adjust the Output Control knob again if necessary to make the actual voltage output 20 volts +/- .5 volts. 9. Wait for the machine’s output to be automatically turned off and then back on. 10. Repeat the above two steps if necessary. 11. Press and release the Mode Select/Memory button to save the calibration. 8. The V350-PRO ammeter must match the test meter within +/- 5 amps. 9. If the voltmeter does not meet the specification then proceed to the Voltage Calibration Procedure. 10. If the ammeter does not meet the specification then proceed to the Current Calibration Procedure. NOTE: Before attempting to calibrate the voltage or current setting of the V350-PRO, be sure to read the entire voltage or current calibration section. If the steps are not completed quickly, the machine will automatically leave the calibration mode without changing the calibration settings. The voltage and current calibration settings of the V350-PRO are completely independent of each other. Adjusting one will not affect the other. V350-PRO NOTE: If the Mode Select/Memory button is not pressed within 30 seconds after adjusting the Output Control knob the machine will leave the calibration mode and use the previous calibration settings. Return to Master TOC Return to Section TOC F-49 TROUBLESHOOTING AND REPAIR VOLTAGE AND CURRENT CALIBRATION PROCEDURE (continued) CURRENT CALIBRATION PROCEDURE 1. Connect the resistive load band (approximately .087 ohms) and test ammeter to the welding output terminals. 2. Press and hold in the Mode Select/Memory button. 3. Turn on the V350-PRO. Return to Master TOC Return to Section TOC 4. Rotate the Output Control knob until the display reads “cur cAL”. 10. Adjust the Output Control knob again if necessary to make the actual output current reading on the test ammeter 300 amps +/-2A. 11. Wait for the machines output to be a u t o matically turned off and then back on. 12. Repeat the above two steps if necessary. 5. Release the Mode Select/Memory button. 13. Press and release the Mode Select/Memory button to save the calibration. 6. The left display will change to “IcAL” to indicate that current calibration is in progress. 14. The left display will scroll the message IcAL SAVEd. 7. The right display will scroll the following message: Adj oCP SorEAL cur-300A. 15. The machine will reset to normal operation. 8. Adjust the Output Control knob until the actual output current reading on the test ammeter is 300amps +/-2A. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 9. Wait for the machines output to be automatically turned off and then back on. V350-PRO NOTE: If the Mode Select/Memory button is not pressed within 30 seconds after adjusting the Output Control knob the machine will leave the calibration mode and use the previous calibration settings. F-49 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-50 NOTES V350-PRO F-50 Return to Master TOC Return to Section TOC F-51 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353) (WELD). DESCRIPTION The following procedure will aid the technician in removing the control board for maintenance or replacement. MATERIALS NEEDED 5/16” Nut Driver 3/8” Nut Driver Return to Master TOC Return to Section TOC Flathead Screwdriver Phillips Head Screwdriver Return to Master TOC Return to Section TOC This procedure takes approximately 30 minutes to perform. V350-PRO F-51 Return to Master TOC Return to Section TOC F-52 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.16 - CONTROL BOARD LOCATION AM PS Return to Master TOC Return to Section TOC A V VO LTS A OU CC -ST ICK 701 -ST 8 ICK TIG 601 GT 0 AW CV -W IRE CV -FL UX CO RE TP CC RN WE LD TE RM INAL S HO D CT LE CT 5 3 LE SE T ST AR T 4 SE WA UT 6 AR 2 ING 8 0 RE MO TE C CO NT RO 7 1 10 9 -4 -2 L 0 +2 -6 +4 -8 -10 SO FT +6 +8 +10 CR ISP PO WE R ON OF F Control Board PROCEDURE 4. Locate the control board behind the front panel of the machine. See Figure F.16. 1. Remove input power to the V350-PRO. Return to Master TOC Return to Section TOC 2. Using a 5/16” nut driver remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 5. Using a 5/16” nut driver remove the two screws from the bottom of the front of the machine. See Figure F.17. FIGURE F.17 CASE FRONT SCREW REMOVAL A MPS V OLTS CONTROL WELD TERMINALS REMOTE LOCAL OUTPUT REMOTE ON SELECT SELECT SELECT ATTRIBUTE TTRIBUTE MEMORY BUTT MEMOR BUTTON ON Return to Master TOC SELECT KNOB Return to Section TOC F-52 Phillips Head Screws ADJUST ATTRIBUTE TTRIBUTE Flathead Screws _ + 5/16" Screws V350-PRO Return to Master TOC Return to Section TOC F-53 F-53 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.18. - CONTROL BOARD ALL PLUG LOCATIONS J5 J6 J7 J8 J9 J3 Return to Master TOC Return to Section TOC J4 A AM PS V VO LTS J10B A OU CC -STI CK CC -STI 7018 CK TIG 60 10 GT AW CV -W IRE CV -FLU X CO RE D WA TP IN WE LD TE RM INA LS HO G SE T ST AR T 4 SE LE CT RN UT LE CT 5 3 6 AR 2 7 1 MO TE TR 8 0 RE CC ON 10 9 -4 -2 OL 0 J10A +2 -6 +4 -8 -1 SO 0 FT +6 +8 +1 CR 0 ISP PO W ER ON Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC OF F 8. The front of the machine may now gently be pulled forward to gain access to the display Board. Note: The front of the machine cannot be removed completely, only pulled forward a few inches. CAUTION Observe static precautions detailed in PC Board Troubleshooting Procedures at the beginning of this section. 9. Beginning at the right side of the control board remove plugs J10A and J10B. Note: Be sure to label each plugs position upon removal. See Figure F.18. 6. Using a flat head screwdriver remove the two screws and their washers from above and below the input power switch. See Figure F.17. 10. Working your way across the top of the board from right to left, label and remove plugs #J9, #J8, #J7, #J6, and #J5. See Figure F.18. 7. Using a phillips head screwdriver remove the four screws from around the two welder output terminals on the front of the machine. See Figure F.17. 11. Working your way down the left side of the board, label and remove plugs #J4 and #J3. See Figure F.18. V350-PRO Return to Master TOC Return to Section TOC F-54 TROUBLESHOOTING & REPAIR F-54 CONTROL BOARD REMOVAL AND REPLACEMENT (continued) 12. Using a 3/8” nut driver remove the two mounting nuts from the top two corners of the control board. See Figure F.19. 14. Replace the control board. 13. Cut any necessary cable ties. Return to Master TOC Return to Section TOC FIGURE F.19 CONTROL BOARD MOUNTING SCREW LOCATION Return to Master TOC Return to Section TOC Mounting Nuts (3/8") t h ig e d i S R 15. Replace the two 3/8” mounting nuts at the top two corners of the control board. 19. Replace the four screws from around the two welder output terminals on the front of the machine. 16. Replace any previously removed cable ties. Return to Master TOC Return to Section TOC 17. Replace plugs #J3, #J4, #J5, #J6, #J7, #J8, #J9, #J10B, and #J10A previously removed. 20. Replace the two case front mounting screws at the bottom of the front of the machine. 21. Replace the case wraparound cover. 18. Replace the two screws and their washers from above and below the input power switch. 22. Perform the Voltage and Current Calibration Procedure. V350-PRO Return to Master TOC Return to Section TOC F-55 TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call or 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the display board for maintenance or replacement. MATERIALS NEEDED 5/16” Nut Driver Flathead Screwdriver Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Phillips Head Screwdriver This procedure takes approximately 30 minutes to perform. V350-PRO F-55 Return to Master TOC Return to Section TOC F-56 TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.20. – DISPLAY BOARD LOCATION Return to Master TOC Return to Section TOC Display Board Mode Board or Advanced Process Board L1 L1 11 07 CS 71 11 D1 30 -1 -2 ST AT US IN PU T MO DE SE LE CT L11 110 A -1 AM PS V VO LTS A OU CC TP -STI CK -STI 7018 CK TIG 60 10 GT AW CV -W IRE CV -FLU X CO RE CC LE CT IN G 6 TE RM IN AL S CT AR C RO 8 10 9 CO NT 7 0 MO LE 5 2 1 RE D TE SE T ST AR T 4 3 SE RN WEL HO D WA UT -4 -2 L 0 +2 -6 +4 -8 -10 SO FT +6 +8 +1 CR 0 ISP PO WE R ON Return to Master TOC Return to Section TOC OF F PROCEDURE 1. Remove input power to the V350-PRO. Return to Master TOC Return to Section TOC 2. Using a 5/16” nut driver remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the display board behind the front panel of the machine. See Figure F.20. V350-PRO F-56 Return to Master TOC Return to Section TOC F-57 TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.21. – CASE FRONT SCREW LOCATION A MPS V OLTS CONTROL WELD TERMINALS REMOTE LOCAL OUTPUT REMOTE ON Return to Master TOC Return to Master TOC SELECT SELECT ATTRIBUTE MEMORY BUTTON SELECT KNOB Phillips Head Screws ADJUST ATTRIBUTE Flathead Screws _ + 5/16" Screws 5. Using a 5/16” nut driver remove the two screws from the bottom of the front of the machine. See Figure F.21. 6. Using a flat head screwdriver remove the two screws and their washers from above and below the input power switch. See Figure F.21. Return to Master TOC Return to Section TOC Return to Section TOC SELECT Return to Section TOC F-57 8. The front of the machine may now gently be pulled forward to gain access to the display Board. Note: The front of the machine cannot be removed completely, only pulled forward a few inches. 9. The display board is now accessible to replace. 7. Using a phillips head screwdriver remove the four screws from around the two welder output terminals on the front of the machine. See Figure F.21. V350-PRO Return to Master TOC Return to Section TOC F-58 TROUBLESHOOTING & REPAIR DISPLAY BOARD REMOVAL & REPLACEMENT (continued) 10. Remove plug J37 from the display board. See the Wiring Diagram. 11. Remove plug J3 originating from the control board located directly across from the display board. See the Wiring Diagram. 12. Remove the display board. Note: Gentle prying from behind the board may be required. 13. Replace the display board. \15. Replace the four phillips head screws removed from the front of the machine located around the two welder output terminals. 16. Replace the two flat head screws and their washers mounting the input power switch. 17. Using a 5/16” nut driver replace the two screws previously removed from the bottom front of the machine. 18. Replace the case wraparound cover. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 14. Replace plugs #J3 and #J37 previously removed. Return to Section TOC F-58 V350-PRO Return to Master TOC TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). Return to Master TOC Return to Section TOC Return to Section TOC F-59 DESCRIPTION The following procedure will aid the technician in removing the main switch board for maintenance or replacement. MATERIALS NEEDED 5/16” Nut Driver Flathead Screwdriver Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 7/16” mm Socket 3/16” Allen Wrench 3/8” Nut Driver This procedure takes approximately 35 minutes to perform. V350-PRO F-59 Return to Master TOC Return to Section TOC F-60 MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.22. – MAIN SWITCH BOARD LEAD LOCATIONS 202 207 J22 - + - Return to Master TOC 201 Return to Section TOC F-60 TROUBLESHOOTING & REPAIR + 209 204 205 208 J21 J20 - + - + 206 203 1. Remove the input power to the V350-PRO. Return to Master TOC Return to Section TOC PROCEDURE 2. Using a 5/16” nut driver remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. Return to Master TOC 6. Using a 7/16” socket, remove leads 201, 202, 203, 204, 205, 206, 207, 208, 209 from the switch board. Note lead terminal locations and washer positions upon removal. 7. Locate and disconnect the three harness plugs associated with the main switch board. Plugs #J20, #J21, #J22. See Figure F.22. CAUTION Return to Section TOC 5. Using a 5/16” and 3/8” nut driver remove the input lead shield from the area at the bottom of the main switch board. Observe static precautions detailed in PC Board Troubleshooting Procedures at the beginning of this section. Failure to do so can result in permanent damage to equipment. 8. Locate the eight capacitor terminals and remove the nuts using a 7/16” socket or nut driver. Note the position of the washers behind each nut for replacement. 