SVM155-A
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July, 2001
TM
MULTI-SOURCE
For use with machines having Code Numbers: 10668
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation .
. . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
%
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IN
G
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F
F
TI-SOURCE
MUL
URCE
EQUIPMENT
WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
SERVICE MANUAL
Copyright © 2001 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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ii
ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
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. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.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.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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.
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.
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 prod-
ucts.
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.
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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
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.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
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iii
iii
SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
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.
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.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.
•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.
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).
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.
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.
FOR ELECTRICALLY
powered equipment.
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.
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.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
MULTI-SOURCE
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iv
iv
SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRÉCAUTIONS DE SÛRETÉ
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 suiv-
antes:
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.
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.
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 met-
allique 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 defonc-
tionnement.
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.
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.
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.
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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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.
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 rayon-
nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
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.
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.
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 debranch-
er à l’interrupteur à la boite de fusibles.
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, pan-
talons sans revers, et chaussures montantes.
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.
Mar. ‘93
MULTI-SOURCE
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v
v
RETURN TO MAIN MENU
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
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
Electrical Diagrams..............................................................................................................Section G
Parts Manual..................................................................................................................P-367 SERIES
MULTI-SOURCE
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Section A-1
Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation ......................................................................................................................Section A
Technical Specifications .............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Select Proper Location ...............................................................................................................A-3
Stacking................................................................................................................................A-3
Tilting .................................................................................................................................A-3
Electrical Input Connections.......................................................................................................A-3
Fuse and Wire Sizes ...................................................................................................................A-4
Input and Grounding Connections .............................................................................................A-4
Reconnect Procedure.................................................................................................................A-4
Output Connections....................................................................................................................A-5
Paralleling .................................................................................................................................A-5
Multi-Source Output Limitations.................................................................................................A-5
Distribution Box ..........................................................................................................................A-5
“Pig Tail” Leads and Connections ..............................................................................................A-5
MULTI-SOURCE
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - Multi-Source K1752-1
INPUT - THREE PHASE ONLY
Input Current at Rated Output
Standard Voltage/Frequency
100% Duty Cycle
380/415/50
400/60
440/50
460/60
550/50
99A
98A
79A
83A
66A
69A
575/60
RATED OUTPUT
60 Hz-40 kW
Amps
533
Volts at Rated Amperes
75
Duty Cycle
100% Duty Cycle
@ 50°C (122°F)
50 Hz-36 kW
Amps
Volts at Rated Amperes
475
75.8
CURRENT RANGE
OCV
Maximum Open Circuit Voltage
80V
0-650 A
RECOMMENDED INPUT WIRE AND FUSE SIZES
TYPE 75°C TYPE 90°C TYPE 75°C TYPE 90°C
TYPE
75°C
FUSE
INPUT
VOLTAGE
HERTZ INPUT
AMPERE
COPPER
WIRE IN
CONDUIT
COPPER
WIRE IN
CONDUIT
COPPER
WIRE IN
COPPER
WIRE IN GROUND
(SUPER
LAG)
OR
RATING
CONDUIT CONDUIT WIRE IN
AWG(IEC-MM2) AWG(IEC-MM2) AWG(IEC-MM2) AWG(IEC-MM2) CONDUIT BREAKER
SIZES
50°C SIZES
50°C
SIZES
40°C
SIZES 40°C
AWG(IEC-
SIZE
(122°F) Ambient (122°F) Ambient (104°F) Ambient (104°F) Ambient MM2) SIZES
(AMPS)
150 Amp
125 Amp
100 Amp
380-415
460
575
50
60
60
99
83
69
1/0 (70)
2 (35)
3 (35)
2 (35)
3 (35)
4 (25)
3 (35)
4 (25)
4 (25)
6 (16)
6 (16)
8 (10)
2 (35)
3 (35)
4 (25)
PHYSICAL DIMENSIONS
HEIGHT
30.8 in
781 mm
WIDTH
22.2in
565 mm
DEPTH
41 in
1040 mm
NET WEIGHT
992 lbs.
450.5 kg.
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-40 to +122ºF
STORAGE TEMPERATURE RANGE
-40 to +185ºF
-40 to +50ºC
-40 to +85ºC
MULTI-SOURCE
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A-3
A-3
INSTALLATION
the two holes in the base rails on the second
machine with the two pins on top at the front of the
bottom machine.
