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Lincoln Electric POWER MIG SVM165-A manual

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Table of contents for the manual

  • Page 1

    PO WER MIG ™ 350MP SER VICE MANUAL SVM165-A January . 2006 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THI[...]

  • Page 2

    i i Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ENGINE powered equipment. 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 [...]

  • Page 3

    SAFETY ii ii Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ARC RA YS can burn. 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. 4.b. U[...]

  • Page 4

    SAFETY iii iii POWER MIG 350MP Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y 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 an[...]

  • Page 5

    POWER MIG 350MP Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ 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 suiv- antes[...]

  • Page 6

    6 6 MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Safety .................................................................................................................................................i-iv Installation ............................................................................................................................. Se[...]

  • Page 7

    A-1 A-1 T ABLE OF CONTENTS - INST ALLA TION SECTION - INSTALLATION ...................................................................................................................... Section A Technical Specifications ....................................................................................................... ......A-2 Safety Precauti[...]

  • Page 8

    A-2 A-2 INST ALLA TION Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Input Voltage/ 230Amps @ 300Amps @ 75°C Copper Wire Fuse Frequency (Hz) 29 Volts 32 Volts AWG (IEC) or (100% Duty Cycle) (60% Duty Cycle) Sizes (MM 2 ) Br[...]

  • Page 9

    A-3 A-3 INST ALLA TION Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ONL Y QUALIFIED PERSONNEL SHOULD INST ALL, USE OR SERVICE THIS EQUIP- MENT . UNCRA TING THE POWER MIG 350MP Cut banding and lift off cardboard carton. Cut [...]

  • Page 10

    A-4 A-4 INST ALLA TION Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A.2 — RECEPTACLE DIAGRAM CONNECT TO A SYSTEM GROUNDING WIRE. SEE THE UNITED STATES NATIONAL ELECTRICAL CODE AND/OR LOCAL CODES FOR OTHER DETAILS A[...]

  • Page 11

    A-5 GUN AND CABLE INST ALLA TION A Magnum 300 gun and 15Ft.(4.6m) cable (12Ft.(3.7m) for Codes 11000 and below) are provid- ed with the Power MIG 350MP. A Magnum cable liner for .035-.045" (0.9-1.2 mm) electrode and contact tips for .035” (0.9mm) and .045” (1.2mm) are included for 15Ft.. Turn the welder power switch off before installing g[...]

  • Page 12

    A-6 A-6 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION DO NOT ATTACH THE REGULATOR IF OIL, GREASE OR DAMAGE IS PRESENT! Inform your gas supplier of this condition. Oil or grease in the presence [...]

  • Page 13

    POWER MIG 350MP Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-1 B-1 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Definitions of Welding Modes .......................[...]

  • Page 14

    POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-2 B-2 OPERA TION COMMON WELDING ABBREVIA- TIONS WFS • Wire Feed Speed CC • Constant Current CV • Constant Voltage GMAW (MIG) • Gas Metal Arc Welding GMA[...]

  • Page 15

    POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-3 B-3 OPERA TION PRODUCT DESCRIPTION The Power MIG 350MP is a complete semiautomatic multi-process DC arc welding machine offering CV and CC DC welding. It is r[...]

  • Page 16

    POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 5. MULTI-PROCESS PANEL - This panel enables selection of weld modes as well as adjustment of certain weld parameters within each weld mode. The eight discrete LED[...]

  • Page 17

    POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-5 B-5 OPERA TION SETTING AND CONFIGURING THE POWER MIG 350MP FOR WELDING • Check that the electrode polarity is correct for the process and turn the Power Swi[...]

  • Page 18

    POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-6 B-6 OPERA TION MUL TI-PROCESS P ANEL FUNCTIONS Weld Mode Setting the Weld Mode is selecting the proper program from the ones available in the machine’s memo[...]

  • Page 19

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-7 B-7 OPERA TION POWER MIG 350MP Arc Control (See Table B.2) There are no specific unit values offered because the setting of this feature largely depends upon operator prefere[...]