4. Locate the main switch board and all associated plug and lead connections. See figure F.22. See Wiring Diagram. V350-PRO Return to Master TOC Return to Section TOC F-61 TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.23. – 3/16” ALLEN BOLT LOCATION - + - + Return to Master TOC Return to Section TOC 3/16" ALLEN BOLTS - + - 9. Using a 3/16” allen wrench remove four allen bolts and washers as shown in Figure F.23. At this point, the board is ready for removal. Carefully remove the board from the 4 nylon mounting pins. Note: Depress the retaining pins on the sides of the nylon mounts to release the board. See Figure F.24. Return to Master TOC Return to Section TOC 10. Carefully maneuver the board out of the machine. 11. Apply a thin coat of Penetrox A-13 to the IGBT heatsinks on the back of the new switch boards mating surfaces. Note: Keep compound away from the mounting holes. 12. Mount the new board on the nylon m o u n t ing pins. + 13. Replace the four allen bolts and washers previously removed. 14. Replace the eight capacitor terminal nuts, washers, and necessary leads previously removed. 15. Reconnect the three harness plugs previously removed. 16. Reconnect the nine leads (#201-#209) that were previously removed. 17. Pre-torque all screws to 25 inch lbs. before tightening to 44 inch lbs. 18. Replace the case wraparound cover. Return to Master TOC Return to Section TOC FIGURE F.24. – NYLON MOUNTING PIN DEPRESS LOCKING TAB ON MOUNTING PIN V350-PRO F-61 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-62 NOTES V350-PRO F-62 Return to Master TOC Return to Section TOC F-63 TROUBLESHOOTING & REPAIR ADVANCED PROCESS PANEL REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the mode board for maintenance or replacement. MATERIALS NEEDED 5/16” Nut Driver Small Flathead Screwdriver Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Flathead Screwdriver Small Phillips Head Screwdriver Phillips Head Screwdriver 9/16” Wrench This procedure takes approximately 40 minutes to perform. V350-PRO F-63 TROUBLESHOOTING & REPAIR F-64 ADVANCED PROCESS PANEL REMOVAL AND REPLACEMENT (continued) Return to Master TOC Return to Section TOC F-64 FIGURE F.25. – MODE BOARD LOCATION Return to Master TOC Return to Section TOC Display Board Mode Board or Advanced Process Board L1 L1 11 07 CS 71 11 D1 30 -1 -2 ST AT US IN PU T MO DE SE LE CT L11 110 A -1 AM PS V VO LTS A OU CC TP -STI CK CC -STI 7018 CK TIG 60 10 GT AW CV -W IRE CV -FLU X CO RE LE CT IN G 6 TE RM IN AL S CT AR C RO 8 10 9 CO NT 7 0 MO LE 5 2 1 RE D TE SE T ST AR T 4 3 SE RN WEL HO D WA UT -4 -2 L 0 +2 -6 +4 -8 -10 SO FT +6 +8 +1 CR 0 ISP PO WE R F Return to Master TOC Return to Section TOC ON OF PROCEDURE 1. Remove input power to the V350-PRO. Return to Master TOC Return to Section TOC 2. Using a 5/16” nut driver remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the advanced process board behind the front panel of the machine. See Figure F.25. V350-PRO F-65 F-65 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR ADVANCED PROCESS PANEL REMOVAL AND REPLACEMENT (continued) FIGURE F.26. – CASE FRONT SCREW REMOVAL A MPS V OLTS Return to Master TOC OUTPUT SELECT SELECT ATTRIBUTE TTRIBUTE MEMORY BUTTON MEMOR BUTTON SELECT KNOB Return to Master TOC ADJUST ATTRIBUTE TTRIBUTE Flathead Screws _ + 5/16" Screws 5. Using a 5/16” nut driver remove the two screws from the bottom of the front of the machine. See Figure F.26. 6. Using a flat head screwdriver remove the two screws and their washers from above and below the input power switch. See Figure F.26.. Return to Section TOC REMOTE ON SELECT Phillips Head Screws Return to Section TOC WELD TERMINALS REMOTE LOCAL Return to Master TOC Return to Section TOC CONTROL 7. Using a phillips head screwdriver remove the four screws from around the two welder output terminals on the front of the machine. See Figure F.26. 8. The front of the machine may now gently be pulled forward to gain access to the mode board. Note: The front of the machine cannot be removed completely, only pulled forward a few inches. V350-PRO ADVANCED PROCESS PANEL REMOVAL AND REPLACEMENT (continued) FIGURE F.27.. – CASE FRONT A MPS V OLTS CONTROL WELD TERMINALS OUTPUT SELECT 5/16" Screws SELECT ATTRIBUTE TTRIBUTE MEMORY BUTT MEMOR BUTTON ON SELECT KNOB ADJUST ATTRIBUTE TTRIBUTE Adjust Knob Select Knob Return to Master TOC _ Return to Section TOC REMOTE ON SELECT Return to Master TOC Return to Section TOC REMOTE LOCAL + 9. Remove plug #J33 from the remote board. See the Wiring Diagram. 10. Open the cover of the weld mode display on the front of the machine. 11. Using a 5/16” nut driver, remove the three 5/16” screws as shown in Figure F.27. Return to Master TOC 12. Place both knobs in the six o’clock position. Return to Section TOC F-66 TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-66 13. Using a small flathead screwdriver, loosen the screw in the “Select” knob and the “Adjust” knob. The knobs should slide off of their shafts. See Figure F.28. 14. Using a 9/16” wrench remove the nuts and their washers behind the two knobs previously removed. 15. Perform the Remote Board Procedure. (Start at step #10) Removal 16. Using a phillips head screwdriver remove the two phillips head mounting screws at the bottom of the Advanced Process board. 17. Remove the Advanced Process board. V350-PRO Return to Master TOC Return to Section TOC F-67 TROUBLESHOOTING & REPAIR F-67 ADVANCED PROCESS PANEL REMOVAL AND REPLACEMENT (continued) FIGURE F.28. – SCREW IN CAP Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Small Flathead Screwdriver 18. Replace the Advanced Process board. 19. Replace the two phillips head screws at the bottom of the advanced process board. 20. Perform the Remote Board Replacement Procedure. 21. Replace the 9/16” nuts and their washers behind the “Adjust” and “Select” knobs. Return to Master TOC Return to Section TOC 22. Using a small screwdriver replace the two knobs previously removed. 25. Replace the four phillips head screws removed from the front of the machine located around the two welder output terminals. 26. Replace the two flat head screws and their washers from around the input power switch. 27. Using a 5/16” nut driver replace the two screws previously removed from the bottom front of the machine 28. Replace the case wraparound cover. 23. Replace the three 5/16” screws previously removed from the front of the machine located around the Advanced Process board. 24. Reconnect plug #J33 previously removed. V350-PRO Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-68 NOTES V350-PRO F-68 Return to Master TOC Return to Section TOC F-69 TROUBLESHOOTING & REPAIR REMOTE BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the status board for maintenance or replacement. MATERIALS NEEDED 5/16” Nut Driver Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Flathead Screwdriver Phillips Head Screwdriver This procedure takes approximately 30 minutes to perform. V350-PRO F-69 Return to Master TOC Return to Section TOC F-70 TROUBLESHOOTING & REPAIR REMOTE BOARD REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the V350-PRO. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 2. Using a 5/16” nut driver remove the case wraparound cover. 4. Locate the remote board behind the front panel of the machine. See Figure F.29. Return to Master TOC Return to Section TOC FIGURE F.29. – REMOTE BOARD LOCATION Remote Board Display Board Mode Board or Advanced Process Board L1 L1 11 07 CS 71 11 D1 30 -1 -2 ST AT US IN PU T MOD E SE LE CT Return to Section TOC Return to Master TOC Return to Master TOC L11 110 Return to Section TOC F-70 A -1 AM PS V VO LTS A OU CC TP -S TIC K 70 CC -S 18 TIC K 60 TIG 10 GT AW CV -W IR E CV -FL UX CO RE D 4 LE CT RN WEL D TE RM INAL S HO T ST AR T SE LE CT 5 3 SE WA UT 6 7 1 8 0 RE MO TE AR C CO NT RO L 2 ING 10 9 -4 -2 0 +2 -6 +4 -8 -10 SO FT +6 +8 +1 CR 0 ISP PO WE R ON OF F V350-PRO Return to Master TOC Return to Section TOC F-71 F-71 TROUBLESHOOTING & REPAIR REMOTE BOARD REMOVAL AND REPLACEMENT (continued) 5. Using a 5/16” nut driver remove the two screws from the bottom front of the machine. See Figure F.30. 6. Using a flat head screwdriver remove the two screws and their washers from around the input power switch. See Figure F.30. 8. The front of the machine may now gently be pulled forward to gain access to the remote Board. Note: The front of the machine cannot be removed completely, only pulled forward a few inches. 9. The remote board is now accessible to replace. Return to Master TOC Return to Section TOC 7. Using a phillips head screwdriver remove the four screws from around the two welder output terminals on the front of the machine. See Figure F.30. FIGURE F.30. – FRONT SCREW REMOVAL A MPS V OLTS CONTROL WELD TERMINALS REMOTE LOCAL OUTPUT REMOTE ON Return to Master TOC Return to Section TOC SELECT SELECT SELECT ATTRIBUTE TTRIBUTE MEMORY BUTTON MEMOR BUTTON SELECT KNOB Phillips Head Screws ADJUST ATTRIBUTE TTRIBUTE Flathead Screws _ + Return to Master TOC Return to Section TOC 5/16" Screws V350-PRO Return to Master TOC Return to Section TOC F-72 TROUBLESHOOTING & REPAIR REMOTE BOARD REMOVAL AND REPLACEMENT (continued) 10. Remove plug J37 from the display board. See Wiring Diagram. 17. Replace plug J37 previously removed from the display board. 11. Remove plugs J33, J333 and J331 from the remote board. 18. Replace the four phillips head screws removed from the front of the machine located around the two welder output terminals. 12. Using a flat head screwdriver, remove the two mounting screws and washers from the bottom of the remote board. See Figure F.31. Return to Master TOC Return to Section TOC 19. Replace the two flat head screws and their washers from around the input power switch. 20. Using a 5/16” nut driver replace the two screws previously removed from the bottom front of the machine 13. Remove the remote board. 14. Replace the remote board. 15. Replace the two flat head mounting screws and washers previously removed from the bottom of the remote board. 21. Replace the case wraparound cover. 16. Replace plugs J331, J333, J33 and previously removed from the remote board. FIGURE F.31. – REMOTE BOARD (PLUG LOCATION) Return to Section TOC Return to Master TOC Return to Master TOC J33 Return to Section TOC F-72 Remote Board J333 J331 Flathead Mounting Screws V350-PRO F-73 F-73 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR SNUBBER BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the snubber board for maintenance or replacement. MATERIALS NEEDED 5/16” Nut Driver Return to Section TOC Return to Master TOC This procedure takes approximately 15 minutes to perform. Return to Section TOC Return to Master TOC 7/16 Socket or Nut Driver V350-PRO Return to Master TOC Return to Section TOC F-74 TROUBLESHOOTING & REPAIR F-74 SNUBBER BOARD REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the V350-PRO. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 2. Using a 5/16” nut driver remove the case wraparound cover. 4. Locate the snubber board.. See Figure F.32. Return to Master TOC Return to Section TOC FIGURE F.32. – SNUBBER BOARD LOCATION Snubber Board LEFT SIDE 5. Remove small lead #B1 from the board. Figure F.33. See 7. Carefully remove the snubber board. Return to Master TOC Return to Section TOC 8. Replace the snubber board. 6. Remove the four bolts using a 7/16” socket. Two of these bolts have leads #30 and #10 connected to them. Note the position of all leads and associated washers upon removal. 9. Replace the bolts, leads, and washers previously removed. Torque bolt to 30-40 Inch Lbs. 10. Replace the case wraparound cover. FIGURE F.33. – SNUBBER BOARD LEADS (CLOSE UP) Return to Master TOC Return to Section TOC Lead 30 Lead B1 Lead 20 V350-PRO F-75 F-75 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR POWER BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the power board for maintenance or replacement. MATERIALS NEEDED 5/16” Nut Driver Return to Master TOC Return to Section TOC 3/8” Nut Driver Return to Master TOC Return to Section TOC This procedure takes approximately 20 minutes to perform. V350-PRO Return to Master TOC Return to Section TOC F-76 TROUBLESHOOTING & REPAIR F-76 POWER BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.34. POWER BOARD LOCATION Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC POWER BOARD LEFT SIDE PROCEDURE 1. Remove input power to the V350-PRO. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 2. Using a 5/16” nut driver remove the case wraparound cover. 4. Locate the power board. See Figure F.34. V350-PRO Return to Master TOC Return to Section TOC F-77 TROUBLESHOOTING & REPAIR POWER BOARD REMOVAL AND REPLACEMENT (continued) 5. Locate the three plug connections. J41, J42 and J43. See figure F.35. 6. Carefully remove the three plugs from the power board. 