Read entire Installation Section before installing the
MULTI-SOURCE.
SAFETY PRECAUTIONS
Note: The machines must be stacked with the Case
Front of each machine flush with each other.
See Figure A.1. below.
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.
STACKING HOLE
• Do not touch electrically hot parts.
• The Multi-Source power supply should not be used if
the green Safe Output light is not lit. The machine is
designed to open its input contactor if output voltage
peaks exceed the limits set by certain approval
agencies. If the Safe Output light is on, the output
voltage is within it designed operating range.
-------------------------------------------------------------------
STACKING PIN
SELECT PROPER LOCATION
FIGURE A.1. - Stacking the MULTI-SOURCE
Place the power supply where clean cooling air can
freely circulate in through the front louvers and out
through the rear louvers. Dirt, dust or any foreign mate-
rial that can be drawn into the welder should be kept at
a minimum. Failure to observe these precautions can
result in excessive operating temperatures and nui-
sance shut-downs.
TILTING
The MULTI-SOURCE must be placed on a stable, level
surface so it will not topple over.
ELECTRICAL INPUT
CONNECTIONS
STACKING
Before installing the machine, check that the input sup-
ply voltage, phase, and frequency are the same as the
machine’s voltage, phase, and frequency as specified
on the machine’s rating plate on the Case Front
Assembly Control Panel. Connect input power supply
by removing the rear access panel and connecting to
the three line terminals on the input panel. See Figure
A.2 for location of the machine’s input cable entry
opening and reconnect panel assembly for dual volt-
age machines.
WARNING
FALLING EQUIPMENT can cause
injury.
• Two Multi-Source machines can be
stacked.
• Lift only with equipment of adequate
lifting capacity.
• Be sure machine is stable when lifting.
• Do not stack more than two high.
• Do not stack the Multi-Source on top of any other
machine.
Rear Panel
---------------------------------------------------------------------
Two MULTI-SOURCE machines can be stacked.
W
Follow these guidelines when stacking:
V
U
1. Select a firm, level surface capable of supporting
the total weight of up to two machines (1984
pounds/901kilograms).
2. Set the bottom machine in place.
3. Stack the second machine on top of it by aligning
FIGURE A.2. - Input Power Supply Connection
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A-4
A-4
INSTALLATION
Input Connection Diagram located on the inside of
Case Back Input Access Door.
FUSE AND WIRE SIZES
Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the Technical
Specifications page of this manual for the machine
being used. They are also called inverse time or ther-
mal/magnetic circuit breakers.
The conductor and fuse sizes in the Technical
Specification Section), are per the National Electrical
Code. The sizes are in American Wire Gauge (and the
next largest standard metric size in mm2). National and
local codes must be consulted before connecting a
machine.
DO NOT use fuses or circuit breakers with a lower amp
rating than recommended. This can result in nuisance
tripping caused by inrush current even when machine
is not being used for welding at high output currents.
Use input and grounding wire sizes that meet local
electrical codes, or see the Technical Specifications
page in this manual.
Protect the input circuit with the super lag fuses or
delay type circuit breakers listed in the Technical
Specification Section. (They are also called inverse
time or thermal / magnetic circuit breakers.)
RECONNECT PROCEDURE
Multiple voltage machines are shipped connected to
the highest input voltage listed on the machine’s rating
plate. Before installing the machine, check that the
Reconnect Panel in the Input Box Assembly is con-
nected for the proper voltage.
INPUT AND GROUNDING
CONNECTIONS
Note: A qualified electrician should connect the
input power supply leads.
Input conductor is brought into the machine input box
area through a hole in the rear panel sized to accom-
modate 2" (trade size) conduit and fittings. This is more
than adequate for the largest conductors required.
CAUTION
Failure to follow these instructions can cause immedi-
ate failure of components within the machine.
-----------------------------------------------------------
Conductors must be lugged to attach to the three 3/8"
studs on the input reconnect panel and the 5/16"
ground stud marked with the symbol . The input volt-
age supplied determines the position required for the
reconnect panel jumper. The three ranges on the stan-
dard machine are 380-415, 440-460 and 550-575. The
machine is rated for 50 and 60 Hz operation. See the
To reconnect a multiple voltage machine to a different
voltage, remove input power and follow the input
Connection Diagram located on the inside of the Case
Back Input Access Door. This connection diagram is
shown below.
