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Lincoln Electric SVM155-A manual

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Table of contents for the manual

  • Page 1

    SERVICE MANUAL • World's Leader in W elding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.com MUL TI-SOURCE M UL TI - SO URCE O U T P U T T H E R M A L F A N P O W E R O N O F F % O U T [...]

  • Page 2

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY i i MUL TI-SOURCE FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, wel[...]

  • Page 3

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY ii ii MUL TI-SOURCE 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 sta[...]

  • Page 4

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iii iii MUL TI-SOURCE FOR ELECTRICALL Y powered equipment. 8.a. T urn of f 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

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iv iv MUL TI-SOURCE 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

    MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v MUL TI-SOURCE Page Safety .................................................................................................................................................i-iv Installation ..................................................................................................................[...]

  • Page 7

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 MUL TI-SOURCE Installation ................................................................................................................... ...Section A T echnical Specifications ..............[...]

  • Page 8

    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 A-2 A-2 MUL TI-SOURCE TECHNICAL SPECIFICA TIONS - Multi-Source K1752-1 PHYSICAL DIMENSIONS TEMPERA TURE RANGES HEIGHT 30.8 in 781 mm WIDTH 22.2in 565 mm DEPTH 41 i[...]

  • Page 9

    SELECT PROPER LOCA TION Place the power supply where clean cooling air can freely circulate in through the front louvers and out through the rear louvers. Dirt, dust or any foreign mate- rial that can be drawn into the welder should be kept at a minimum. Failure to observe these precautions can result in excessive operating temperatures and nui- sa[...]

  • Page 10

    INST ALLA TION A-4 A-4 MUL TI-SOURCE 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 FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the T echnical Specifications[...]

  • Page 11

    OUTPUT CONNECTIONS The Multi-Source has two parallel connected output studs for positive and negative connections. Each one is rated to carry the full output current. For its maximum rated current at 100% duty cycle a minimum size of 4/0 A WG welding cable is recommended. Connection of Electrode and Work Leads to Output terminals. 1. Set the POWER [...]

  • Page 12

    NOTES A-6 A-6 MUL TI-SOURCE 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 13

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Instructions ........................................................[...]

  • Page 14

    OPERA TION B-2 B-2 MUL TI-SOURCE 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 SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourse[...]

  • Page 15

    OPERA TION B-3 B-3 MUL TI-SOURCE 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 Multi-Source is designed to supply power to the Multi-Weld welders. It has a wide range three phase AC input and can be o[...]

  • Page 16

    OPERA TION B-4 B-4 MUL TI-SOURCE 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 RECOMMENDED EQUIPMENT/CONNECTIONS The Multi-weld 350 (K1735-1) is the recommended means by which to control the MUL TI-SOURCE power supply . Conn[...]

  • Page 17

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Factory Installed Options/Accessories ...............................................[...]

  • Page 18

    F ACTOR Y INST ALLED OPTIONS / ACCESSORIES There ar e no factory installed options. FIELD INST ALLED OPTIONS / ACCESSORIES K1735-1 Multi-W eld 350, Multi-process controller . K857, K857-1 Remote contr ol, Control multi-weld remotely (25 or 100 ft.) K1736-1 Distribution box, Connects up to 10 Multi- W elds. K449 LN-25, Across the ar c wire feeder . [...]

  • Page 19

    D-1 D-1 T ABLE OF CONTENTS -MAINTENANCE- MUL TI-SOURCE Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Maintenance ......................................................................................................................... Section D Safety Precautions.................................................[...]

  • 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 MAINTENANCE D-2 D-2 MUL TI-SOURCE W ARNING SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this mainte- nance. • T ur n the input power [...]

  • Page 21

    FIGURE D.1 – MAJOR COMPONENT LOCA TION MAINTENANCE D-3 D-3 MUL TI-SOURCE 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. Case Front Assembly 2. Case back Assembly 3. Fan 4. Base 5. Sides 6. Roof 7. Rectifier Assembly MU L[...]

  • Page 22

    NOTES D-4 D-4 MUL TI-SOURCE 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 23

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 MUL TI-SOURCE FIGURE E.1 – MUL TI-SOURCE BLOCK LOGIC DIAGRAM LED LED LED DIGIT AL METER G Y W CONTROL BOARD THERMOST A T CONTROL SIGNAL RESISTOR BANK FIRING BOARD GA TE SIGNALS TO CONTROL BOARD SHUNT SCR OUTPUT RECTIFIER FIL TER CAP ACITOR [...]