7. Remove the three nuts and at the corners of the board using a 3/8” nut driver. Board is ready for removal. 9. Replace with new power board. 10. Secure the new power board into its proper position with the three 3/8” nuts previously removed. 11. Replace the three plugs previously removed. Plugs J41, J42 and J43. 12. Replace the case wraparound cover. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 8. Remove the power board. Return to Section TOC F-77 FIGURE F.35. – POWER BOARD LEAD LOCATION J42 J41 V350-PRO J43 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-78 NOTES V350-PRO F-78 Return to Master TOC Return to Section TOC F-79 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the input rectifier for maintenance or replacement. MATERIALS NEEDED 3/16” Allen wrench Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5/16” Nut Driver Flathead Screwdriver Penetrox A-13 Heatsink Compound Silicon Sealant This procedure takes approximately 30 minutes to perform. V350-PRO F-79 Return to Master TOC Return to Section TOC F-80 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) PROCEDURE 6. Remove the six screws from the terminals using a flathead screwdriver. Carefully note the position of all leads and their positions upon removal. See Figure F.37. 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 7. Using a 3/16”in. allen wrench remove the two mounting screws and washers from the input bridge. See Figure F.37. 4. Locate the input rectifier. See figure F.36. 8. Remove the input bridge. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5. Carefully remove the silicon sealant insulating the six input rectifier terminals. FIGURE F.36. – INPUT RECTIFIER LOCATION INPUT RECTIFIER A AM PS V VO LTS A CC -S CC -S TIC OU TP K 70 18 TIC K 60 TIG 10 GTA W CV -W IR E CV -FLU XC OR E TE S CT IN LD INA L G 5 3 LE RN WE RM TS 4 SE WA UT HO D SE LE TA CT RT 6 AR 2 C TE 10 9 CO RO 8 0 MO NT 7 1 RE -4 -2 L 0 +2 -6 +4 -8 -1 SO 0 FT +6 +8 +1 CR 0 ISP PO W ER ON Return to Master TOC O FF Return to Section TOC F-80 V350-PRO Return to Master TOC Return to Section TOC F-81 F-81 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) 9. Apply a thin coat of Penetrox A-13 heatsink compound to the point of contact between the input rectifier and the mounting surface. 10. Secure the new input bridge into its proper position with the two 3/16”in. allen mounting screws previously removed. Torque to 44 inch pounds. 11. Reconnect the previously removed leads to their proper locations. Torque to 31 inch pounds. 12. Cover the input rectifier and its six terminals with silicon sealant. 13. Replace the case wraparound cover. Return to Master TOC Small Lead "H1" To Auxiliary Transformer 3/16" ALLEN BOLTS C B #207 #207A Return to Master TOC Return to Section TOC Return to Section TOC FIGURE F.37. – INPUT RECTIFIER (CLOSE-UP) Return to Master TOC Return to Section TOC A #209 FRONT REAR V350-PRO Small Lead "A" To Circuit Breaker Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-82 NOTES V350-PRO F-82 Return to Master TOC Return to Section TOC F-83 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the output rectifier modules for maintenance or replacement. MATERIALS NEEDED 3/16” Allen wrench Return to Master TOC Return to Section TOC 9/64” Allen wrench 5/16” Nut Driver 7/16” Wrench Flathead Screwdriver Penetrox A-13 Heatsink Compound Thin Knife/Screwdriver Return to Master TOC Return to Section TOC This procedure takes approximately 30 minutes to perform. V350-PRO F-83 Return to Master TOC Return to Section TOC F-84 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 4. Locate the output diode modules located behind the snubber board. See figure F.38. 5. Before the output rectifier modules can be reached, the Snubber Board Removal Procedure must be performed. 6. After the snubber board is removed, remove the four leads connected to the modules using a 3/16” allen wrench. These leads are #X4, #X2, #20, #40. Note their positions for reassembly. See Figure F.39. 7. Remove the copper plates from the tops of the modules. FIGURE F.38. – OUTPUT RECTIFIER MODULE LEAD LOCATIONS Output Diode Modules Snubber Board Return to Master TOC LEFT SIDE Return to Section TOC F-84 V350-PRO Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-85 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER MODULES REMOVAL AND REPLACEMENT (continued) 8. Under the copper plate previously removed, there is an allen bolt. Remove it using a 9/64” allen wrench. See Figure F.39. 13. The screw threads may catch on the threads of the heat sink, so be sure to get the face of the screw into contact with the surface of the module (using just hand torque). 9. Using a 7/16” socket remove the mounting bolts at the top and bottom of the modules. See Figure F.39. 14. Using a 7/16” socket, tighten each mounting bolt to between 5 and 10 inch pounds. 10. The output rectifier modules are ready for removal and/or replacement. 15 Tighten the center allen screw to between 12 and 18 inch pounds. 11. Before replacing the diode module, apply a thin even coat of Penetrox A-13 heatsink compound to the bottom surface of the diode module. Note: Keep the compound away from the mounting holes. 16. Tighten each mounting bolt again (30 to 40 inch pounds this time). 12. Press the module firmly against the sink while aligning the mounting holes. Insert each outer screw through a spring washer and then a plain washer and into the holes. Start threading all three screws into the heat sink (2 or 3 turns by hand). 15. Replace leads #X2, #X4, #20, #40 to their original terminals in their proper positions. Torque bolts to 30-40 Inch Pounds. 16. Perform the Snubber Board Replacement Procedure detailed earlier in this section. 17. Replace the case wraparound cover. FIGURE F.39. – OUTPUT RECTIFIER MODULE MOUNTING BOLT LOCATIONS Return to Section TOC Return to Master TOC Return to Master TOC 40 Return to Section TOC F-85 20 Mounting Bolts X4 X2 3/16" Allen Bolts 9/64" Allen Bolts Mounting Bolts V350-PRO Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-86 NOTES V350-PRO F-86 F-87 F-87 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. Return to Master TOC Return to Section TOC If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD). DESCRIPTION The following procedure will aid the technician in removing the current transducer for maintenance or replacement. MATERIALS NEEDED 5/16” Nut Driver 1/4” Nut Driver Return to Master TOC Return to Section TOC 1/2” Nut driver 3/8” Nut Driver Channel Locks Flathead Screwdriver Phillips Head Screwdriver Hammer Crescent Wrench Pliers Return to Master TOC Return to Section TOC This procedure takes approximately 45 minutes to perform. V350-PRO Return to Master TOC Return to Section TOC F-88 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) PROCEDURE 4. Using a 5/16” nut driver remove the four screws from the bottom and right side of the rear assembly. See Figure F.40. 1. Remove input power to the V350-PRO. 2. Using a 5/16” nut driver remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FIGURE F.40. – CASE BACK SCREW LOCATIONS REAR OFF OFF OFF Return to Master TOC Plastic Nut Return to Section TOC F-88 5/16" Mounting Screws V350-PRO Return to Master TOC Return to Section TOC F-89 F-89 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) 5. Label and remove the five leads connected to the reconnect panel. Pliers may be necessary. 6. Label and remove the two leads connected to the CB2 circuit breaker. 7. Using a crescent wrench, remove the large plastic nut from around the input power line located at bottom of the rear assembly. See Figure F.41. 9. Using a hammer and a flathead screwdriver, firmly tap the metal nut from the bottom of one of its ribs. This tapping will loosen the nut. Note: Be sure to tap from the bottom so the nut loosens in a counter clockwise fashion if viewed from the front of the machine. 10. Using a 3/8” nut driver label and remove leads #202, #203, #206, #207A from the reconnect switches. See Figure F.41. 8. Locate the steel nut located directly on the other side of the rear assembly behind the plastic nut that was previously removed. See Figure F.41. Return to Master TOC Return to Section TOC FIGURE F.41. LEAD LOCATIONS #206 #202 #207A Return to Master TOC Return to Section TOC #203 A AM PS V VO LTS A OU TP LIN C ELOLN EC TR IC WA RN IN G IN R EM O TE VE UT WE LD TE RM IN AL S SE LE CT RT EC V3 50 -P RO PO W ut Nut N tal stic e M Pla ER ON Return to Master TOC Return to Section TOC O FF V350-PRO Return to Master TOC Return to Section TOC F-90 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) 11. The back of the machine may now gently be pulled away to gain access to the current transducer. Note: The rear of the machine cannot be removed completely. 16. Using a 3/8” wrench, remove the three mounting screws from the output diode heatsink assembly. Take note placement of insulation for reassembly. See Figure F.42. 12. Carefully swing the rear of the machine open to the left while facing the rear of the machine. 17. Cut any necessary cable ties and carefully remove the heavy lead from the diode heatsink using a 1/2” nut driver. Return to Master TOC Return to Section TOC 13. Perform the Procedure. Snubber Board Removal 18. Remove the output diode heatsink assembly through the rear of the machine. 14. Remove leads #X2 and #20 from the output diode module. 19. Remove plug #J90 from the current transducer. 15. Remove leads #X4 and #40 from the other output diode module. 20. Using a 3/8” nut driver, remove the two mounting nuts from the current transducer. FIGURE F.42– OUTPUT HEATSINK MOUNTING SCREW LOCATION Return to Section TOC Return to Master TOC Return to Master TOC 3/8" MOUNTING BOLTS Return to Section TOC F-90 V350-PRO Return to Master TOC Return to Section TOC F-91 TROUBLESHOOTING & REPAIR F-91 CURRENT TRANSDUCER REMOVAL AND REPLACEMENT (continued) 21. Replace the current transducer. 22. Replace the two 3/8” mounting nuts previously removed. 23. Reconnect plug #J90 to the current transducer. 30. Using a 3/8” wrench, replace leads #202, #203, #206, and #207A previously removed from the reconnect switches. 31. Tighten the metal nut previously removed from the inside of the rear wall on the back of the machine. Channel locks may be necessary. 24. Replace any necessary cable ties previously cut. Return to Master TOC Return to Section TOC 25. From the rear of the machine, replace the heavy flex lead to the bottom of the output diode heatsink assembly using a 1/2” wrench. Note: Don’t forget to include all washers. 32. Replace the large plastic nut from around input power line located at the back of the machine. 33. Replace the five leads to the reconnect panel in their proper locations. 26. Replace the output diode heatsink assembly previously removed using a 3/8” wrench. 34. Replace the two CB2 circuit breaker leads previously removed. Note: Be sure to place insulation in its original location. 35. Using a 5/16” nut driver, replace the four screws at the bottom and right side of the rear assembly. 27. Replace leads X2, #20, X4, # 40 previously removed from the two output diode modules. Torque to 30-40 inch lbs. 36. Replace the case wraparound cover. 37. Perform the Voltage and Current Calibration Procedure. 28. Perform the Snubber Board Replacement Procedure. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 29. The rear of the machine may now be placed back into its original position. V350-PRO Return to Master TOC Return to Section TOC F-92 TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR Retest a machine: If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. If you repair or replace any electrical components: Press and hold the MODE SELECT button (or the MEMORY button if an advanced process panel is installed) while applying power to the machine. Rotate the output control knob until the display reads SPIdIAG. Release the MODE SELECT button. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Test Steps Return to Section TOC F-92 Required Action Expected Results Lft.display Rt. display 1 Adjust the output control potentiometer to its highest setting (completely clockwise). oCP HI 2 Adjust the output control potentiometer to its lowest setting (completely counterclockwise). oCP Lo NOTE: If a standard Mode Select Panel is not installed in the machine, skip steps 3-12 3 HI HSP Adjust the hot start potentiometer to its highest setting. 4 Lo HSP Adjust the hot start potentiometer to its lowest setting. 5 HI ACP Adjust the arc control potentiometer to its highest setting. 6 Lo ACP Adjust the arc control potentiometer to its lowest setting. 