FIGURE A.3. - Input Connection Diagram
550-575V Connection
WARNING
L3
L2
L1
W
INPUT
LINES
All input power must be electrically discon-
nected before touching reconnect panel.
V
U
1. Mount the movable reconnect bar to
the stationary reconnect panel as
shown, and secure firmly with the
three hex nuts provided.
440-460V Connection
L3
L2
L1
W
V
INPUT
LINES
2. Connect L1, L2, and L3 input supply
lines to the input side of the recon-
nect panel as shown.
U
380-415V Connection
3. Connect terminal marked to ground
per national electrode code.
L3
L2
L1
W
V
INPUT
LINES
U
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A-5
A-5
INSTALLATION
MULTI-SOURCE OUTPUT LIMITATIONS
The number of Multi-Weld Converters that may be con-
nected to a single Multi-Source Power Source is deter-
mined by the following formula:
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
AWG welding cable is recommended.
Power Source (Volts x Amps) capacity > 1.1 x Sum
of Converters’ (Volts x Amps) arcs
Connection of Electrode and Work Leads to Output
terminals.
The number of Multi-Weld 350s, the procedures used
and the combined duty cycle of the arcs are only limit-
ed by the 40,000 (36,000 watts on 50Hz) watt rating of
the Multi-Source supply. The machine is IP-23S rated
and is designed for outdoor applications.
1. Set the POWER ON/OFF Toggle Switch to OFF.
2. Raise the hinged cover protecting the output termi-
nals.
3. Insert the electrode lead up through the elliptical
hole in the machine base below the positive output
terminal. Pull through enough cable to reach the out-
put terminal.
4. Connect electrode lead to the terminal .
5. Tighten the output terminal nut with a wrench.
6. Connect the work lead to the negative output termi-
nal following steps 3-5.
DISTRIBUTION BOX
The Multi-Weld Distribution Box (K1736-1) is available
for interconnection of the Multi-System using the same
“pig-tail” connection method provided with the Multi-
Weld 350 converter. Six cable strain-relief ports are
provided for connection of up to (12) cables for distrib-
ution or “daisy-chain” inter-connection to other boxes.
Four “pig-tail” leads (see below) are included with the
Box.
7. Lower the cover to protect the output terminals.
“PIG TAIL” LEADS AND CONNEC-
TIONS
FIGURE A.4. - Output Terminal Connections
Accessory “pig tail” leads and Twist-Mate connectors
are available from Lincoln for extra connections to the
Multi-Weld 350 or the Distribution Box:
Order No.
CL012705
Description:
22in. (56cm) long 2/0 (70mm2) cable
with 0.5in. (13mm) hole lug and cut-off
ends.
K852-70
K852-95
K1759-70
K1759-95
Twist-Mate male insulated plug for 1/0-
2/0 (50-70mm2) cable
Twist-Mate male insulated plug for 2/0-
3/0 (70-95mm2) cable.
Twist-Mate female insulated recepta-
cle for 1/0-2/0 (50-70mm2) cable.
PARALLELING
Machines may be paralleled for increased output. The
S20428 paralleling kit permits paralleling of two MULTI-
SOURCE power supplies for supplying currents of up
to 1000 amps, 100% duty cycle.
Twist-Mate female insulated recepta-
cle for 2/0-3/0 (70-95mm2) cable
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A-6
A-6
NOTES
MULTI-SOURCE
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Section B-1
Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Safety Instructions......................................................................................................................B-2
General Description....................................................................................................................B-3
Recommended Equipment/Processes.......................................................................................B-3
Design Features and Advantages...............................................................................................B-3
Recommended Equipment/Connections ...................................................................................B-4
Controls and Settings.................................................................................................................B-4
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B-2
B-2
OPERATION
Read and understand this entire section before
operating your machine.
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• 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.
------------------------------------------------------------
Only qualified personnel should operate
this equipment. See additional warning
information at the front of this operators
manual.