  • Page 24

    GENERAL DESCRIPTION The Multi-Source is designed to supply power to the Multi-W eld Arc Converter welders. The Multi-Source is an SCR controlled constant voltage (CV) DC power supply that can operate with a wide range of three phase input voltages. The machine's peak output voltage helps regulate against wide variations in out- put loading and[...]

  • Page 25

    E-3 E-3 FIGURE E.3 – MAIN TRANSFORMER, CONTROL BOARD, COOLING F AN MOTOR, & LEDs TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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, CONTROL BOARD, COOLING F AN M[...]

  • Page 26

    E-4 E-4 FIGURE E.4 – SCR BRIDGE, RESISTOR BANK, FIRING BOARD, & OUTPUT CAP ACITOR/RESISTOR TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 SCR BRIDGE, RESISTOR BANK, FIRING BOA[...]

  • Page 27

    E-5 E-5 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 PROTECTION DEVICES AND CIR- CUITS Several thermostats protect the Multi-Sour ce from over temperature and /or excessive loadin[...]

  • Page 28

    E-6 E-6 FIGURE E.5 SCR OPERA TION TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 SCR OPERA TION A silicon controlled r ectifier (SCR) is a three terminal device used to control rath[...]

  • Page 29

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS -TROUBLESHOOTING & REP AIR SECTION- T roubleshooting & Repair Section ....................................................................................... Section F How to Use T roubleshooting Guide .....................................[...]

  • Page 30

    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-2 F-2 MUL TI-SOURCE HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. U[...]

  • Page 31

    ELECTRIC SHOCK can kill. Have an electrician install and ser- vice this equipment. T ur n the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failur es. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshootin[...]

  • Page 32

    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 MUL TI-SOURCE TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 33

    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 MUL TI-SOURCE TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 34

    TROUBLESHOOTING & REP AIR F-6 F-6 MUL TI-SOURCE 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 CAUTION If for any reason you do not understand the test pr ocedures or ar e unable to perform the test/r epairs safely , con-[...]

  • Page 35

    TROUBLESHOOTING & REP AIR F-7 F-7 MUL TI-SOURCE 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 GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 36

    INST ALLA TION F-8 F-8 MUL TI-SOURCE 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 GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not understand the[...]

  • Page 37

    CONTROL TRANSFORMER (T2) VOL T AGE TEST F-9 F-9 MUL TI-SOURCE 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 Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs perf[...]

  • Page 38

    Control T ransformer (T2) X3 H2 H1 X1 F-10 F-10 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Remove the T op an[...]

  • Page 39

    F-11 F-11 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 6. Carefully apply primary power and test for the correct secondary voltages. See T able F .1. NOTE: If the correct main AC [...]

  • Page 40

    F-12 F-12 CONTROL TRANSFORMER (T2) VOL T AGE TEST MUL TI-SOURCE 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 NOTE: If the secondary voltage is not pre- sent at terminal #X3 but is present at terminal #X2 the internal thermo[...]

  • Page 41

    F-13 F-13 INPUT CONT ACTOR TEST TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 W ARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Un[...]

  • Page 42

    F-14 F-14 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 CONT ACTOR TEST (Continued) CONT ACT OR COIL 240 241 1. Disconnect the main input supply power to the machine. 2. With[...]

  • Page 43

    F-15 F-15 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 T3 T2 T1 U V W TOP VIEW T est Points T est Points T est Points TEST FOR CONT ACT CONTINUITY 1. Disconnect the main input sup[...]

  • Page 44

    F-16 F-16 NOTES MUL TI-SOURCE 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 45

    F-17 F-17 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 (T1) VOL T AGE TEST W ARNING Service and repair should be performed only by Lincoln Electric factory traine[...]

  • Page 46

    F-18 F-18 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 (T1) VOL T AGE TEST (continued) Reconnect Panel Assembly Input Contactor TEST PROCEDURE 1. Disconnect main [...]

  • Page 47

    F-19 F-19 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 (T1) VOL T AGE TEST (continued) T ransformer Secondary Leads Lift Bail Common Buss T ransformer Assembly #2[...]

  • Page 48

    F-20 F-20 NOTES MUL TI-SOURCE 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 49

    F-21 F-21 ST A TIC SCR TEST TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 W ARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauth[...]