  • Page 20

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-8 B-8 OPERA TION POWER MIG 350MP In the case of special waveforms designed for pulsed weld- ing aluminum, Pulse on Pulse ™ , the effect is similar to what occurs with standar[...]

  • Page 21

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-9 B-9 OPERA TION POWER MIG 350MP 5. Rotate the spindle and adapter so the retaining spring is at the 12 o'clock position. 6. Position the Readi-Reel so that it will rotate[...]

  • Page 22

    POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-10 B-10 OPERA TION 4. Re-install the Retaining Collar. Make sure that the Release Bar “pops up” and that the collar retainers fully engage the retaining rin[...]

  • Page 23

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-11 B-11 OPERA TION POWER MIG 350MP SPECIAL WELDING PROCESSES AV AILABLE ON THE POWER MIG 350MP PULSE WELDING (GMA W-P) The pulsed-arc process is, by definition, a spray trans- [...]

  • Page 24

    B-12 B-12 OPERA TION Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 350MP PULSE-ON-PULSE™ (GMA W-PP) Pulse on Pulse™ is a Lincoln process specifically designed for use in welding relatively thin (less than 1/4&q[...]

  • Page 25

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-13 B-13 OPERA TION POWER MIG 350MP POWER MODE™ The Power Mode™ process was developed by Lincoln to maintain a stable and smooth arc at low procedure settings which are need[...]

  • Page 26

    B-14 NOTES POWER MIG 350MP B-14 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 27

    POWER MIG 350MP C-1 C-1 T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Drive Roll Kits .............................................................................................................................C-2 [...]

  • Page 28

    C-2 C-2 ACCESSORIES POWER MIG 350MP DRIVE ROLL KITS Refer to Table C.1 for various drive roll kits that are available for the Power MIG. All items in Bold are supplied standard with the Power MIG. TABLE C.1 * .035 Aluminum recommended for Push-Pull systems only. 3/64" (1.2 mm) ALUMINUM FEEDING KIT (K2153-1) This kit helps push feeding aluminum[...]

  • Page 29

    C-3 C-3 ACCESSORIES MIG 350MP does not control the WFS at the spool gun. Rather, it is adjusting the Power MIG 350MP synergic work point. Therefore, adjusting the SPD value will not change your actual WFS at the spool gun. WFS can only be changed at the spool gun. PUSH-PULL FEEDING CONNECTION ADAPTER KIT (K2154-1) The push-pull adapter kit provides[...]

  • Page 30

    C-4 C-4 NOTES POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 31

    POWER MIG 350MP D-1 D-1 T ABLE OF CONTENTS -MAINTENANCE- Maintenance .......................................................................................................................... Section D Safety Precautions & General Maintenance ...............................................................................D-2 Liner Removal and Re[...]

  • Page 32

    MAINTENANCE D-2 D-2 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONT ACT TIP AND GAS NOZZLE INST ALLA TION a. Choose the correct size contact tip for the elec- trode being used (wire size is stenciled on th[...]

  • Page 33

    D-3 D-3 MAINTENANCE 5. Seat Liner bushing into back of gun. Secure Liner by tightening set screw. Do not install the gas dif- fuser at this time. 6 . Lay the cable straight and trim Liner to 9/16”. Remove burrs. 7. Secure the gas diffuser into the tube. 8. Tighten the set screw against the Liner. This screw should only be gently tightened. Over t[...]

  • Page 34

    D-4 D-4 MAINTENANCE POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 2 6 5 3 4 1. Case Front Assembly 2. Center Assembly 3. Wire Drive Assembly 4. Base Assembly 5. Case Back Assembly 6. Cover Assembly[...]

  • Page 35

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 POWER MIG 350MP Theory of Operation ............................................................................................................ .Section E General Description ..................................................................[...]

  • Page 36

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GENERAL DESCRIPTION The Power MIG 350MP is a complete semiautomatic, multi-process DC arc welding machine offering CV and CC DC welding. It is rated for 350 amps, 32 volts, at 60[...]

  • Page 37

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT VOL T AGE AND MAIN TRANS- FORMER Single-phase input power is brought into the rear of the Power MIG 350MP through a three-prong plug and input cable. A reconnect panel, als[...]