7 1 NodE All weld mode indicator LEDs should be off. Press the weld mode select push button to select the first weld mode. Only the top weld mode indicator LED should be on, all others should be off. 8 2 NodE Press the weld mode select push button again to select the second weld mode. Only the second weld mode indicator LED should be on, all others should be off. 9 Press the weld mode select push button again to select 3 NodE the third weld mode. Only the third weld mode indicator LED should be on, all others should be off. 4 Press the weld mode select push button again to select NodE 10 the fourth weld mode. Only the fourth weld mode indicator LED should be on, all others should be off. 5 NodE Press the weld mode select push button again to select 11 the fifth weld mode. Only the bottom weld mode indicator LED should be on, all others should be off. Press the weld mode select push button again and veri12 NodE CLr fy that all weld mode indicator LEDs are off. The test will automatically advance to step 25 V350-PRO Return to Master TOC Return to Section TOC F-93 TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR Expected Results Lft.display Rt. display NOTE: If an Advanced Process Panel is not installed in the machine, skip steps 13-24 =100 LEnc 13 Turn the Advanced Process Panel left encoder clockwise until the value displayed on the Advanced Process Panel lower left display equals 100. Note that this should require exactly one revolution of the encoder knob. Test Steps Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Required Action Turn the Advanced Process Panel left encoder counterclockwise until the value displayed on the Advanced Process Panel lower left display equals zero. Note that this should require exactly one revolution of the encoder knob. Turn the Advanced Process Panel right encoder clockwise until the value displayed on the Advanced Process Panel lower left display equals 100. Note that this should require exactly one revolution of the encoder knob. LEnc =0 rEnc =100 16 Turn the Advanced Process Panel right encoder counterclockwise until the value displayed on the Advanced Process Panel lower left display equals zero. Note that this should require exactly one revolution of the encoder knob. rEnc =0 17 Press and hold the Advanced Process Panel Memory button until the right display changes to on. EorY oFF 18 Release the Advanced Process Panel Memory button. EorY on 19 Press and hold the Advanced Process Panel Select button. rSEL oFF 20 Release the Advanced Process Panel Select button. rSEL on 21 Verify that the Advanced Process Panel upper left display contains the following pattern and that the brightness of the characters is uniform: “0123456789ABCDEF” Press and release the Advanced Process Panel Memory button to advance to the next step. dISP 1 22 Verify that the Advanced Process Panel lower left display contains the following pattern and that the brightness of the characters is uniform: “0123456789ABCDEF” Press and release the Advanced Process Panel Memory button to advance to the next step. dISP 2 14 Return to Section TOC F-93 15 V350-PRO Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-94 TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR Test Steps Return to Master TOC Return to Master TOC Return to Section TOC Required Action Expected Results Lft.display Rt. display 23 Verify that the Advanced Process Panel upper right display contains the following pattern and that the brightness of the characters is uniform: “0123456789ABCDEF” Press and release the Advanced Process Panel Memory button to advance to the next step. dISP 3 24 Verify that the Advanced Process Panel lower right display contains the following pattern and that the brightness of the characters is uniform: “0123456789ABCDEF” Press and release the Advanced Process Panel Memory button to advance to the next step. dISP 4 25 The weld terminals “ON” and “REMOTE” LEDs should both be off. Press the weld terminals push button to select weld terminals (studs) “ON” and verify that the weld terminals “ON” LED turns on. SudS on 26 Press the weld terminals push button again to select weld terminals “REMOTE” and verify that the weld terminals “ON” LED turns off and that the weld terminals “REMOTE” LED turns on. Press the weld terminals push button again and verify that both of the weld terminals LEDs are off. The “LOCAL” and “REMOTE” workpoint source LEDs should both be off. Press the workpoint source push button to select “LOCAL” and verify that the workpoint source “LOCAL” LED turns on and that the “REMOTE” workpoint source LED remains off. SudS rE SudS cLr LorE LocL 29 Press the workpoint source pushbutton again to select workpoint source “REMOTE” and verify that the workpoint source “LOCAL” LED turns off and the workpoint source “REMOTE” workpoint source LED turns on. LorE rE 30 Press the workpoint source pushbutton again and verify that both workpoint source LEDs are off. LorE cLr 31 This will only appear if a potentiometer is already connected to the 6-pin amphenol connector on the front of the machine. If this message appears, disconnect the potentiometer from the 6-pin amphenol connector. dcon 6-PIn roCP 32 Connect a remote output control potentiometer to the 6pin amphenol connector on the front of the machine. con 6-PIn roCP 27 Return to Section TOC F-94 28 V350-PRO Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-95 TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR Test Steps Return to Master TOC Required Action Expected Results Lft.display Rt. display 33 Adjust the remote output control potentiometer connect- 6-PIn roCP ed to the 6-pin amphenol connector to its highest setting. HI 34 Adjust the remote output control potentiometer connect- 6-PIn roCP ed to the 6-pin amphenol connector to its lowest setting. Lo 35 This will only appear if a trigger switch is already con6-PIn rIgr nected to the 6-pin amphenol connector on the front of the machine and the trigger switch is presently on. Turn the trigger switch connected to the 6-pin amphenol connector off. oFF 36 Turn the trigger switch connected to the 6-pin amphenol 6-PIn Rigr connector on. Turn the trigger switch connected to the 6-pin amphenol 6-PIn rLgr connector off. on 37 oFF 38 This will only appear if a potentiometer is still connected to the 6-pin amphenol connector. If this message appears, disconnect the potentiometer from the 6-pin amphenol connector. dcon 6-PIn roCP 39 This will only appear if a potentiometer is already connected to the 14-pin amphenol connector. If this message appears, disconnect the potentiometer from the 14-pin amphenol connector. dcon 14-PIn roCP 40 Connect a remote output control potentiometer to the 14-pin amphenol connector. con 14-PIn roCP 41 Adjust the remote output control potentiometer connect- 14-PIn roCP ed to the 14-pin amphenol connector to its highest setting. Adjust the remote output control potentiometer connect- 14-PIn roCP ed to the 14-pin amphenol connector to its lowest setting. 42 43 Return to Section TOC F-95 44 45 This will only appear if a trigger switch is already connected to the 14-pin amphenol connector and the trigger switch is presently on. Turn the trigger switch connected to the 14-pin amphenol connector off. Turn the trigger switch connected to the 14-pin amphenol connector on. Turn the trigger switch connected to the 14-pin amphenol connector off. V350-PRO HI Lo 14-PIn rIgr oFF 14-PIn rIgr on 14-PIn rIgr oFF Return to Master TOC RETEST AFTER REPAIR Test Steps 46 This will only appear if a potentiometer is still connected to the 14-pin amphenol connector. If this message appears, disconnect the potentiometer from the 14-pin amphenol connector. dcon 14-pIn roCP 47 Test steps 21-24 verify the functionality of the gas solenoid. If an oscilloscope is available, verify that the current flowing through the gas solenoid is zero before the solenoid is energized, increases to approximately 700mA (pull in current), remains at 700 mA for approximately 150 msec, and decreases to approximately 200mA (hold current). Press the local/remote pushbutton to turn the gas solenoid on. GAS On GAS OFF < - 150msec - > 700mA +------------------------+ +-----....------+ Return to Master TOC 0mA- - - - + Return to Section TOC Expected Results Lft.display Rt. display Required Action 200mA +------------- Or, the signal can be verified by measuring 12.3 VDC +/- .5V from lead 553A to 554A (Lead 553A should be positive) 48 Press the local/remote pushbutton again to turn the gas solenoid off. After completing all of the above tests, the following will appear on the display. Return to Master TOC Verify this message appears for approximately 3 seconds Return to Section TOC F-96 TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC Return to Section TOC F-96 V350-PRO DIAg PASS Return to Master TOC Return to Master TOC G-1 ELECTRICAL DIAGRAMS G-1 TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTIONELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 MACHINE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3 CONTROL PC BOARD SCHEMATIC #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4 CONTROL PC BOARD SCHEMATIC #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5 CONTROL PC BOARD SCHEMATIC #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6 CONTROL PC BOARD SCHEMATIC #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7 CONTROL PC BOARD ASSEMBLY (L11088-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * POWER SUPPLY PC BOARD SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8 POWER SUPPLY PC BOARD ASSEMBLY (G3632-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * SWITCH PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9 SWITCH PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10 DISPLAY PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11 DISPLAY PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12 LED SELECT PC BOARD SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-13 LED SELECT PC BOARD ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-14 LED POTENTIOMETER PC BOARD SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-15 LED POTENTIOMETER PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-16 SPI REMOTE PC BOARD SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-17 SPI REMOTE PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-18 SNUBBER PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-19 SNUBBER PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-20 Return to Master TOC Return to Master TOC * NOTE: Many PC Board Assemblies are now totally encapsulated and are therefore considered to be unserviceable. The Assembly numbers are provided on this page but the actual drawings are no longer included. V350-PRO WIRING DIAGRAM INVERTEC V350 RIGHT SIDE OF MACHINE C1,C3 440460V 550575V H6 H5 H2 200208V 207A 220230V 207 F H3 MAIN TRANSFORMER AUXILIARY TRANSFORMER TP1 B TP2 C H1 X2 X4 OUTPUT RECTIFIER 605 610 612 611 602 65 66B ~ C O N T R O L 8 16 7 15 6 14 5 13 J6 R E M O T E J1 5 13 3213 4 12 3212 3 11 3211 2 10 J332 1 9 6 12 5 11 3215 4 10 3 9 2 8 1 7 553 SNB 4 75 76 554 553 2 77 J61 4 12 554 3 11 553 10 405 406 403 2 3 1 2 1 4 5 6 3 4 7 3 8 9 10 11 12 J43 J41 4 5 8 7 6 2 1 251 ADVANCED PROCESS 254 253 1 14 SPI FLEX CIRCUIT 253 2 4 1 3 J2 J5 3 1 4 2 J3 J4 12 11 10 9 8 7 10 9 8 7 6 6 3 2 1 5 4 3 2 1 5 4 ('CE' Model will not contain leads 31A or32) 251 254 E D A B 77A POWER 41A CB1 41B 21 24 32A 3.5A CB2 10A 541 532 75A 76A 76 _ 6 D M G E F 4A 32 42 J B K I 41B 2A C L N H C 75A 77A 41 32 31A A 2 2A SPI FLEX CIRCUIT (REAR VIEW) GND (REAR VIEW ) 4 WIRE FEEDER REMOTE 31 31A 31B 6 PIN REMOTE 401 402 2 J34 9 GND F 66 65 13 25 OR 75 1 J42 MODE 2 10 77 407 410 412 411 408 9 76A 21 S1 903A 903 901A 903B + COLOR CODE: B = BLACK G = GREEN R = RED W = WHITE U = BLUE N = BROWN Y = YELLOW S N U B B E R 3 SPI FLEX CIRCUIT 20 40 10 3202 54 GAS SOLENOID 275 276 3201 IN PARENTHESIS COLORS FOR "CE" MACHINES G(G/Y) 901B W(N) W R(B) V B(U) U C B A R1 TP4 TP5 NOTES: N.A. 1. FOR MACHINES WITH RED, BLACK AND WHITE POWER CORDS FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL CODE. CONNECT BLACK AND WHITE LEADS TO SUPPLY CIRCUIT. WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. 