  • Page 50

    F-22 F-22 ST A TIC SCR TEST (Continued) TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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. Remove main supply power to the machine. 2. Remove the roof and case sides. 3. Lower the fr[...]

  • Page 51

    F-23 F-23 ST A TIC SCR TEST (Continued) TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 Leads 4. Using the 9/16” wrench, r emove the two positive output leads connecting the out- p[...]

  • Page 52

    F-24 F-24 ST A TIC SCR TEST (Continued) TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 7. Repeat previous step(s) testing SCR 2, SCR 3, SCR 4, SCR 5, and SCR 6. T o further check th[...]

  • Page 53

    F-25 F-25 ACTIVE SCR TEST TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 W ARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthor[...]

  • Page 54

    F-26 F-26 ACTIVE SCR TEST (Continued) TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 FIRING BOARD J5 J6 J8 J4 J7 Plug J4 1. Remove main supply power to the Multi- Source. 2. Remove [...]

  • Page 55

    F-27 F-27 ACTIVE SCR TEST (Continued) TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 Leads 4. Using a 9/16” wrench, r emove the two positive output leads connecting the out- put b[...]

  • Page 56

    F-28 F-28 ACTIVE SCR TEST (Continued) TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 Remove Red Paint Anode Cathode 5. Remove the r ed insulating paint fr om heat sink test points. [...]

  • Page 57

    F-29 F-29 ACTIVE SCR TEST (Continued) TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 T o test SCRs construct the circuit outlined above. Resistor values are plus or minus ten percen[...]

  • Page 58

    F-30 F-30 NOTES MUL TI-SOURCE 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 59

    F-31 F-31 CONTROL BOARD TEST TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 W ARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unaut[...]

  • Page 60

    F-32 F-32 CONTROL BOARD TEST (Continued) TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 J1 J2 J3 J5 J6 J8 Firing Board Control Board J4 J7 TEST PROCEDURE FOR NORMAL CON- TROL BOARD [...]

  • Page 61

    F-33 F-33 CONTROL BOARD TEST (Continued) TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 F .15. Control Board with LED, Plug and Lead Locations 10. LED 6 indicates that the fa[...]

  • Page 62

    F-34 F-34 NOTES MUL TI-SOURCE 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 63

    F-35 F-35 FIRING BOARD TEST TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 W ARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauth[...]

  • Page 64

    F-36 F-36 FIRING BOARD TEST (Continued) TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 J1 J2 J3 J5 J6 J8 Firing Board Control Board J4 J7 TEST PROCEDURE FOR NORMAL FIRING BOARD OPER[...]

  • Page 65

    F-37 F-37 FIRING BOARD TEST (Continued) TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 T ABLE F .2. - LED 7, 8 and 9 Check List IF LED 7 is ON LED 7 is OFF or is DIM- MER than other[...]

  • Page 66

    TROUBLESHOOTING & REP AIR FIRING BOARD TEST (Continued) F-38 F-38 MUL TI-SOURCE 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 FIRING BOARD J6 J4 J7 Jumper Plug J5 J8 #284 #283 #286 #287 #285 #340 #215 #231 #288 FIGURE F [...]

  • Page 67

    F-39 F-39 MUL TI-SOURCE METER ACCURACY CHECK TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 W ARNING Service and repair should be performed only by Lincoln Electric factory trained [...]

  • Page 68

    F-40 F-40 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 MUL TI-SOURCE METER ACCURACY CHECK (Continued) METER ACCURACY CHECK 1. With power off, connect a resistive load and the mete[...]

  • Page 69

    F-41 F-41 NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM - NO LOAD TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 0 volts 2 ms 50 volts This is the typical DC open circuit volt- age wavef[...]

  • Page 70

    F-42 F-42 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 ABNORMAL OPEN CIRCUIT VOL T AGE W A VEFORM ONE OUTPUT SCR NOT FUNCTIONING - NO LOAD 0 volts 2 ms 50 volts This is NOT the ty[...]

  • Page 71

    F-43 F-43 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 TYPICAL SCR GA TE VOL T AGE W A VEFORM - NO LOAD 0 volts 2 ms 1 volt This is the typical SCR gate pulse volt- age waveform. [...]