  • Page 38

    THEOR Y OF OPERA TION E-4 E-4 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFIER, CHOPPER ASSEMBL Y AND FEEDBACK The 60 V AC output from the main transformer sec- ondary is connected to an output [...]

  • Page 39

    DIODE CONTROL RECTIFIER AND POWER BOARD The Power Board receives approximately 40 VDC from the Diode Control Rectifier . In turn, the Power Board supplies a variety of regulated DC voltages to the Weld Control Board, which it uses to power its many circuits and communication functions. The Power Board also supplies +20 VDC to the Chopper Assembly .[...]

  • Page 40

    WELD CONTROL BOARD The Weld Control Board performs the primary interfac- ing functions to establish and maintain output control of the Power MIG 350MP machine. The function genera- tor and weld files reside within the Weld Control Board hardware and software. Digital command signals and feedback information from other machine components are receive[...]

  • Page 41

    E-7 E-7 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WIRE DRIVE MOT OR AND FEED- BACK The Wire Drive Motor is controlled by the Feeder Board and the Weld Control Board. A motor speed feedback signal is gener[...]

  • Page 42

    THERMAL PROTECTION T wo normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are con- nected to the Weld Control Board. One of the ther- mostats is located on the Chopper Assembly Board, and one is on the secondary of the Main T ransformer . Excessive temperatures may [...]

  • Page 43

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-9 E-9 POWER MIG 350MP FIGURE E.8 – IGBT OPERA TION DRAIN SOURCE GATE  INJECTING LAYER BUFFER LAYER DRAIN DRIFT REGION BODY REGION p + n + n - p n + n[...]

  • Page 44

    PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION 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 MODULA TION. 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[...]

  • Page 45

    CHOPPER TECHNOLOGY FUNDAMENT ALS The new era of welding machines such as the Power MIG 350MP employ a technology whereby a DC source is turned on and off (chopped up) at high speed, then smoothed through an inductor to control an arc. Hence the name “Chopper .” The biggest advantage of chopper technology is the high-speed control of the arc, si[...]

  • Page 46

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES E-12 E-12 POWER MIG 350MP[...]

  • Page 47

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 POWER MIG 350MP T roubleshooting & Repair Section ................................................................................ Section F How to Use T roubleshooting Guide ...............................................................[...]

  • Page 48

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HOW T O USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may[...]

  • Page 49

    POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-3 F-3 Sometimes machine failures appear to be due to PC Board failures. These problems can sometimes be traced to poor electrical [...]

  • Page 50

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 POWER MIG 350MP If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the L[...]

  • Page 51

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 POWER MIG 350MP TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not under[...]

  • Page 52

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 POWER MIG 350MP If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the L[...]

  • Page 53

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-7 F-7 POWER MIG 350MP TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not under[...]

  • Page 54

    F-8 F-8 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the L[...]

  • Page 55

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 POWER MIG 350MP If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the L[...]

  • Page 56

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-10 F-10 POWER MIG 350MP If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the[...]

  • Page 57

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-11 F-11 POWER MIG 350MP TROUBLESHOOTING & REP AIR If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the[...]

  • Page 58

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-12 F-12 POWER MIG 350MP TROUBLESHOOTING & REP AIR If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the[...]

  • Page 59

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-13 F-13 POWER MIG 350MP If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the[...]

  • Page 60

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 F-14 POWER MIG 350MP PUSH PULL WIRE FEEDING PROBLEMS ST ALL F ACTOR - an adjustment to the Power Mig 350MP that allows the welder to adjust the[...]

  • Page 61

    F-15 F-15 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the[...]

  • Page 62

    CHOPPER BOARD CAP ACIT OR DISCHARGE PROCEDURE 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[...]

  • Page 63

    TROUBLESHOOTING & REP AIR F-17 F-17 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CHOPPER BOARD CAP ACIT OR DISCHARGE PROCEDURE (continued) FIGURE F .1 – CHOPPER BOARD CAP ACITOR TERMINAL DISCHARGE PROC[...]