2. FOR MACHINES WITH BROWN, BLACK AND BLUE POWER CORDS FOR SINGLE PHASE INPUT: CONNECT GREEN/YELLOW LEAD TO GROUND PER NATIONAL ELECTRICAL CODE. CONNECT BLUE AND BROWN LEADS TO SUPPLY CIRCUIT. WRAP BLACK LEAD WITH TAPE TO PROVIDE 600V. INSULATION. FOR THREE PHASE INPUT: CONNECT GREEN/YELLOW GROUND PER NATIONAL ELECTRIC CODE. CONNECT BLUE, BLACK & BROWN LEADS TO SUPPLY CIRCUIT. J90 FRONT VIEW OF MACHINE 1 234 LEGEND ALL MACHINES OPTION COMPONENT OUTLINE 901 802 804 801 806 + 4 277 3204 3203 65B 554 4 OUTPUT 5 CONTROL 1 3205 4A J331 R5 10K/2W 2 6 J7 15 3216 7 16 3206 2 6 14 3207 3313 3316 3314 3305 1 2 3 1 7 15 J60B 8 8 16 5 J60A 5 4 WELD 3 TERMINALS 3304 3312 3315 3303 3 6 3301 9 9 DISPLAY 4 1 2 CONTROL RECTIFIER 66 2 10 1 1 502 503 ~ 3 11 J33 J61 5 4 12 10 6 5 1 15 2 3204 3203 3206 3205 2 J37 3314 3313 3304 3312 3303 14 608 616 607 615 609 CURRENT TRANSDUCER Return to Master TOC 505 506 503 TP3 C 5 13 J333 30 L2 REACTOR 41A or 541A (construction) 7 3315 277 3305 13 30 10 X4 40 2 J8 20 CHOKE 10 B 7 L1 REACTOR N.E. A A X3 X1 T OS BO J9 406 412 405 411 380415V + _ E _ D T OS BO 7 C SE 8 3 715 X2 + 209 A C SE PR I-IN 24V 28V 42V COM2 COM1 A 4 716 + INPUT BRIDGE A 3.5A PR I-IN PR I-O UT 208 H2 H3 H4 H5 H6 115V CB3 3 204 202 A 802 806 801 B 2 1 11 5 14 7 16 ( 380-575VAC POSITION ) 804 6 PR I-O UT 532 31 42 54 24 541 FAN 532A 31C 54 541A J52 All Other Models COM2A 206 H4 Return to Master TOC 32A FAN 31B FAN 207A H1 REAR OF MACHINE Return to Master TOC Return to Section TOC OR J52 (Construction) N.C. Return to Section TOC +C2,C4 FANFAN 203 201 205 505 - PRIMARY RECONNECT 4 1 J10A J10B xxxxxxx Pin 3 lead 31B or 31C Pin 2 lead 32A or 532A 207 5 1 1 275 12 3200/300 202 xxxxxxx 4 3 502 2 901 6 6 14 9 5 201 204 2 3 7 15 8 11 1 J22 1 903 9 3 8 6 4 10 2 1002 1020 1001 1010 7 7 3316 6 N.D. 8 3 8 16 5 J21 4 4 10 4 209 5 3201 3202 3207 3212 3213 3216 3215 3 NOTE: IF ADVANCED PROCESS PANEL IS NOT INSTALLED SPI FLEX CIRCUIT IS PLUGGED INTO J33. 276 1010 1020 610 605 608 616 1001 1002 3 2 7 208 2 6 8 205 1 402 408 401 407 5 203 3200/300 1 206 SWITCH J20 410 403 INPUT PER N.A. + Return to Master TOC WIRING DIAGRAM - INVERTEC V350-PRO 607 615 716 715 611 612 609 602 Return to Section TOC G-2 ELECTRICAL DIAGRAMS } Return to Section TOC G-2 N.D. INPUT POWER LINE FILTER IS PRESENT ONLY ON "CE" MODELS. LEFT SIDE OF MACHINE N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. J1,J6,J7, P52, CONNECTION SHOWN IS FOR 550-575V OPERATION. (CE MODELS ONLY GO TO 440VAC.) J332, J333 1 TOP CENTER PANEL FAN SHROUD CASE FRONT BASE PROTECTIVE BONDING CIRCUIT 9 ELECTRICAL SYMBOLS PER E1537 N.E. ON "CE" MODELS, MOV's ARE IN THE INPUT POWER LINE FILTER. J2,J5,J11, J22, J41, J311, P55 J9, J42, P53 J31,J33, J34,J37 8 16 1 6 5 1 10 3 2 4 1 4 J8, J20,J21 3 1 4 6 5 8 J4 J43, J331 1 7 J60 J10A, J10B 6 12 1 1 5 J61 2 15 1 CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD) 1-25-2002 G4082 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. V350-PRO CR1 B-OUT S J21-7 24V J52-7 J52-14 28V J52-5 42V 24 54 42 541 J52-16 COM1 115V J52-1 532 COM2 J52-11 31 715 6A 615 POWER BOARD 65B 41A 4 76 76A 2 77 553 4A 75 554 M L 76 E E B D 2 77A D C A 4 +5 SPI (b) SPI +15 SPI (b) POWER SUPPLY SPI GND (b) +5 RS232 (e) RS232 GND (e) SUPPLY 65 75A 4A 2B 2A 6 PIN REMOTE C 75 WIRE FEEDER REMOTE +10 Volts AMPHENOLS ARE VIEWED FROM FRONT OF MACHINE 554 GAS SOLENOID + Return to Master TOC J42-5 J42-2 J5-3 J5-2 605 610 1010 1020 611 612 615 607 715 716 J6-5 J6-10 J10B-1 J10B-2 J6-11 J6-12 J6-15 J6-7 J7-15 J7-16 VOLTAGE / FREQUENCY CONVERTER #2 (+) VOLTAGE / FREQUENCY CONVERTER #2 (-) PRIMARY CURRENT SENSE #2 (-) PRIMARY CURRENT SENSE #2 (+) GND (a) SOFT START CONTROL PULSE TRANSFORMER GATE DRIVE PULSE TRANSFORMER GATE DRIVE + 15 (a) FAN CONTROL J4-7 J4-12 J4-8 J4-10 POWERDOWN SIGNAL (HIGH=RUN) +15V (a) 408 410 407 412 408 410 411 411 J4-11 407 412 403 403 J4-3 +5V SPI (b) 402 401 406 402 401 406 J4-2 +15V SPI (b) J4-1 J4-6 GND SPI (b) +5V RS232 (e) J43-9 405 405 J4-5 GND (e) 553 graphical representation of potentiometer connection REMOTE BOARD J332-16 J332-15 J332-14 J332-13 J332-12 J332-11 J332-7 J332-6 J332-5 J332-4 J332-3 J332-2 J332-1 3303 3315 3312 J60A-2 3304 J60A-4 J60A-1 J43-8 CHOPPER GND (c) POWER SUPPLY +20 (d) GND (d) J43-7 J43-1 3207 J61-3 3202 J61-2 LED 2 LED 3 3201 J61-1 3216 J61-6 LED 4 LED 5 3215 +15V R5 REMOTE 10K/2W +15V 276 277 275 3212 3206 J61-14 3204 J61-12 J61-4 AMPS 5 8 J4, J43, J331 6 1 J61-5 DISPLAY PANEL J3-10 OR +15V 13 N.D. HOT +10V START ARC +10V CONTROL J61-13 J61-15 3213 MODE PANEL 3215 25 (+)15 VOLT SPI (+)5 VOLT SPI /SS CS1 CS2 CS3 CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD) LEGEND ALL MACHINES OPTION COMPONENT OUTLINE N.D. MISO SCK MOSI GROUND SPI J2-1 J2-3 J2-4 251 253 254 254 253 ADVANCED PROCESS PANEL NOTES : N.A. PC BOARD COMPONENTS SHOWN FOR REFERENCE ONLY. ALL COMPONENTS ARE NOT SHOWN. N.B. INPUT POWER LINE FILTER IS PRESENT ONLY ON "CE" MODELS. N.C. ON "CE" MODELS, MOV's ARE IN THE INPUT POWER LINE FILTER. ELECTRICAL SYMBOLS PER E1537 N.D. THE SPI CIRCUIT PIN ASSIGNMENTS ARE SHOWN AT THE CONTROL PCB. THIS PIN ASSIGNMENT IS THE SAME FOR ALL THE SPI CONNECTORS. 251 MODE SWITCH +15V 12 OUTPUT CONTROL +15V 3213 6 2 J3-1 J3-2 J3-3 J3-4 J3-5 J3-6 J3-7 J3-8 J3-9 VOLTS +10V +15V +15V 4 J8,J20, J21 4 1 SPI CIRCUIT SPI CIRCUIT LED 1 4 3 J9,J42,P53 1 3 J43-2 +15V +15V J60B-1 +15V REMOTE J60B-2 LOCAL J60B-3 +15V J60B-4 3313 3316 3314 3305 3216 3215 3213 3212 3211 3207 3206 3205 3204 3203 3202 3201 10 J2,J5,J11, J22,J41, J311,P55 2 1 J10A, J10B 1 SPI CIRCUIT ON WELD TERMINALS 6 7 +15V +15V +15V J60A-3 16 J31,J33, 1 J34,J37 5 +5V (a) GND (a) -15V (a) J43-3 N.D. 3316 3315 3314 3313 3312 276 275 277 3305 3304 3303 15 9 THERMOSTAT J43-6 J43-12 J43-4 +20 (c) SPI CIRCUIT J333-16 J333-15 J333-14 J333-13 J333-12 J333-8 J333-7 J333-6 J333-5 J333-4 J333-3 J333-2 J333-1 THERMOSTAT 502 THERMAL B F J331-6 J331-5 J331-4 J331-3 J331-2 N K A G 14 PIN'S "4" LEAD 6 PIN'S "4" LEAD "75" LEAD 6 PIN'S "76" LEAD SOLENOID COIL (-) 32 J F J331-11 J331-10 J331-9 J331-8 I 31 503 J42-4 J42-1 J42-3 5 J1,J6,J7, J332, J333, P52 8 1 N.D. H "2" LEAD "77" LEAD 14 PIN'S "76" LEAD SOLENOID COIL (+) Return to Master TOC Return to Section TOC 76A 503 506 POWER DOWN SIGNAL MACHINE +15 (a) CONTROL +5 (a) POWER GND (a) SUPPLY -15 (a) 66B 21 J60-A, J60-B C2/TP2 320V .05uF 160J 600V 611 J41-2 +40 VDC 66 J41-1 42 (+) STUD VOLTAGE SENSE (-) STUD VOLTAGE SENSE 1 612 54 77 J9-1 J9-3 NEGATIVE 502 41A 75A 250 Ohms X2 0 FR-IN X3 X1 3 506 31B 24 901 903 505 31B 41 CURRENT FEEDBACK ( 4V=500A ) +15V -15V CONTROL BOARD COMMON J61 - B1 41 32 32A J8-1 J8-2 J8-4 J8-6 1 505 541 CB1 801 802 804 806 TP3 150V 80J THERMOSTAT REACTOR 32A 532 3.5A CB2 R1 S1 POSITIVE C1/TP1 320V .05uF 160J 600V 903B 1010 1020 + 901B SOFT START J20-7 J20-1 607 716 FAN 901A 21 MAIN CHOKE 903A 201 J20-3 J20-2 FAN CONTROL J20-6 (200-208) (220-230) (380-415) (440-460) (550-575) H1 H2 H3 H4 H5 H6 FAN 115 VAC FAN (+) +15 801 802 804 806 CURRENT TRANSDUCER SNB xxxxxxx J22-4 J22-1 J22-2 FAN POWER J22-3 Shown connected for 200 - 240 Volt Input Voltage (-) B-IN S PULSE TRANSFORMER 207 J21-4 J21-8 J20-5 Dashed lines represent copper bus connections. CE COLORS IN PARANTHESYS 610 J21-3 + 4200 uF 2 V/F CONVERTER # 2 3.5A CB3 CONSTRUCTION MODELS DO NOT HAVE CB1, CB2 OR REMOTE, LEAD 532 GOES TO J22 AND LEAD 541 GOES TO THE CONTROL RECTIFIER IN THE CONSTRUCTION MODEL. 605 S - I OUT J90-3 +15V J90-1 -15V J90-2 GND J90-4 BK-IN A-OUT + 4200 uF A AUXILIARY TRANSFORMER X3 0 204 NEG X1 0 AC1 OUTPUT DIODES X4 202 TP1 J6-9 J6-2 J6-16 J6-8 J10A-1 J10A-2 S 208 AC2 A +15V MAIN RELAY CONTROL VOLTAGE / FREQUENCY CONVERTER #1 (+) VOLTAGE / FREQUENCY CONVERTER #1 (-) PRIMARY CURRENT SENSE #1 (-) PRIMARY CURRENT SENSE #1 (+) 609 602 616 608 1001 1002 REACTOR X2 - 203 J21-2 608 J21-1 1001 J21-5 1002 S B 4200 uF POS AC3 TP3 TP2 J21-6 616 6 V/F CONVERTER # 1 + H1 C SNUBBER BOARD S 7 - A-IN 4200 uF INPUT SWITCH Return to Master TOC 205 X4 0 206 CONTROL BOARD 602 J20-8 MAIN TRANSFORMER RECONNECT SWITCH N.C. N.B. 609 J20-4 MAIN CR1 INPUT RELAY xxxxxxx 209 GND Return to Section TOC +15 SWITCH BOARD L1 W WHITE (BROWN) INPUT L2 LINES V RED (BLACK) L3 U BLACK (BLUE) L3 G GREEN (GREEN/YELLOW) Return to Section TOC G-3 Enhanced Diagram SCHEMATIC - COMPLETE MACHINE S Return to Master TOC ELECTRICAL DIAGRAMS + Return to Section TOC G-3 14 1 J61-7 B G4093 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO Return to Master TOC ELECTRICAL DIAGRAMS G-4 SCHEMATIC - DIGITAL CONTROL PC BOARD #1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-4 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO Return to Master TOC ELECTRICAL DIAGRAMS G-5 SCHEMATIC - DIGITAL CONTROL PC BOARD #2 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-5 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO Return to Master TOC ELECTRICAL DIAGRAMS G-6 SCHEMATIC - DIGITAL CONTROL PC BOARD #3 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-6 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO Return to Master TOC ELECTRICAL DIAGRAMS G-7 SCHEMATIC - DIGITAL CONTROL PC BOARD #4 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-7 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO SCHEMATIC - POWER SUPPLY PRINTED CIRCUIT BOARD R50 D18 10 11 VCC OUT 6 8 VREF VFB 2 4 RT/CT COMP 1 5 GND CS J41 3 R15 R16 1 R10 R5 100K 100K 5 J42 D19 3A 600V IN X8 OCI1 1 OUT CNY17-3 2 6 4 Vfb1 ADJ OV1 C11 22 35V T1 475 C14 0.1 50V C47 1.0 35V 1.21K .33W R52 1.82K 221K R14 D21 1.0A 30V R46 6.19K 7 T1 4 6 C7 0.1 50V C6 4.7 35V C8 820p 50V R39 R12 56.2K 5.62K C45 150p 100V 3W 0.05 C32 10p 100V J41 R11 Return to Master TOC .750 Amp D24 9 R55 Machine Control Shut Down Capacitor +15Volts Q1 21A 200V DZ8 18V 3W Vfb1 R3 +t S 10.0 X5 4 Vref 1 12 D R51 D3 1A 600V 2 33.2 44.2K R60 R8 J41 DC Input (+) 7 Vref 1 33.2 332 10.0 R61 C13 1 200V C39 0.1 50V 3 R9 D22 1.0A 30V C41 100 16V 43.2K 10.0K +5Volts, .750 Amp C43 100 16V T1 R49 10.0K R27 R2 T1 10.0K +t .13 60V LED2 C12 .0015 2000V 10-55 VDC Operation J42 3 6A 200V R53 R6 R7 2 47.5 47.5 R57 R58 47.5 47.5 1 D4 6A 200V G C42 R13 2700p 50V 10.0K 3 1 J41 5 C44 0.1 50V C40 1.0 35V 8 DZ1 24V 3W R36 30.1 30.1 R35 IN OCI2 2 G 2 RT/CT COMP 1 221K 5 R1 C26 1 200V 150p 100V GND Overvoltage Shutdown 3 D20 1.0A 30V Vfb2 75K C53 .1 OV2 C4 820p 50V S R31 X4 C2 0.1 50V C3 4.7 35V CS R32 15.0 R29 Q2 21A 200V J43 DZ7 18V 3W 3 R38 R28 56.2K 5.62K 1.21K .33W 15Volts, .250Amps SPI C28 10p 100V 249 3W 0.05 J43 R40 3 +t .13 60V D16 16A 200V LED1 2 +5Volts, 3 Amps 150 .33W 150 .33W SPI Vref 2 332 C33 4.7 35V J43 D15 X7 5 IN OUT 1A 600V C1 4.7 35V T2 1 GND C5 0.1 50V C30 1.0 35V R44 4 15 150 .33W +5Volts, .100 Amp OCI3 CNY17-3 8 CAN 11 6 +t D7 1A 600V C17 4.7 35V 9 C18 4.7 35V C21 0.1 50V R19 10 T2 2 .24 2.49K .33W R21 2 X6 4 10 OUT 7 C29 1.0 35V R20 .24 +5Volts, .100 Amp 150 .33W 8 RS232 C20 4.7 35V C19 4.7 35V C22 0.1 50V R23 C10 4.7 35V T2 C16 R22 2700p 50V 10.0K +t D6 1A 600V GND R25 T2 1.82K 7 J43 D1 IN Vfb2 475K C46 150p 100V J43 R24 C9 0.1 50V 4 J43 D12 1A 600V 6 +20Volts .200 Amps Gate Drive J43 5 5 J43 R17 R42 13 150 .33W 44.2K C34 0.1 50V R18 C35 100 16V 43.2K D13 C36 100 16V R43 C37 100 16V R63 D17 T2 Return to Master TOC C23 1.0 35V C25 0.1 50V C24 4.7 35V 12 OV1 DZ4 3.3V 3W 6 OUT ADJ T2 > 55 VDC D14 D9 1A 600V 100K C52 150p X3 IN R30 6 VFB R33 R45 gnd_mcps OUT VREF 4 C27 DZ3 27V .5W VCC 8 15.0K R56 R34 7 R62 6 Vref 2 C49 .022 D10 D 4 DZ2 27V .5W 5.62K D25 1 CNY17-3 J42 6 C31 .0015 2000V D23 1.0A 30V 4 J42 gnd_mcps R37 D2 1A 600V 5 J42 2 D8 1A 600V R41 R26 Operation 30-55 VDC 1.00K 1 6 J42 OUT X9 14 +5V 5 1.21K .33W -15Volts, .100Amp ADJ T2 Undervoltage Detect <30VDC R48 C38 4.7 35V T1 OV2 8 X1 TL431 REF GND 1 R64 DC Input (-) 10.0K Return to Section TOC +5V Machine Control Power Supply 10.0 Return to Section TOC G-8 ELECTRICAL DIAGRAMS R4 Return to Master TOC Return to Section TOC G-8 2.49K .33W 1 +20Volts .200 Amps Gate Drive 8 X2 TL431 REF 6 J43 11 J43 J43 9 J43 1 12 LAST NO. USED ELECTRICAL SYMBOLS PER E1537 MFD ( .022/50V CAPACITORS = UNLESS OTHERWISE SPECIFIED) RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) 1A, 400V DIODES = (UNLESS OTHERWISE SPECIFIED) NOTES : N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. RC- LABELS D- SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS ± .02 ON 3 PLACE DECIMALS IS ± .002 ON ALL ANGLES IS ± .5 OF A DEGREE MATERIAL TOLERANCE (" t ") TO AGREE WITH PUBLISHED STANDARDS. DO NOT SCALE THIS DRAWING "X" INFO. Chg. Sheet No. 6-2-2000A 10-27-2000E DESIGN INFORMATION REFERENCE: DRAWN BY: JP\TK ENGINEER: APPROVED: SUPERSEDING: EQUIPMENT TYPE: SUBJECT: SCALE: NONE Digital Systems Schematic, Digital Power Supply DATE: 11-30-98 DRAWING No.: G 3631 SOLID EDGE THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A. EN-170 Return to Master TOC Return to Section TOC FILENAME: G3631-2D2 GENERAL INFORMATION NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO Return to Master TOC ELECTRICAL DIAGRAMS G-9 SCHEMATIC - SWITCH