  • Page 72

    F-44 F-44 NOTES MUL TI-SOURCE 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 73

    F-45 F-45 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 CONT ACTOR CLEANING AND/OR REPLACEMENT W ARNING Service and repair should be performed only by Lincoln Electric factor[...]

  • Page 74

    F-46 F-46 INPUT CONT ACTOR CLEANING AND/OR REPLACEMENT (Continued) TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 T3 T2 T1 U V W TOP VIEW REMOV AL PROCEDURE 1. Disconnect input powe[...]

  • Page 75

    F-47 F-47 INPUT CONT ACTOR CLEANING AND/OR REPLACEMENT (Continued) TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 F .21. INPUT CONT ACTOR CLEANING/INSPECTION CONT ACTOR COIL [...]

  • Page 76

    F-48 F-48 NOTES MUL TI-SOURCE 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 77

    F-49 F-49 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 BOARD REPLACEMENT PROCEDURE W ARNING Service and repair should be performed only by Lincoln Electric factory trained[...]

  • Page 78

    F-50 F-50 CONTROL BOARD REPLACEMENT PROCEDURE (Continued) TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 J1 J2 J3 J5 J6 J8 Firing Board Control Board J4 J7 REMOV AL PROCEDURE 1. Dis[...]

  • Page 79

    F-51 F-51 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 FIRING BOARD REPLACEMENT PROCEDURE W ARNING Service and repair should be performed only by Lincoln Electric factory trained [...]

  • Page 80

    F-52 F-52 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 FIRING BOARD REPLACEMENT PROCEDURE (Procedure) J1 J2 J3 J5 J6 J8 Firing Board Control Board J4 J7 REMOV AL PROCEDURE 1. Disc[...]

  • Page 81

    F-53 F-53 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 SCR BRIDGE / HEA T SINK ASSEMBL Y REPLACEMENT PROCEDURE W ARNING Service and repair should be performed only by Lincoln Elec[...]

  • Page 82

    F-54 F-54 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 SCR BRIDGE / HEA T SINK ASSEMBL Y REPLACEMENT PROCEDURE REMOV AL PROCEDURE 1. Disconnect input power to the machine. 2. Usin[...]

  • Page 83

    F-55 F-55 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 SCR BRIDGE / HEA T SINK ASSEMBL Y REPLACEMENT PROCEDURE 6. Using a 9/16” nut driver , remove the two positive output leads[...]

  • Page 84

    F-56 F-56 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 SCR BRIDGE / HEA T SINK ASSEMBL Y REPLACEMENT PROCEDURE 13. Clear all leads and carefully maneuver SCR bridge out of the rig[...]

  • Page 85

    F-57 F-57 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 REMOV AL OF INDIVIDUAL SCR HEA T SINK ASSEMBLIES 1. Using a 9/16” nut driver , remove the nuts and respective washers secu[...]

  • Page 86

    F-58 F-58 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 SCR BRIDGE / HEA T SINK ASSEMBL Y REPLACEMENT PROCEDURE INST ALLA TION OF SCR OUTPUT BRIDGE NOTE: Upon reassembly , apply a [...]

  • Page 87

    F-59 F-59 TROUBLESHOOTING & REP AIR MUL TI-SOURCE 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 MAXIMUM OPEN CIRCUIT VOL T AGE Open Circuit V olts 79.5/80 VDC PERFORM METER ACCURACY TEST RETEST AFTER REP AIR T esting is [...]

  • Page 88

    F-60 F-60 NOTES MUL TI-SOURCE 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 89

    MUL TI-SOURCE G-1 ELECTRICAL DIAGRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 90

    ELECTRICAL DIAGRAMS G-2 WIRING DIAGRAM - CON TROL P C B OAR D FIRIN G P C BOA RD 283 284 285 286 287 288 2 R3 R4 R5 R6 R7 R8 03 204 205 206 207 208 TO T1 AUX ILIAR IES J1 1 2 3 4 5 6 7 8 9 10 J3 J2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 201 261 263 231 202 215A 230 341 222A 260 264 235 234 215B[...]

  • Page 91

    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 ELECTRICAL DIAGRAMS G-3 SCHEMA TIC - CONTROL PC BOARD G-3 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.[...]

  • Page 92

    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 93

    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 ELECTRICAL DIAGRAMS G-5 SCHEMA TIC - FIRING PRINTED CIRCUIT BOARD G-5 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.[...]

  • Page 94

    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 95

    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 96

    SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. W e 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 w[...]