  • Page 64

    MAIN TRANSFORMER TEST 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 pr[...]

  • Page 65

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-19 F-19 POWER MIG 350MP MAIN TRANSFORMER TEST (continued) FIGURE F .2 – MAIN TRANSFORMER TEST POINT LOCA TIONS PROCEDURE The ON/OFF POWER SWITCH[...]

  • Page 66

    CHOPPER BOARD TEST 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 preca[...]

  • Page 67

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-21 F-21 POWER MIG 350MP CHOPPER BOARD TEST (continued) FIGURE F .3 – CHOPPER BOARD CONNECTIONS T able F .1– CHOPPER BOARD RESIST ANCE TEST T A[...]

  • Page 68

    TROUBLESHOOTING & REP AIR F-22 F-22 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CHOPPER BOARD TEST (continued) FIGURE F .4 L1 1088-1 J6 PWM SIGNAL TEST 1. Locate 607 (7J6) and 615 (15J6) on the control [...]

  • Page 69

    CONTROL RECTIFIER TEST 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 elec- trical shock, please observe all safety notes and[...]

  • Page 70

    TROUBLESHOOTING & REP AIR F-24 F-24 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL RECTIFIER TEST (continued) FIGURE F .5 FIGURE F .6 - + CONTROL RECT IF IER + 6800/75 X6 X5 X4 X3 30 VA C 115 V AC [...]

  • Page 71

    OUTPUT RECTIFIER ASSEMBL Y TEST 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 no[...]

  • Page 72

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-26 F-26 POWER MIG 350MP OUTPUT RECTIFIER ASSEMBL Y TEST (continued) FIGURE F .7– OUTPUT RECTIFIER ASSEMBL Y LOCA TION TEST PROCEDURE 1. Disconne[...]

  • Page 73

    WIRE DRIVE MOT OR AND T ACHOMETER FEEDBACK TEST 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 obser[...]

  • Page 74

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-28 F-28 POWER MIG 350MP WIRE DRIVE MOT OR AND T ACHOMETER FEEDBACK TEST (continued) FIGURE F . 8 – PLUG J83 AND J84 LOCA TIONS ON FEEDER BOARD T[...]

  • Page 75

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-29 F-29 POWER MIG 350MP WIRE DRIVE MOT OR AND T ACHOMETER FEEDBACK TEST (continued) TEST FOR SUPPL Y VOL T AGE T O T ACHOMETER AND FEEDBACK VOL T [...]

  • Page 76

    ENCODER PC BOARD TEST 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 elec- trical shock, please observe all safety notes and [...]

  • Page 77

    F-31 F-31 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR ENCODER PC BOARD TEST (continued) G3884 J82 3243 J85 858 857 855 851 1 8510 859 FIGURE F . 9 - FEEDHEAD P .C. BOARD TEST P[...]

  • Page 78

    TROUBLESHOOTING & REP AIR F-32 F-32 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENCODER PC BOARD TEST (continued) FROM LEAD TO LEAD EXPECTED VOL T AGE 855 3243 15 VDC 5J85 3J82 851 1 3243 0 OR 15 VDC 1 [...]

  • Page 79

    CURRENT TRANSDUCER TEST 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 elec- trical shock, please observe all safety notes an[...]

  • Page 80

    TROUBLESHOOTING & REP AIR F-34 F-34 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CURRENT TRANSDUCER TEST (continued) FIGURE F .10 L1 1088-1 J8 804 802 801 806 TEST PROCEDURE 1. Remove input power to the [...]

  • Page 81

    TROUBLESHOOTING & REP AIR F-35 F-35 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CURRENT TRANSDUCER TEST (continued) T able F .2 – Current T ransducer Feedback V oltage OUTPUT LOAD CURRENT 500 450 400 [...]

  • Page 82

    POWER MIG 350MP SCROLLING DASHES TEST 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 elec- trical shock, please observe all s[...]

  • Page 83

    TROUBLESHOOTING & REP AIR F-37 F-37 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 350MP SCROLLING DASHES TEST (continued) TEST PROCEDURES: 1. Hold “select” switch up while powering up machin[...]