PRINTED CIRCUIT BOARD Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-9 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO G-10 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-SWITCH ITEM REQ'D N.E., N.F. G3830-1 V350 SWITCH R2 R1 S20500-4 CAPACITOR,PPMF,.0047,1000V,BOX C2,C24 2 S20500-7 CAPACITOR,PPMF,.047,1600V,BOX,10% C3,C18 2 S13490-93 CAPACITOR,TAEL,27,35V,10% C4,C21 2 S20500-1 CAPACITOR,PPMF,0.1,1000V,10%,BOX C5,C6,C15,C16 4 S16668-6 CAPACITOR,CEMO,4700p,50V,10% C7,C12,C13,C14,C20,C27,C28 8 S16668-5 CAPACITOR,CEMO,.022, 50V,20% C8,C9,C22 3 S16668-9 CAPACITOR,CEMO,150p, 100V,5% C10,C11 2 S13490-85 CAPACITOR,PCF,.027,50V,5% C25,C26 2 T11577-57 CAPACITOR,PEF,0.1,400V,10% C31,C32 2 S16668-7 CAPACITOR,CEMO,820p,50V,5% CR1,CR2 2 S14293-18 J21 R126 R127 RELAY,DPST,12VDC,AG-CDO D1,D4,D16,D17 4 T12705-59 6 DIODE,AXLDS,3A,600V,UFR D7,D8,D9,D12,D14,D18,D19 9 T12199-1 7 DIODE,AXLDS,1A,400V D20,D21 DZ1,DZ2,DZ3,DZ5,DZ6,DZ15 B201 R98 1 DZ17 C12 R86 N.C. ZENER DIODE, 1W,18V,5% 1N4746A DZ11,DZ22 2 T12702-4 ZENER DIODE, 1W,20V,5% 1N4747A J20,J21 2 S24016-8 CONNECTOR,MOLEX,MINI,PCB,RT-L,8-PIN J22 1 S24016-4 CONNECTOR,MOLEX,MINI,PCB,RT-L,4-PIN OCI1,OCI2,OCI3 3 S15000-22 OPTOCOUPLER,PHOTO-Q,70V,CNY17-3/VDE OCI4 1 S15000-29 OPTOCOUPLER,TRIAC,DRV,RANDOM,600V N.A. Q1 1 T12704-75 TRANSISTOR,NMF,T247,4A,900V(SS) N.A. Q2,Q3,Q4,Q5 4 T12704-73 MOSFET,4-PIN DIP,1A,100V,RFD110(SS) T14648-5 RESISTOR,WW,5W,3.3K,5%,SQ R87 R59 R45 T12702-45 R1,R2,R3,R4,R7,R8,R9,R10 Q3 C21 R131,R132,R133 R81 R80 R66 D20 C7 R51 R34 R5,R6,R19,R26,R93,R105 DZ23 R49 R48 R50 R33 2 C2 R129 C24 A1 R68 C11 D14 A2 X3 R46 R47 R134 R32 R82 B216 R53 B205 B204 DZ12 D12 DZ18 DZ19 3 D17 R106 R100 DZ20 Q1 DZ5 DZ6 20 R105 C16 N.B., N.G., N.J. (5 PLACES) B202 PART NO. R36 C8 R132 R56 DZ8 N.N. Return to Master TOC B209 T1 R138 R137 OCI1 R140 R139 CR2 CR1 C25 OCI4 C27 R141 D18 R109 D19 D7 C26 0 9.00 ±.04 N.K. 2 N.M. Return to Master TOC TP1 R58 J22 0 2 S19400-1652 RESISTOR,MF,1/4W,16.5K,1% 12 S19400-10R0 RESISTOR,MF,1/4W,10.0,1% 16 S19400-1003 RESISTOR,MF,1/4W,100K,1% R35,R52,R73,R84 4 S19400-6191 RESISTOR,MF,1/4W,6.19K,1% R36,R37,R123 3 S19400-2213 RESISTOR,MF,1/4W,221K,1% 12 S19400-1002 RESISTOR,MF,1/4W,10.0K,1% R41,R67 2 S19400-4752 RESISTOR,MF,1/4W,47.5K ,1% R44,R68 2 T12300-79 RESISTOR,WW, 1W,1.0,1% R46,R76 2 S19400-3322 RESISTOR,MF,1/4W,33.2K,1% R47,R64 2 S19400-2000 RESISTOR,MF,1/4W,200,1% R55,R56,R57,R58 4 S24376-3 RESISTOR,WW,10W,100,5% R61,R77 2 S19400-8251 RESISTOR,MF,1/4W,8.25K,1% R65,R120 2 S19400-2001 RESISTOR,MF,1/4W,2.00K,1% R78,R79 2 S16296-5 TRIMMER,MT,1/2W,10K, 10%,LINEAR R83,R122,R141 3 S19400-1000 RESISTOR,MF,1/4W,100,1% R137 1 S19400-3570 RESISTOR,MF,1/4W,357,1% R138 1 S19400-1500 RESISTOR,MF,1/4W,150,1% R139 1 S19400-4750 RESISTOR,MF,1/4W,475,1% R140 1 S19400-39R2 RESISTOR,MF,1/4W,39.2,1% T1 1 S13000-46 TRANSFORMER,PCB; TP1 1 T13640-24 MOV,175VRMS,120J,20MM TRI1 1 S15161-27 TRIAC,T220,8A,800V X1,X4 2 S15128-10 VOLTAGE REF,ADJ, PRECISION,431I X2,X3 2 S15128-18 OP-AMP,QUAD, HIGH-PERF,33074 R38,R40,R42,R45,R53,R59 R57 R55 R31 R12 R11 J20 RESISTOR,MF,1/4W,3.32K,1% R14,R107 R66,R69,R70,R72,R80,R82 R131 TRI1 N.H. S19400-3321 R86,R87,R134,R135 IDENTIFICATION CODE R30 R9 R10 6 R51,R62,R63,R74,R75,R85 G3830-1DO R101 R133 R7 RESISTOR,MF,1/4W,150K,1% R13,R39,R43,R60,R81,R92 R97,R98,R99,R100,R101,R106 R130 R8 RESISTOR,MF,1/4W,1.00K,1% S19400-1503 R32,R33,R34,R48,R49,R50 R142 R27 B206 20 S19400-1001 5 R15,R20,R21,R22,R27,R28 MANUFACTURED AS: B212 R69 R70 DZ13 DZ7 D4 R28 R26 C6 R67 C28 R61 R79 R22 20 Q5 Q4 R52 9 R11,R12,R30,R31,R142 R109,R128,R129 R128 DZ1 R6 16 R124,R125,R126,R127,R130 N.D. C23 C13 C20 R5 1 4 B217 D16 C31 R35 R60 ZENER DIODE, 1W,12V,5% 1N4742A DZ9,DZ10,DZ12,DZ13 B211 R97 DZ10 D1 C1 T12702-19 N.L. R93 C15 DZ16 DZ15 R78 1 NON-COMPONENT SIDE Q2 R44 C10 DZ2 DZ3 D9 ZENER DIODE, 1W,6.2V,5% 1N4735A DZ8 EYELET DETAIL R99 DZ9 ZENER DIODE, 1W,15V,5% 1N4744A T12702-40 B207 R41 R43 R20 B218 R85 C29 R77 R75 R63 R21 DZ4 R19 C5 D8 R40 R42 R15 N.L. B213 C14 R84 R62 R76 R64 R74 R73 R120 Return to Master TOC R72 C32 R39 R38 C4 Return to Section TOC OCI2 R135 X2 B208 B203 2 R65 C18 T12702-29 4 DZ16,DZ18,DZ19,DZ23 MAX. .105 CRIMP HEIGHT R125 T2 T3 R4 5 X4 OCI3 C3 10 DZ4,DZ7,DZ17,DZ20 .275 .285 R .045 R124 DZ11 R37 C9 R92 R107 R14 R13 R3 X1 R83 R123 C22 1 R122 DZ22 D21 Return to Section TOC DESCRIPTION 2 C29 11.00 ±.04 Return to Section TOC PART NO. C1,C23 NOTES: N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY. LINCOLN ELECTRIC TO SEE E2454 BEFORE HANDLING. N.B. SNAP POWER TERMINALS INTO COMPONENT SIDE OF BOARD. N.C. UNLESS OTHERWISE SPECIFIED, THESE AREAS TO BE COVERED ON BOTH SIDES OF BOARD (WHERE POSSIBLE) WITH SEALANT PRIOR TO E NCAPSULATION. N.D. INJECT SEALANT ITEM 8 THROUGH THE PC BOARD HOLES (16 HOLES) TO SEAL MODULE LEADS. CAVITY BETWEEN BOARD AND MODULE TO BE COMPLETELY FILLED WITH ITEM 8 SEALANT MATERIAL AS PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS. COVER ALL MODULE LEADS THAT PROTRUDE FROM THE NON-MODULE SIDE OF THE BOARD WITH ITEM 8 SEALANT. N.E. FEMALE EYELET TO BE AGAINST THE NON-COMPONENT SIDE AS SHOWN EYELET MUST NOT SPIN AFTER CLINCHING. N.F. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET AND ALL AROUND EYELET ON COPPER SIDE ONLY. NO ICICLES OR SOLDER BLOBS PERMITTED. N.G. AFTER SOLDERING, INSPECT POWER TERMINAL CONNECTIONS PER E1880. N.H. THIS AREA TO BE COVERED ON COMPONENT SIDE OF BOARD WITH SEALANT PRIOR TO ENCAPSULATION. MATERIAL MUST BE APPLIED FROM TOP TO COMPLETELY FILL TO UNDERSIDE OF DEVICE. THEN APPLY SEALANT AROUND BASE OF DEVICE. N.J. THIS AREA TO BE COVERED ON OPPOSITE COMPONENT SIDE OF BOARD WITH ITEM 8 PRIOR TO ENCAPSULATION. DO NOT COAT WITH ENCAPSULATION MATERIAL ON THE TOP SURFACES NOR THE THREADS. N.K. SEALANT HEIGHT BETWEEN MODULES NOT TO EXCEED .17” MAX. N.L. ITEM 5 MUST HAVE FULL CONTACT WITH ITEM 3 ON THE CONTACT SURFACE. N.M. THE TWO MODULES, ITEM 2 MUST BE MATCHED. THE LAST TWO DIGITS OF THEIR SORT CODES MUST BE IDENTICAL. N.N. SMALL PC BOARD HOLES TO BE FREE OF ENCAPSULATION MATERIAL FOR A CEN TERED .40 MINIMUM DIAMETER AND .45 MAXIMUM DIAMETER (4 HOLES). TO BE CENTERED WITHIN .06 (DO NOT GET ON MATING SURFACES). MASK PER APPROPRIATE MANUFACTURING WORK INSTRUCTIONS. N.P. ELECTRONIC MODULES TO BE ASSEMBLED AND ENCAPSULATED PER E3875. PC. BOARD BLANK REFERENCE INFORMATION BUY COMPLETE AS G3831-D (4 LAYER BOARD PER E3281) (MAKES 2 BOARDS PER PANEL, SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION) PANEL SIZE PER E1911 N.A.,N.M.,N.P. CAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTOR = OHMS ITEM 1 2 3 4 5 6 7 8 PART NO. SEE DETAIL M16100-44 S23006 M19612 S24866 T9147-11 T9147-15 E2861 DESCRIPTION P.C. BOARD BLANK ELECTRONIC MODULE (A1, A2) TERMINAL (B211,B218,B204,B205,B209) CURRENT TRANSDUCER (T2, T3) POWER TERMINAL (B201, B208) EYELET-FEMALE EYELET-MALE SEALANT QTY 1 2 5 2 2 8 8 5.0oz SCHEMATIC REFERENCE L11487-1D0 MAKE PER E1911 ENCAPSULATE WITH E1844, 3 COATS TEST PER E3817-SW FOR PARTS ORDERS AND SUBSIDIARY ORDERS: INCLUDE (1) S25191PRINT AND (1) T12837-1. THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A. UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 6-2-2000A ON ALL ANGLES IS ± .5 OF A DEGREE MATERIAL TOLERANCE (" t ") TO AGREE WITH PUBLISHED STANDARDS. 9-22-2000A DO NOT SCALE THIS DRAWING NOTE: Chg. Sheet No. ON 2 PLACE DECIMALS IS ± .02 ON 3 PLACE DECIMALS IS ± .002 10-27-2000F 5-25-2001C "X" INFO. DESIGN INFORMATION REFERENCE: DRAWN BY: F.V./JB ENGINEER: APPROVED: SUPERSEDING: EQUIPMENT TYPE: SUBJECT: SCALE: FULL INVERTER WELDERS SWITCH P.C. BOARD ASSEMBLY DATE: 11-18-99 DRAWING No.: G 3830-1 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 provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. SOLID EDGE Return to Master TOC Return to Section TOC G-10 V350-PRO 2 X1 HC14AD 10 12 11 8 1.00K 0.1W R21 TO CONVERT TO TEST CONNECT A SPDT SWITCH AS FOLLOWS: VIA 2 GSPI FIXTURE DISPLAY BOARD: REMOVE R22 AND R23. CONNECT A NORMALLY OPEN PUSHBUTTON AS FOLLOWS: A VIA 3 VIA 5 SPDT B VIA 4 10 12 11 8 THE LOCATIONS OF VIA 1 THRU VIA 5 ARE SILKSCREENED ON THE BOARD. 1.50K 0.1W R6 VIA 1 POSITION B TO TESTS CS7 (DISPLAY) BOARDS. POSITION A TO TESTS ALL OTHER CHIP SELECT BOARDS. GSPI 9 J37 MOSI 4 X3 R14 12.1K 0.1W HC368D 5 6 X3 1 1 GSPI GSPI +5SPI 14 C1 47 20V L 11108 Return to Master TOC +5SPI 2 J37 GSPI GSPI C2 0.1 50V 10 J37 GSPI X1 HC14AD 7 16 Vcc 16 Vcc C4 0.1 50V X2 HC151D GND 8 C3 0.1 50V X3 HC368D GND 8 16 Vcc C5 0.1 50V X4 HC165D GND 8 3 Vdd C12 X5 0.1 50V MC14489DW Vss 14 J37 7 MISO GSPI DATA_OUT18 BANK1 9 BANK2 13 BANK315 BANK4 16 BANK5 17 ENABLE A 7 DATA_IN X5 B 6 CLOCK Rx C 5 D 4 MC14489DW E 2 F 1 G 20 H 19 LED5 LED6 LEFT DISPLAY LED7 LED1 LED2 3 8 THERMAL LEDS RIGHT DISPLAY LED3 LED4 THERMAL LEDS DATA_OUT18 BANK1 9 BANK2 13 BANK315 BANK4 16 BANK5 17 ENABLE A 7 DATA_IN X6 B 6 CLOCK C 5 Rx D 4 MC14489DW E 2 F 1 G 20 H 19 a1 b1 c1 d1 e1 f1 g1 h1 LED3 e1 d1 c1 h1 b1 a1 f1 g1 1 2 4 5 6 7 9 10 3 8 DISP5 e1 d1 c1 h1 b1 a1 f1 g1 1 2 4 5 6 7 9 10 3 8 e1 1 d1 2 c1 4 h1 5 b1 6 a1 7 f1 9 g1 10 DISP6 DISP7 e1 d1 c1 h1 b1 a1 f1 g1 1 2 4 5 6 7 9 10 e d c h b a f g 1 2 4 5 6 7 9 10 3 DATA_OUT18 BANK1 9 BANK2 13 BANK315 BANK4 16 BANK5 17 ENABLE A 7 DATA_IN X7 B 6 CLOCK Rx C 5 D 4 MC14489DW E 2 F 1 G 20 H 19 a b c d e f g h 8 DISP8 a1,b1,c1,d1,e1,f1,g1,h1 LED1 e d c h b a f g LED2 1 2 4 5 6 7 9 10 3 DISP1 8 e d c h b a f g 1 2 4 5 6 7 9 10 3 8 e d c h b a f g DISP2 1 2 4 5 6 7 9 10 3 DISP3 8 3 8 FRAME CONNECTION EARTH GROUND CONNECTION COMMON CONNECTION POWER SUPPLY SOURCE POINT SUPPLY VOLTAGE NET LED4 UNIFIED SPI PANELS DISPLAY PCB SCHEMATIC SHT. NO. L 11108 SUP’S’D’G. R20 267 0.1W 29 20 0 LAST NO. USED 11 HC368D RIGHT DISPLAY BLOCK 10 12 11 8 HC368D 7 1.50K 0.1W R16 Return to Master TOC GSPI 4 X1 15 DISP4 SUBJECT 3 12 X3 EQUIP. TYPE 8 HC14AD GSPI THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. NONE PG # 01 SCALE MLD CHK. DR. DATE 11/06/00 1 +5SPI GSPI HC14AD R10 12.1K 0.1W 1 HC368D 3 XD 6-2-2000A 11-10-2000C X1 10 HC14AD 2 X3 Ch’ge.Sht.No. 9 X1 GSPI UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E-2056 ON 2 PLACE DECIMALS IS + .O2 ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS R13 12.1K 0.1W HC14AD Y6 CO. THE LINCOLN ELECTRIC CO. 11 12 HC368D CLK2 15 CLK1 2 QH 7 QH 9 THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF Return to Master TOC 8 J37 SCK R12 12.1K 0.1W X1 13 N/C X3 FILENAME: L11108_3D 6 J37 13 1 SS/PL 10 SA HC165D 6 H G 5 4 F 3 E 14 D 13 C X4 12 B A 11 14 N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. 5 J37 R11 12.1K 0.1W R26 1.00K 0.1W VIA 4 1.00K 0.1W R28 NOTES : 4 J37 47.5K 0.1W R27 LABELS R25 1.00K 0.1W 15 +5SPI VIA 5 Y 5 RCD- VIA 2 GENERAL INFORMATION VIA3 4 D0 3 D1 2 D2 1 D3 15 D4 14 D5 X2 13 D6 12 D7 HC151D 11 A0 10 A1 9 A2 7 STROBE VIA 1 CS3 Return to Section TOC 6 HC14AD ELECTRICAL SYMBOLS PER E1537 CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED) RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED) X1 GSPI CS2 Return to Section TOC 5 R9 12.1K 0.1W J37 R29 1.00K 0.1W R22 10.0 0.1W R23 10.0 0.1W 3 /SS GSPI X- 8 SCHEMATIC - DISPLAY PRINTED CIRCUIT BOARD CS1 Return to Section TOC G-11 ELECTRICAL DIAGRAMS R24 4.75K 0.1W Return to Master TOC Return to Section TOC G-11 a,b,c,d,e,f,g,h LEFT DISPLAY BLOCK 3 Vdd C11 X6 0.1 50V MC14489DW Vss 14 3 Vdd C19 X7 0.1 50V MC14489DW Vss 14 BOARD I.D. x0000010 LOGIC TABLE C20 0.1 50V HC368D X3 9 INPUTS /SS CS3 CS2 CS1 10 X L X X L H Z X X L X L H Z X X X L L H Z L H H H H L H...A, SA * H H H H L H Z 1 GSPI J37 1 J37 OUTPUTS X2: /Y X2: Y X6: _EN X3: Pin 11 X4: SS/PL X7: _EN MISO * NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO Return to Master TOC Return to Section TOC G-12 G-12 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-DISPLAY V N.A.,N.D. Return to Master TOC N.B. N.B. N.B. N.B. 1 N.A.,N.E. N.A. 2.95 1.75 1.60 1.45 C20 SPI DISPLAY R6 R21 L11130-3 LED5 C11 Return to Section TOC N.A. N.A. ITEM REQ'D PART NO. DESCRIPTION 1 1 L11130-D DISPLAY P.C. BOARD BLANK (REF ONLY) 2 1 L11166-1 FLEX CIRCUIT 3 4 T15176-2 LED, SPACER, 0,140 HIGH 4 .01 OZ. E3539 ELECTRICAL INSULATING COMPOUND FOR ITEMS BELOW REFER TO ELECTRONIC COMPONENTS DATABASE FOR COMPONENT SPECIFICATIONS C1 1 S25024-7SMT CAPACITOR, SMD, TANTALUM, 47ME, 20V, 10% , S7343 C2, C3, C4, C5, C11, C12, C19, 8 S25020-3SMT CAPACITOR, SMD, CERAMIC, 0.1ME, 50V, 10% , X7R, S0805 C20 DISP1, DISP2, DISP3, DISP4 8 S17395-6 LED, DISPLAY, 7-SEGMENT, CC, BRIGHT DISP5, DISP6, DISP7, DISP8 J37 1 S18248-10 CONNECTOR, MOLEX, MINI, PCB, 10-PIN LED1, LED2, LED3, LED4 4 T13657-6 LED, T-1, RED, HLMP-K101 LED 5, LED6, LED7 3 T13657-12 LED, T-1, 3/4, YELLOW, HIGH-INTENSITY R6, R16 2 S25000-1501SMT RESISTOR, SMD, METAL FILM, 1/10W, 1.50K, 1% , S0805 R9, R10, R11, R12, R13, R14 6 S25000-1212SMT RESISTOR, SMD, METAL FILM, 1/10W, 12.1K, 1% , S0805 R20 1 S25000-2670SMT RESISTOR, SMD, METAL FILM, 1/10W, 267OHMS, 1% , S0805 R21, R25, R26, R28, R29 5 S25000-1001SMT RESISTOR, SMD, METAL FILM, 1/10W, 1.00K, 1% , S0805 R22, R23 2 S25000-10R0SMT RESISTOR, SMD, METAL FILM, 1/10W, 10.0OHMS, 1% , S0805 R24 1 S25000-4751SMT RESISTOR, SMD, METAL FILM, 1/10W, 4.75K, 1% , S0805 R27 1 S25000-4752SMT RESISTOR, SMD, METAL FILM, 1/10W, 47.5K, 1% , S0805 X1 1 S17900-8SMT IC, SMD, CMOS, INVERTER, SCHMITT, HEX, HC14A (SS) X2 1 S17900-26SMT IC, CMOS, SMD, MUX, DAT, 8-INPUT, HC151 (SS) X3 1 S17900-28SMT IC, SMD, CMOS, INVERTING BUFFER, 3-ST (SS) X4 1 S17900-10SMT IC, SMD, CMOS, REGISTER, SHFT, S-PI/SO, 8-BIT (SS) X5, X6, X7 3 S20496-1SMT IC, SMD, CMOS, DRIVER, DISPLAY, LED, CC, MCU LED X6 N.A. 1 R25 Return to Master TOC Return to Section TOC 3 C2 0 0 N.A. J37 R14 R9 R10 2 R23 DISP7 X4 LED4 R29 DISP5 DISP6 LED3 C3 R11 3 DISP8 R20 X3 R13 C1 X1 C19 N.C. DISP4 LED2 R16 R24 DISP3 X7 C4 R22 DISP2 LED1 R12 DISP1 .50 X2 X5 LED6 LED7 C12 R28 C5 5 UNLESS OTHERWISE SPECIFIED: CAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTANCE = OHMS R26 4 R27 GROUND SIDE 5.65 5.75 NOTES: N.A. DO NOT COAT WITH ENCAPSULATION MATERIAL. N.B. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY. SEE E2454 BEFORE HANDLING. N.C. USE ITEM 3 TO STAND LED1, LED2,LED3 AND LED4 FROM THE P.C. BOARD. THERE MUST NOT BE MORE THAN .020 GAP BETWEEN SPACER AND P.C. BOARD OR BETWEEN SPACER AND LED. ENCAPSULATE P.C.BOARD, SPACER AND LOWER HALF OF LED. 5.90 N.D. DISP 1 THRU DISP 8 MUST ALWAYS BE MATCHED BY VENDOR NAME. DO NOT MIX DIFFERENT VENDORS ON THE SAME BOARD ASSEMBLY. N.E. CONNECTOR MUST BE GREASED WITH ITEM 4 PRIOR TO ENCAPSULATION. 2 BUY AS: ENCAPSULATE WITH HUMISEAL 1A27LU PER E1844 OR WITH EQUIVALENT AS APPROVED BY LINCOLN ELECTRIC COMPANY. (2 COATS) IDENTIFICATION CODE BUY PER E3867 TEST PER E3856-D THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A. UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS ± .02 ON 3 PLACE DECIMALS IS ± .002 ON ALL ANGLES IS ± .5 OF A DEGREE MATERIAL TOLERANCE (" t ") TO AGREE WITH PUBLISHED STANDARDS. DO NOT SCALE THIS DRAWING NOTE: "X" INFO. Chg. Sheet No. XM5626 6-2-2000A XA 8-4-2000C DESIGN INFORMATION REFERENCE: DRAWN BY: L11130-2 ENGINEER: APPROVED: JB/ SUPERSEDING: EQUIPMENT TYPE: SUBJECT: SCALE: FULL MISCELLANEOUS SPI DISPLAY P.C. BOARD ASSEMBLY DATE: 5-11-2000 DRAWING No.: L 11130-3 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 provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. SOLID EDGE Return to Master TOC Return to Section TOC PART NO. V350-PRO Return to Master TOC +15 VDC 1 J60 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC SCHEMATIC - LED SELECT PRINTED CIRCUIT BOARD 5 J60 LED_BANK_1 2 J60 LED_BANK_2 3 J60 SWITCH 4 J60 LED4 LED2 LED5 LED3 LED6 LED_BANK_1 LED_BANK_2 R2 750 S1 THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO. AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. N.A. Return to Master TOC LED1 R1 750 J60 NOTES : Return to Section TOC G-13 ELECTRICAL DIAGRAMS S 25259-1B0 Return to Section TOC G-13 A PRINTED SINCE COMPONENTS OR CIRCUITRY ON CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD. THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS CODE NUMBER. OR CIRCUITRY OF CONTROLS HAVING A COMMON UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E2056 ON 2 PLACE DECIMALS IS + .O2 ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS DO NOT SCALE THIS DRAWING Chg. Sheet No. XA 1-25-2002 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 UNLESS OTHERWISE SPECIFIED) CAPACITORS = MFD ( RESISTORS = Ohms ( UNLESS OTHERWISE SPECIFIED) DIODES = (UNLESS OTHERWISE SPECIFIED) ------------------ "X" INFO. DESIGN INFORMATION DRAWN BY: ENGINEER: REVISED BY: LABELS SUPPLY LAST NO. USED VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION EARTH GROUND CONNECTION FILENAME: EQUIPMENT TYPE: V-350 SUBJECT: SCHEMATIC, DATE: 01/17/02 SCALE: ---- RCD- FRAME CONNECTION 2 _ _ S25259_1B LED SELECT PC BOARD DRWG. REF.: ------ NO. S25259-1B0 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO Return to Master TOC Return to Section TOC G-14 G-14 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-LED SELECT P.C. BOARD BLANK INFORMATION: MAKE FROM S19399 (MAKES 63 BOARDS PER PANEL, SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION) BLANK PART NUMBER M19875-B ITEM REQ'D 1 2 1 1 PART NO DESCRIPTION SEE BLANK P.C. BOARD BLANK CI001498 E3165-.25-.75-.20 FOR ITEMS BELOW REFER TO ELECTRONIC COMPONENTS DATABASE FOR COMPONENT SPECIFICATIONS J60 LED1,LED2,LED3,LED4,LED5, LED6 R1,R2 S1 CATHODE (SQUARE) 1 S19365-5 CONNECTOR,PCB,WW,MALE,RT-L,15-PIN 6 T13657-13 LED,T-1,3/4,RED,HIGH-INTENSITY, OVAL 2 1 S19400-7500 RESISTOR, MF, 1/4W, 750, 1% T13381-16 SWITCH,PUSHBUTTON,SPST RESISTANCE = OHMS Return to Master TOC Return to Section TOC ANODE (ROUND) 1 ENLARGED DETAIL (LED ORIENTATION) N.A. N.D. 1.33 M19875-1 LED3 Return to Master TOC 2 N.B. LED5 LED4 LED2 LED1 LED SELECT R1 R2 LED6 Return to Section TOC MANUFACTURE AS: M19875-1B0 S1 IDENTIFICATION CODE PART NO. J60 ENCAPSULATE WITH E1844. (2 COATS) BRUSH COAT ACCEPTABLE 0 0 N.C. N.E. 2.55 NOTES: N.A. DO NOT COAT WITH ENCAPSULATION MATERIAL. N.A. N.B. INSERT ITEM 2 BETWEEN ROWS OF LED'S. ITEM 2 MUST BE FLUSH WITH LED BULB. FOR PARTS ORDERS ONLY: TEST PER E3964-ST SCHEMATIC REFERENCE: S25259-1B0 UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS ± .02 ON 3 PLACE DECIMALS IS ± .002 ON ALL ANGLES IS ± .5 OF A DEGREE MATERIAL TOLERANCE (" t ") TO AGREE WITH PUBLISHED STANDARDS. DO NOT SCALE THIS DRAWING NOTE: "X" INFO. Chg. Sheet No. 1-25-2002 DESIGN INFORMATION REFERENCE: DRAWN BY: M19874-1 F.V. ENGINEER: Craig Hejl APPROVED: SUPERSEDING: EQUIPMENT TYPE: SUBJECT: SCALE: FUL INVERTER WELDERS LED SELECT PC BD AS'BLY DATE: 3-21-2001 DRAWING No.: M 19875-1 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 provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. SOLID EDGE THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A. EN-166 Return to Master TOC Return to Section TOC N.C. ENCAPSULATE PC BOARD AND LOWER HALF OF LED. N.D. ENCAPSULATE AROUND BASE OF COMPONENT N.E. COAT EXTERNAL PINS WITH ENCAPSULATION MATERIAL. V350-PRO +15V Return to Master TOC Return to Section TOC Return to Master TOC POT_1 S1 +15 VDC 4 J61 POT_SUPPLY VDC 14 J61 GND CW 10K +10VREF +10VREF POT_2 13 J61 GND 10 J61 11 J61 LED_2 2 J61 LED_3 1 J61 LED_4 6 J61 LED_5 7 J61 LED1 LED2 GND 12 J61 CW 10K GND J61 LED3 LED4 LED5 THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO. AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. NOTES : N.A. Return to Master TOC 15 J61 LED_1 3 J61 R1 5 J61 +15V 8 J61 9 J61 Return to Section TOC +15V +10VREF R2 Return to Master TOC SCHEMATIC - LED POTENTIOMETER PRINTED CIRCUIT BOARD SWITCH Return to Section TOC G-15 ELECTRICAL DIAGRAMS S 25258 Return to Section TOC G-15 A PRINTED SINCE COMPONENTS OR CIRCUITRY ON CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD. THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLES SIZES PER E2056 ON 2 PLACE DECIMALS IS + .O2 ON 3 PLACE DECIMALS IS + .OO2 ON ALL ANGLES IS + .5 OF A DEGREE MATERIAL TOLERANCE ("t") TO AGREE WITH PUBLISHED STANDARDS DO NOT SCALE THIS DRAWING Chg. Sheet No. GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 UNLESS OTHERWISE SPECIFIED) CAPACITORS = MFD ( RESISTORS = Ohms ( UNLESS OTHERWISE SPECIFIED) DIODES = (UNLESS OTHERWISE SPECIFIED) ------------------ "X" INFO. DESIGN INFORMATION 5011992 DRAWN BY: CFH XA ENGINEER: CFH REVISED BY: --- LABELS SUPPLY LAST NO. USED VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION FILENAME: RCD- _ _ _ S25258-1A EQUIPMENT TYPE: V350 LED/POT SUBJECT: LED/POT PCB SCHEMATIC DRWG. DATE: 03/08/01 SCALE: ---- REF.: -----NO. S 25258 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO Return to Master TOC Return to Section TOC G-16 G-16 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-LED POTENTIOMETER P.C. BOARD BLANK INFORMATION: MAKE FROM S19399 (MAKES 18 BOARDS PER PANEL, SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION) BLANK PART NUMBER M19874-A ITEM REQ'D 1 2 1 10 PART NO SEE BLANK T15176-1 DESCRIPTION P.C. BOARD BLANK LED SPACER FOR ITEMS BELOW REFER TO ELECTRONIC COMPONENTS DATABASE FOR COMPONENT SPECIFICATIONS J61 LED1,LED2,LED3,LED4,LED5 R1,R2 S1 1 5 2 1 S19365-15 T13657-11 S19366-1 T13381-17 CONNECTOR,PCB,WW,MALE,RT-L,15-PIN LED,T-1,3/4,RED,HIGH-INTENSITY POT,ST,0.5W,10K,10%,LINEAR SWITCH,PUSHBUTTON,SPST,GREEN,W/BLACK RESISTANCE = OHMS N.B. Return to Master TOC Return to Section TOC N.C. N.D. N.C. 1.90 LED/POT J61 LED1 MANUFACTURE AS: M19874-1A2 M19874-1 LED2 .88 LED3 S1 LED4 R2 R1 IDENTIFICATION CODE PART NO. LED5 2 0 1.80 5.35 N.A. Return to Master TOC Return to Section TOC 0 ENCAPSULATE WITH E1844. (2 COATS) BRUSH COAT ACCEPTABLE N.C. NOTES: N.A. DO NOT COAT WITH ENCAPSULATION MATERIAL. N.B. THERE MUST NOT BE MORE THAN A .010 GAP BETWEEN SPACER & LED, OR BETWEEN SPACER & P.C. BOARD. ENCAPSULATE P.C. BOARD, SPACERS & LOWER HALF OF LED. LEDS MUST BE PERPENDICULAR WITH P.C. BOARD. FOR PARTS ORDERS ONLY: TEST PER E3964-MS SCHEMATIC REFERENCE: S25258-1A1 UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS ± .02 ON 3 PLACE DECIMALS IS ± .002 NOTE: ON ALL ANGLES IS ± .5 OF A DEGREE MATERIAL TOLERANCE (" t ") TO AGREE WITH PUBLISHED STANDARDS. DO NOT SCALE THIS DRAWING "X" INFO. Chg. Sheet No. 1-25-2002 DESIGN INFORMATION DRAWN BY: ENGINEER: Craig Hejl APPROVED: REFERENCE: F.V. SUPERSEDING: EQUIPMENT TYPE: SUBJECT: SCALE: FULL INVERTER WELDERS LED POT P.C. BOARD ASSEMBLY DATE: 3-9-2001 DRAWING No.: M 19874-1 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 provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. SOLID EDGE THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A. EN-166 Return to Master TOC Return to Section TOC N.C. ENCAPSULATE AROUND BASE OF COMPONENT N.D. COAT EXTERNAL PINS WITH ENCAPSULATION MATERIAL. V350-PRO SCHEMATIC-SPI REMOTE PRINTED CIRCUIT BOARD SPI CONNECTIONS SCLK 7 J33 R6 12.1K 0.1W 13 12 X1 HC14AD 5 R5 12.1K 0.1W 1 R3 12.1K 0.1W 9 6 X1 AD_CS AD_DI HC14AD 2 X1 HC14AD 8 X1 HC14AD R7 267 0.1W R13 R10 243 1W C3 0.1 50V REMOTE OUTPUT ENABLES \ 4.75K 0.1W H=OPEN L=CLOSED 14 PIN 6 J331 R14 R11 243 1W C4 0.1 50V R27 SOL_PULL_IN SOL_DRIVE ENABLE STAT MOD REM MISO 6PIN_OUT_EN 14PIN_OUT_EN INV_OUT_SW OUTPUT_SW MODE_SEL_SW STUDS_SW AD_CLK INVCLK MAIN_OSC Q2 0.5A 40V R19 332 0.1W DZ2 5.1V 3W 500 221 0.1W +5SPI GSPI +5VREF FUNCTION ENABLE JUMPERS STATUS MODE R30 4.75K 0.1W 1 J333 11 J332 LOCAL SWITCH INTERFACE STATUS_SENSE 4.75K 0.1W 4.75K 0.1W +15SPI +15V TO MODE 12 J332 MODE SELECT SW 13 J332 STUD CONTROL SW OUTPUT CONTROL SW 4 J333 5 J333 2 R68 2.67K 0.1W R100 13 J333 R22 10.0K 0.1W 1.00K 0.1W D6 0.2A 30V 3 1 2 R64 1.21K R63 1.21K R62 1.21K +5SPI 6_PIN_DETECT 14_PIN_DETECT 10.0K 0.1W Q5 0.115A 60V MODE LED 2 MODE LED 3 J332 16 J332 15 MODE LED 4 MODE LED 5 J333 9 J333 14 OUTPUT LOCAL LED OUTPUT REMOTE LED J333 11 J333 15 R72 1.21K 10.0K 0.1W MODE LED 1 J333 10 J333 16 R71 1.21K 35 EX2 36 MODE_LED1 37 MODE_LED2 38 MODE_LED3 43 MODE_LED4 44 MODE_LED5 24 OUTPUT_LOCAL 25 OUTPUT_REMOTE 26 STUDS_HOT 27 STUDS_REMOTE 28 29 33 STATUS_STOP 34 EX1 17 15 30 16 STUD HOT LED J333 12 STUD REMOTE LED Q6 0.115A 60V GSPI CPLD2 STATUS_STOP I/O1B1 I/O1B2 39 SOLENOID I/O2B1 I/O2B2 38 OSC_NEG_PS I/O4B1 I/O4B2 37 6_PIN_SENSE I/O6B1 I/O7B2 32 31 14_PIN_SENSE I/O8B1 I/O8B2 I/O9B1 I/O9B2 30 EX1 BLOCK 1 I/O10B1 I/O10B2 29 EX2 I/O11B1 I/O11B2 28 BLOCK 2 I/O12B1 I/O12B2 27 I/O13B1 I/O13B2 23 X3 I/O14B1 I/O14B2 22 I/O15B1 I/O15B2 21 XC9536 I/O16B1 I/O16B2 20 AD_DOUT I/O17B1 I/O17B2 19 I/O/GCK1 TCK 11 TDI 9 I/O/GCK2 TDO 24 I/O/GCK3 I/O/GTS1 TMS 10 I/O/GTS2 I/O/GSR FTP1 FTP2 FTP3 FTP4 LOCAL POT INTERFACE 10.0K 0.1W 0.5% R35 +5VREF 9 R49 10.0K 0.1W 10 X7 8 33074D R106 56.2K 0.1W +10VREF 6 R33 100 0.1W J332 6 J333 6 +10VREF_MODE +10VREF_STATUS 3 J332 LEFT_MODE POT_WIPER R103 56.2K 0.1W C57 0.1 50V 10.0K 0.1W 0.5% C48 0.1 50V X6 5 C54 0.1 50V 7 33074D GSPI R107 56.2K 0.1W +5VREF J332 4 J333 7 C24 0.1 50V +10V_COM_MODE +10V_COM_STATUS 2 5 J332 RIGHT_MODE POT_WIPER GSPI R104 56.2K 0.1W GSPI C49 0.1 50V 2 R50 4.75K 0.1W 0.5% D4 0.2A 30V 3 1 GSPI LMODE_POT 4.75K 0.1W 0.5% C58 0.022 50V +5SPI GSPI GSPI 16 AD_DOUT 19 14 13 +5SPI +10VREF A/D CONVERTER C55 0.1 50V X7 3 1 33074D GSPI R23 10.0K 0.1W 1.00K 0.1W R24 10.0K 0.1W 1.00K 0.1W GSPI D7 0.2A 30V 3 1 2 2 R52 4.75K 0.1W 0.5% D2 0.2A 30V 3 1 GSPI RMODE_POT 4.75K 0.1W 0.5% C59 0.022 50V +5SPI 