  • Page 84

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-38 F-38 POWER MIG 350MP This is a typical DC output voltage waveform generated from a properly operating machine. Note that each vertical division[...]

  • Page 85

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-39 F-39 POWER MIG 350MP SCOPE SETTINGS V olts/Div .....................20V/Div . Horizontal Sweep ..2.0 ms/Div . Coupling ........................[...]

  • Page 86

    MOT OR & GEAR BOX ASSEMBL Y REMOV AL AND REPLACEMENT 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, ple[...]

  • Page 87

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-41 F-41 POWER MIG 350MP MOT OR & GEAR BOX ASSEMBL Y REMOV AL AND REPLACEMENT (continued) REMOV AL PROCEDURE ELECTRIC SHOCK can kill . High vol[...]

  • Page 88

    TROUBLESHOOTING & REP AIR F-42 F-42 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MOT OR & GEAR BOX ASSEMBL Y REMOV AL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE 1. Bolt the wire drive assembly[...]

  • Page 89

    TROUBLESHOOTING & REP AIR F-43 F-43 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MOT OR & GEAR BOX ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .1 1 15 14 9 10 13 12 11 6 8 5[...]

  • Page 90

    OUTPUT RECTIFIER REMOV AL AND REPLACEMENT 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 elec- trical shock, please observe a[...]

  • Page 91

    TROUBLESHOOTING & REP AIR F-45 F-45 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFIER REMOV AL AND REPLACEMENT (continued) ELECTRIC SHOCK can kill . High voltage is present when input power i[...]

  • Page 92

    TROUBLESHOOTING & REP AIR F-46 F-46 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFIER REMOV AL AND REPLACEMENT (continued) washers holding the rectifier bracket to the machine base. 10. Clear[...]

  • Page 93

    CHOPPER BOARD ASSEMBL Y REMOV AL AND REPLACEMENT 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 elec- trical shock, please ob[...]

  • Page 94

    TROUBLESHOOTING & REP AIR F-48 F-48 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CHOPPER BOARD ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .13 – CHOPPER BOARD ASSEMBL Y DET AILS REMOV AL PR[...]

  • Page 95

    TROUBLESHOOTING & REP AIR F-49 F-49 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CHOPPER BOARD ASSEMBL Y REMOV AL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE 1. Attach the chopper assembly brackets[...]

  • Page 96

    TROUBLESHOOTING & REP AIR F-50 F-50 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAIN TRANSFORMER AND OUTPUT CHOKE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric[...]

  • Page 97

    REMOV AL PROCEDURE ELECTRIC SHOCK can kill . High voltage is present when input power is applied to the machine. Note: Cut cable ties as needed to improve access. PREP ARA TION 1. Disconnect main input power from the machine. 2. Remove the case side panels using a 3/8” nut dri- ver . 3. Perform the Chopper Board Capacitor Discharge Procedure . 4.[...]

  • Page 98

    TROUBLESHOOTING & REP AIR F-52 F-52 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAIN TRANSFORMER AND OUTPUT CHOKE REMOV AL AND REPLACE- MENT (continued) LEAD DISCONNECTION 8. Using a phillips head screw[...]

  • Page 99

    TROUBLESHOOTING & REP AIR F-53 F-53 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAIN TRANSFORMER AND OUTPUT CHOKE REMOV AL AND REPLACE- MENT (continued) FIGURE F .14 BACK BACK SIDE SIDE 5 12 12 11 1 1 8[...]

  • Page 100

    TROUBLESHOOTING & REP AIR F-54 F-54 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F AN MOTOR ASSEMBL Y REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trai[...]

  • Page 101

    TROUBLESHOOTING & REP AIR F-55 F-55 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F AN MOTOR ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .15 – F AN MOTOR ASSEMBL Y REMOV AL 6 4B 4A 6 5 REMOV[...]

  • Page 102

    VOL T AGE & CURRENT CALIBRA TION PROCEDURE 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 elec- trical shock, please obse[...]