6 D8 0.2A 30V 3 1 MODE_SEL_SW C45 1.0 35V 8 J333 STATUS POT_WIPER +5VREF +5SPI 14 C28 0.1 50V STUDS_SW +15SPI +5SPI GSPI C44 1.0 35V X1 HC14AD 7 C25 0.1 50V 21 41 32 X4 XC9572 10 23 31 C36 0.1 50V C37 0.1 50V C26 0.1 50V 15 35 26 X3 XC9536 17 4 25 C35 0.1 50V X13 9 MC1413BD 8 C27 0.1 50V R105 56.2K 0.1W C50 0.1 50V C56 0.1 50V X7 5 7 33074D 2 R54 4.75K 0.1W 0.5% D3 0.2A 30V 3 1 GSPI STATUS_POT 4.75K 0.1W 0.5% C60 0.022 50V GSPI 20 Vdd X5 MC145051DW Vss 10 GSPI J332 10 NO CONN. GENERAL INFORMATION J332 9 NO CONN. ELECTRICAL SYMBOLS PER E1537 CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED) RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED) J332 8 GSPI KEY ON MODE CONNECTOR LABELS R- 108 C- 62 D- 20 LAST NO. USED D-20 DZ-10 Q-9 X-13 L-1 SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT COMMON CONNECTION GSPI R70 2.67K 0.1W R65 1.21K R108 56.2K 0.1W GSPI R69 2.67K 0.1W R101 +15V TO STATUS MC1413BD +5SPI R102 +15V TO STATUS C2 0.1 50V 40 41 42 2 3 5 6 7 8 12 13 14 16 18 43 44 1 36 34 33 X13 J332 7 J332 2 J332 1 GSPI +15SPI 3 J333 STATUS_POT MODE_SENSE C1 0.1 50V I/O/GTS1 I/O/GTS2 I/O/GSR I/O1B I/O2B I/O3B I/O4B I/O5B I/O6B I/O1D I/O2D I/O3D I/O4D I/O5D I/O6D I/O7D I/O8D TCK TDI TDO TMS 17 Din 1 AN0 2 AN1 3 AN2 4 AN3 5 AN4 Dout 6 AN5 EOC X5 INV_OUT_SW 7 AN6 Vref 8 AN7 Vag 9 AN8 MC145051DW 11 AN9 12 AN10 15 CS AD_CS AD_CLK 18 SCLK AD_DI 6_PIN_POT 14_PIN_POT LMODE_POT RMODE_POT +5SPI 14 J332 2 J333 I/O1A I/O2A I/O3A BLOCK 1 BLOCK 2 I/O4A I/O5A I/O6A I/O1C I/O2C I/O3C I/O4C X4 I/O5C I/O6C BLOCK3 BLOCK4 I/O7C I/O8C I/O/GCK1 I/O/GCK2 XC9572 I/O/GCK3 +5VREF GSPI R26 Return to Master TOC 8 OSCIN VCC 3 7 XTAL I/O 1 MAIN_OSC 6 OE X2 OUT0 2 5 PDN/SELX GND 4 C23 0.1 DS1075Z 50V GSPI CPLD1 GSPI 221 0.1W +5SPI GSPI 2 1 2 3 INVSS 4 INVCS3 8 INVCS2 9 INVCS1 11 INVMOSI 12 REM 13 MOD 14 STAT 18 ENABLE 19 SOL_DRIVE 20 SOL_PULL_IN 22 INVCLK 5 MODE_SENSE 6 STATUS_SENSE 7 42 40 39 Q1 0.5A 40V R18 332 0.1W DZ1 5.1V 3W 500 R28 5 J331 4.75K 0.1W H=OPEN L=CLOSED R31 6 PIN 4 500 R32 \ 2 +15SPI R16 R9 243 1W 250KHZ OSCILLATOR Return to Master TOC +5SPI HC14AD R1 12.1K 0.1W 11 J331 4 Return to Section TOC 4 X1 +5SPI Return to Master TOC Return to Section TOC MISO 3 R67 1.21K R66 1.21K R51 8 J33 R2 12.1K 0.1W I0 I1 I2 I3 I4 I5 I6 R53 9 J33 MOSI HC14AD O0 16 O1 15 O2 14 O3 13 O4 12 O5 11 O6 10 R55 4 J33 1 2 3 4 5 6 7 R46 5 J33 CS2 LOCAL LED INTERFACE 10 X1 R45 6 J33 CS3 11 R4 12.1K 0.1W R34 3 J33 /SS CS1 Return to Section TOC G-17 ELECTRICAL DIAGRAMS R25 Return to Master TOC Return to Section TOC G-17 OUTPUT_SW C46 1.0 35V THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER. Ch’ge.Sht.No. 1-25-2002 FRAME CONNECTION CO. THE LINCOLN ELECTRIC CO. THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. NONE PG # 01 SCALE --DR. DATE 01/10/02 CHK. EARTH GROUND CONNECTION EQUIP. TYPE SUBJECT COMMON CONTROLS SPI REMOTE/UI PCB SCHEMATIC SHT. SUP’S’D’G. NO. G 4017-1C0/1 PLOTTING DELIMITER - DON’T DELETE NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO Return to Master TOC Return to Section TOC G-18 PC BOARD ASSEMBLY-SPI REMOTE V N.B. N.C. N.D. N.K. N.F. 2 1 N.G. 3 N.E. 6.14 Return to Master TOC Return to Section TOC G-18 ELECTRICAL DIAGRAMS N.L. REMOTE G4018-1 N.A. 3.64 N.A. ITEM REQ'D PART No. DESCRIPTION 1 1 G4018-C SPI REMOTE/UI PC BOARD BLANK 2 1 M19436-3 POTTING TRAY 3 2 S8025-80 SELF TAPPING SCREW 4 1 L11166-1 FLEX CIRCUIT ASSEMBLY EPOXY ENCAPSULATING RESIN 5 4.00 fl oz E2527 ELECTRICAL INSULATING COMPOUND 6 .108 fl oz E3539 7 1 S25336-1 SOFTWARE CPLD (X3) 8 1 S25337-1 SOFTWARE CPLD (X4) 9 1 PROGRAM X2 to 250K Hz 10 1 S24671 KEYING PLUG FOR ITEMS BELOW, REFER TO ELECTRONIC COMPONENTS DATABASE FOR COMPONENT SPECIFICATIONS C1,C2,C3,C4,C5,C6,C7,C8,C9 44 S25020-3SMT CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X7R,S0805 C10,C11,C12,C13,C14,C15 C16,C17,C18,C19,C20,C21 C22,C23,C24,C25,C26,C27 C28,C29,C30,C31,C32,C33 C34,C35,C36,C37,C48,C49 C50,C54,C55,C56,C57 C38,C39 2 S25020-5SMT CAPACITOR,SMD,CERAMIC,2700pF,50V,5%,X7R,S0805 C40 1 S13490-183 CAPACITOR,ALEL,120MF,50V,20% C41 1 S25020-17SMT CAPACITOR,SMD,CERAMIC,0.27MF,50V,10%,X7R,S1812 C42 1 S13490-179 CAPACITOR,ALEL,1000,35V,20% C43 1 S25024-10SMT CAPACITOR,SMD,TANTALUM,22MF,25V,10%,S7343 C44,C45,C46 3 S25024-2SMT CAPACITOR,SMD,TANTALUM,1.0MF,35V,10%,S3528 C47,C51,C52,C53 4 S25024-3SMT CAPACITOR,SMD,TANTALUM,2.2MF,20V,10%,S3528 C58,C59,C60,C61,C62 5 S25020-2SMT CAPACITOR,SMD,CERAMIC,0.022MF,50V,10%,X7R,S0805 D1,D2,D3,D4,D5,D6,D7,D8 8 S25049-4SMT DIODE,SMD,DUAL,200MA,30V,SCHOTTKY,SOT-23 D9,D10,D11 3 S25040-1SMT DIODE,SMD,1A,400V,FAST RECOVERY,DO-214BA D12,D13,D14,D15 4 S25040-2SMT DIODE,SMD,1A,400V,DO-214BA/AC D16,D17 2 S25040-5SMT DIODE,SMD,DUAL,0.200A,70V,UFR D18,D19 2 S25040-4SMT DIODE,SMD,DUAL,0.200A,70V,UFR D20 1 S25049-2SMT DIODE,SMD,1A,30V,SMA,SCHOTTKY DZ1,DZ2 2 S25044-1SMT ZENER DIODE,SMD,3W,5.1V,5%, SMB DZ3,DZ4,DZ5,DZ6,DZ7,DZ8 6 S25044-3SMT ZENER DIODE,SMD,3W,12V,5%, SMB DZ9,DZ10 2 S25045-1SMT ZENER_DIODE,SMD,225mW,12V,5%,SOT-23 FTP1,FTP2,FTP3,FTP4,FTP5 6 TESTPT_FUNTION FUNCTIONAL TEST POINT FTP6 J33 1 S18248-10 CONNECTOR,MOLEX,MINI,PCB,10-PIN J331 1 S24020-12 CONNECTOR,MOLEX,MINI,PCB,12-PIN,TIN J332,J333 2 S24020-16 CONNECTOR,MOLEX,MINI,PCB,16-PIN,TIN L1 1 S25083-3SMT CHOKE,SMD,POWER,47UH,10%,1.25A, Q1,Q2,Q3,Q4 4 S25050-1SMT TRANSISTOR,SMD,NPN,0.5A,40V,SOT-23,MMBT4401LT1 Q5,Q6 2 S25051-4SMT TRANSISTOR,SMD,NMF,SOT-23,0.115A,60V,7002LT1(SS) Q7,Q8 2 S25050-2SMT TRANSISTOR,SMS,PNP,SOT23,0.5A, 40V,MMBT4403LT1 Q9 1 S25051-6SMT TRANSISTOR,SMD,NMF,DPAK,TO-252,10A,100V(SS) N.A. N.A. N.A. N.A. N.A. N.A. N.A. R1,R2,R3,R4,R5,R6 R7 R8,R9,R10,R11,R12 R13,R14,R15,R16,R17 R18,R19 R20,R21,R25,R26,R27,R28 R29,R30 R22,R23,R24,R36,R37,R45 R46,R47,R48,R49 R31,R32 R33 R34,R35 R50,R51,R52,R53,R54,R55 R56,R57,R58,R59,R60,R61 R62,R63,R64,R65,R66,R67 R71,R72 R68,R69,R70 R74 R75,R76,R77,R78 R79,R80 R81,R82 R83,R84,R85,R86 R87,R88,R89,R90 R91,R92 R93,R94 R95 R96 R97 R98,R99 R100,R101,R102 R103,R104,R105,R106,R107 R108 X1 X2 X3 X4 X5 X6,X7,X8 X9 X10 X11 X12 X13 6 1 5 5 2 8 S25000-1212SMT S25000-2670SMT S25004-2430SMT S18380-14 S25000-3320SMT S25000-4751SMT RESISTOR,SMD,METAL FILM,1/10W,12.1K,1%,S0805 RESISTOR,SMD,METAL FILM,1/10W,267OHMS,1%,S0805 RESISTOR,SMD,1W,243OHMS,1% THERMISTOR,PTC,500OHMS,28mA RESISTOR,SMD,METAL FILM,1/10W,332OHMS,1%,S0805 RESISTOR,SMD,METAL FILM,1/10W,4.75K,1%,S0805 10 S25000-1002SMT RESISTOR,SMD,METAL FILM,1/10W,10.0K,1%,S0805 2 1 2 12 S25000-2210SMT S25000-1000SMT S25008-1002SMT S25008-4751SMT RESISTOR,SMD,METAL FILM,1/10W,221OHMS,1%,S0805 RESISTOR,SMD,METAL FILM,1/10W,100OHMS,1%,S0805 RESISTOR,SMD,PREC,MF,1/10W,10.0K,0.5%,S0805 RESISTOR,SMD,PREC,MF,1/10W,4.75K,0.5%,S0805 8 S25001-1211SMT RESISTOR,SMD,1.21K,1/4W,1206,1%,TR 3 1 4 2 2 4 4 2 2 1 1 1 2 3 6 S25000-2671SMT S25001-1001SMT S25001-1000SMT S25000-2211SMT S25001-1213SMT S25000-3321SMT S25010-3SMT S25000-4752SMT S25000-2001SMT S25000-3741SMT S25000-3011SMT S25000-2672SMT S25000-2002SMT S25000-1001SMT S25000-5622SMT RESISTOR,SMD,METAL FILM,1/10W,2.67K,1%,S0805 RESISTOR,SMD,1K,1/4W,1206,1%,TR RESISTOR,SMD,100OHMS,1/4W,1206,1%,TR RESISTOR,SMD,METAL FILM,1/10W,2.21K,1%,S0805 RESISTOR,SMD,121K,1/4W,1206,1%,TR RESISTOR,SMD,METAL FILM,1/10W,3.32K,1%,S0805 RESISTOR,SMD,MF,1W,20.0K,1%,SURGE RESISTOR,SMD,METAL FILM,1/10W,47.5K,1%,S0805 RESISTOR,SMD,METAL FILM,1/10W,2.00K,1%,S0805 RESISTOR,SMD,METAL FILM,1/10W,3.74K,1%,S0805 RESISTOR,SMD,METAL FILM,1/10W,3.01K,1%,S0805 RESISTOR,SMD,METAL FILM,1/10W,26.7K,1%,S0805 RESISTOR,SMD,METAL FILM,1/10W,20.0K,1%,S0805 RESISTOR,SMD,METAL FILM,1/10W,1.00K,1%,S0805 RESISTOR,SMD,METAL FILM,1/10W,56.2K,1%,S0805 1 1 1 1 1 3 1 1 1 1 1 S17900-8SMT S25070-11SMT S25070-3SMT S25070-10SMT M15105-7SMT S15128-18SMT S15018-11SMT S15128-10SMT S15018-21SMT S25068-14SMT M15102-4SMT IC,SMD,CMOS,INVERTER,SCHMITT,HEX,HC14A(SS) IC,SMD,CMOS,OSCILLATOR,DIVIDER,60MHZ,SOIC8,(SS) CPLD,PROGRAMMABLE,XC9536,44-PIN,VQFP(SS) IC,SMD,CMOS,CPLD,XC9572,PLCC44(SS) IC,SMD,CMOS,CONVERTER,A/D,MPU,10-BIT(SS) IC,OP-AMP,SMT,QUAD,HIGH-PERF,33074D IC,SMD,CMOS,SWITCH,ANALOG,QUAD,201(SS) IC,SMD,VOLTAGE REF,ADJ, PRECISION,431I,SOIC-8 IC,SMD,CMOS,DRIVER,MOSFET,4451, SOIC-8(SS) IC,SMD,VOLTAGE REGULATOR,ADJ,FLYBACK,3A,TO-263 IC,ARRAY,DRIVER,PERIPHERAL,NPN,DARLINGTON P.C. BOARD BLANK REFERENCE INFORMATION BUY COMPLETE AS G4018-C (4 LAYER BOARD PER E3281) UNLESS OTHERWISE SPECIFIED: CAPACITANCE = MFD/VOLTS INDUCTANCE = HENRIES RESISTANCE = OHMS N.K. N.E. N.H. N.E. SCHEMATIC REFERENCE: G4017-1C0 BUY AS: G 4 0 1 8 - 1 C 0 N.K PLACE ITEM 10 ON PIN 8 OF J332 AS SHOWN. N.L. BOARD TO BE POTTED WITH ITEM 4 LAYING ACROSS BOARD AS SHOWN. ONLY 0.4" OR LESS OF ITEM 4 TO BE COVERED WITH ITEM 5. PART NUMBER IDENTIFICATION CODE BUY PER E3867 TEST PER E3964-RM THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A. UNLESS OTHERWISE SPECIFIED TOLERANCE MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS ± .02 ON 3 PLACE DECIMALS IS ± .002 NOTE: ON ALL ANGLES IS ± .5 OF A DEGREE MATERIAL TOLERANCE (" t ") TO AGREE WITH PUBLISHED STANDARDS. DO NOT SCALE THIS DRAWING "X" INFO. Chg. Sheet No. 1-25-02 DESIGN INFORMATION DRAWN BY: F.V. ENGINEER: Ed Furman APPROVED: REFERENCE: L11346-1 SUPERSEDING: EQUIPMENT TYPE: SUBJECT: SCALE: FULL MISCELLANEOUS SPI REMOTE/UI P.C. BOARD ASSEMBLY DATE: 3-27-2001 DRAWING No.: G 4018-1 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 provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. SOLID EDGE Return to Master TOC Return to Master TOC NOTES: N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY. SEE E2454 BEFORE HANDLING. N.B. PROGRAM X3 WITH ITEM 7. N.C. PROGRAM X4 WITH ITEM 8. N.D. PROGRAM X2 WITH ITEM 9. N.E. ALL CONNECTORS MUST BE GREASED WITH ITEM 6 PRIOR TO ENCAPSULATION. N.F. ATTACH ITEM 1 TO ITEM 2 WITH ITEM 3. TIGHTEN ITEM 3 TO .60 ± .05 Nm (5.3 ± .5 in-lbs.). N.G. PLACE BARCODED ASSEMBLY NUMBER IDENTIFICATION AND BARCODED SERIAL IDENTIFICATION IN AREA SHOWN. N.H. THESE COMPONENTS MUST BE COMPLETELY COVERED WITH ITEM 5. EN-170 Return to Section TOC Return to Section TOC 4 V350-PRO Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-19 ELECTRICAL DIAGRAMS G-19 SCHEMATIC-SNUBBER PRINTED CIRCUIT BOARD 6-2-2000 S24761 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V350-PRO Return to Master TOC Return to Section TOC G-20 G-20 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-SNUBBER ITEM C1,C2,C3,C4 R1,R3 R2,R4 1 REQ'D 4 2 2 PART NO. DESCRIPTION S20500-4 CAPACITOR,PPMF,.0047,1000V,BOX T14648-20 RESISTOR,WW,5W,150,5%,SQ T14648-25 RESISTOR,WW,5W,10,5%,SQ Return to Master TOC 2.90 +.04 3 ITEM 1 2 3 4 2 4 C3 RW5F M195321 BOXCP4 C1 BOXCP4 T14710 RW5F 1.92 1 R3 R1 QC1 6 1 R .045 2 Return to Master TOC 2 .105 CRIMP HEIGHT T14710 RW5F R4 B30 B40 0 .60 1.75 2.90 QTY 1 1 4 4 COPPER SIDE MANUFACTURED AS: M19532-1A0 MAKE PER E1911 ENCAPSULATE WITH E1844, 2 COATS TEST PER E3817-SN 3.50 +.04 IDENTIFICATION CODE EN-166 ON 2 PLACE DECIMALS IS ± .02 ON 3 PLACE DECIMALS IS ± .002 ON ALL ANGLES IS ± .5 OF A DEGREE MATERIAL TOLERANCE (" t ") TO AGREE WITH PUBLISHED STANDARDS. DO NOT SCALE THIS DRAWING NOTE: Chg. Sheet No. 6-2-2000 "X" INFO. XM5626 XC-UF DESIGN INFORMATION DRAWN BY: ENGINEER: APPROVED: REFERENCE: F.V. SUPERSEDING: EQUIPMENT TYPE: SUBJECT: SCALE: NONE INVERTER WELDERS SNUBBER P.C. BOARD ASSEMBLY DATE: 10-6-99 DRAWING No.: M 19532-1 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 provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. SOLID EDGE THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A. MANUFACTURING TOLERANCE PER E2056 Return to Master TOC DESCRIPTION P.C. BOARD BLANK TAB TERMINAL EYELET-FEMALE EYELET-MALE NOTES: N.A. FEMALE EYELET TO BE AGAINST THE COPPER SIDE AS SHOWN EYELET MUST NOT SPIN AFTER CLINCHING. N.B. SOLDER EYELET SO THAT SOLDER COVERS ENTIRE EYELET AND ALL AROUND EYELET ON COPPER SIDE ONLY. NO ICICLES OR SOLDER BLOBS PERMITTED. EYELET DETAIL 0 UNLESS OTHERWISE SPECIFIED TOLERANCE Return to Section TOC .275 .285 1 T14710 RW5F B20 1 T14710 SNUBBER R2 ∅ MAX. C4 BOXCP4 .55 Return to Section TOC 2 BOXCP4 C2 PART NO. M19532-A T13157-16 T9147-11 T9147-15 B10 B1 2 Return to Section TOC N.A., N.B. V350-PRO Return to Master TOC We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three column troubleshooting chart, please share this information with us. Please include the machine’s code number and how the problem was resolved. Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199 Return to Master TOC Return to Section TOC Return to Section TOC SVM ERROR REPORTING FORM FAX 216-481-2309 SVM Number ___________________________ Page Number if necessary__________________ Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99