  • Page 103

    TROUBLESHOOTING & REP AIR F-57 F-57 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC VOL T AGE & CURRENT CALIBRA TION PROCEDURE (continued) CALIBRA TION CHECK The calibration of the Power MIG 350MP can b[...]

  • Page 104

    TROUBLESHOOTING & REP AIR F-58 F-58 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC VOL T AGE & CURRENT CALIBRA TION PROCEDURE (continued) 9. W ait for the machine’ s output to be automati- cally turn[...]

  • Page 105

    RETEST AFTER REP AIR 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. OR • If you repair or replace any electrical components. TEST MODE 5 INPUT IDLE W A TTS AND AMPS Input V olts/Hertz Maximum Idle W atts Maximum Idle Amps 230/60 [...]

  • Page 106

    NOTES F-60 F-60 POWER MIG 350MP Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 107

    G-1 ELECTRICAL DIAGRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM (G4678) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 108

    ELECTRICAL DIAGRAMS G-2 POWER MIG 350MP WIRING DIAGRAM - ENTIRE MACHINE EN -170 S O L ID E D G E G4678 P O W E R MI G 35 0 MP W I RI NG DI A G RA M NONE G4511 cstubl e J. SKE R B E C - UNLESS OTHERWISE SPECIFIEDTOLERANCE MANUFACTURING TOLERANCE PER E2056 ON 2 PLACE DECIMALS IS ± .02 ON 3 PLACE DECIMALS IS ± .00 2 ON ALL AN GLES IS ± .5OF A DEGRE[...]

  • Page 109

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-3 POWER MIG 350MP SCHEMA TIC - ENTIRE MACHINE EN- 170 S O L I D E D G E G 4677 E NGINEERING CONTROLLED MANUFACTURER: No CHA N G E DET AIL: R EL E A S EDA.[...]

  • Page 110

    ELECTRICAL DIAGRAMS G-4 POWER MIG 350MP SCHEMA TIC - CONTROL PC BOARD (G3789-1E2/1) G-4 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Ret[...]

  • Page 111

    ELECTRICAL DIAGRAMS G-5 POWER MIG 350MP SCHEMA TIC - CONTROL PC BOARD (G3789-1E2/2) G-5 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Ret[...]

  • Page 112

    ELECTRICAL DIAGRAMS G-6 POWER MIG 350MP SCHEMA TIC - CONTROL PC BOARD (G3789-1E2/3) G-6 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Ret[...]

  • Page 113

    ELECTRICAL DIAGRAMS G-7 POWER MIG 350MP SCHEMA TIC - CONTROL PC BOARD (G3789-1E2/4) G-7 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Ret[...]

  • Page 114

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 115

    ELECTRICAL DIAGRAMS G-9 POWER MIG 350MP SCHEMA TIC POWER SUPPL Y P .C. BOARD (G3631-3F0) G-9 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TO[...]

  • Page 116

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 117

    ELECTRICAL DIAGRAMS G-11 POWER MIG 350MP SCHEMA TIC - CHOPPER P .C. BOARD (M20046-1M0) G-11 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC[...]

  • Page 118

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 119

    ELECTRICAL DIAGRAMS G-13 POWER MIG 350MP SCHEMA TIC - MSP3 PC BOARD (L1 1612-2D0) G-13 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Retu[...]

  • Page 120

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 121

    ELECTRICAL DIAGRAMS G-15 POWER MIG 350MP SCHEMA TIC - FEEDER P .C. BOARD (G3883-1E0/1) G-15 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC[...]

  • Page 122

    ELECTRICAL DIAGRAMS G-16 POWER MIG 350MP SCHEMA TIC - FEEDER P .C. BOARD (G3883-1E0/2) G-16 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC[...]

  • Page 123

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 124

    ELECTRICAL DIAGRAMS G-18 POWER MIG 350MP SCHEMA TIC - SPOOL GUN P .C. BOARD (L12008-2D0) G-18 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master T[...]

  • Page 125

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 126

    ELECTRICAL DIAGRAMS G-20 POWER MIG 350MP SCHEMA TIC - DISPLA Y P .C. BOARD (L11756-1E1) G-20 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TO[...]

  • Page 127

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 128

    SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information wi[...]