-----------------------------------------------------------
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B-3
B-3
OPERATION
GENERAL DESCRIPTION
RECOMMENDED
EQUIPMENT/PROCESSES
The Multi-Source is designed to supply power to the
Multi-Weld welders. It has a wide range three phase
AC input and can be operated on 50 or 60 Hz. The
Multi-Source output peak voltage regulates against
wide changes in output loading and input line voltage
variations to supply a consistently stable voltage high
enough to allow the Multi-Welds to provide good man-
ual electrode capability.
The only recommended use for the Multi-Source is to
power the Multi-Weld welders. It is conceivable that
the machine could be used as a constant voltage DC
power supply up to its rating of 40,000 watts (36,000
watts on 50Hz) output. Its output is stable with a wide
range of inductive, resistive and capacitive loads but
each application would have to be tested. The output
is peak voltage regulated and at light resistive loads
(maximum ripple) the average voltage deviates from
peak voltage the most.
Primary input voltage taps are selected by a single
movable link on the reconnect panel. Main transformer
auxiliary windings power the firing circuit and fan
motor. The control auxiliary transformer has a single,
wide range primary and is not reconnectable.
The Multi-Weld 350 K1752-1 is the recommended
means by which to control the Multi-Source power sup-
ply. Connections between Multi-Source and Multi-
Weld may be easily made using Twist-Mate male and
female connectors and the K1736-1 distribution box.
The Multi-Weld 350 has multi-process capability and
may be used with manual and semi-automatic
processes. When a wire feeder is required, an LN-25
(K449) is recommended. The Multi-Source 40kW
(36kW on 50Hz) 80VDC buss power source (K1752-1)
The Fan As Needed feature is activated by an output
current of 20 amps DC or a thermostat on the main
transformer iron.
An independent safety circuit on the Control board
monitors the voltage peaks and opens the input con-
tactor if the limit is exceeded. The green Safe Output
light indicates when the machine output voltage is with-
in the safe operating range.
is recommended for use in the Multi-Weld system.
Other indicator lights include the amber Thermal light
that signals when the long term output current limit has
been exceeded. This limit is determined by a thermo-
stat sensing the temperature of the negative output
lead from the secondary coils. The white Power light
indicates when the Control board is energized. The
three lights are high intensity LEDs for improved visi-
bility in daylight.
DESIGN FEATURES AND ADVAN-
TAGES
• 80 volt peak OCV.
• 40,000 watts of output (36,000 watts on 50Hz) at
100% Duty Cycle.
• 75 volts at 533 amps (75.8 volts at 475 amps on 50
Hz) over 900 amps for 5 seconds without harming
the machine.
• The machine has copper windings and a varnish
dipped transformer for added environmental protec-
tion.
The Output Power display uses high intensity LEDs to
indicate the percentage of full rated output the machine
is supplying.
Two additional thermostats protect the machine in the
case of fan failure or blocked air flow. The SCR heat
sink thermostat responds first to loss of air flow at nor-
mal output loads. This thermostat will disable the
machine output. The transformer iron rear thermostat
senses that the lamination (and thus the coil insulation)
is over heating (which can happen even if the output is
disabled). This thermostat will interrupt power to the
Control board causing the input contactor to open until
the iron cools.
• Sealed external controls.
• Voltage ratings have been upgraded and used with
higher voltage MOVs.
• Input lines are protected by the most rugged surge
protection we’ve ever used.
• Indicator lights and digital display are extra bright to
enhance visibility outdoors.
• HP_Cooling fan can operate on a wider range of
voltage.
The only user controls are an on-off toggle Power
switch that energizes the machine and a 10 A cir-
cuit breaker protecting the fan auxiliary against
short circuits.
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B-4
B-4
OPERATION
RECOMMENDED EQUIPMENT/CONNECTIONS
The Multi-weld 350 (K1735-1) is the recommended means by which to control the MULTI-SOURCE power supply.
Connections between the MULTI-SOURCE and the Multi-weld may be easily made using Twist-Mate male and
female connectors and the K1736-1 Distribution box.
Twist-Mate Male Connector
K852-70
K1759-70
K852-90
K1759-90
For 1/0 Cable
For 3/0 Cable
Twist-Mate Female Connector
Twist-Mate Male Connector
Twist-Mate Female Connector
The Multi-weld 350 has multi-process capability and may be used in manual and semi-automatic processes. When
a wire feeder is required an LN-25 (K449) is recommended. The number of Multi-Weld 350s, the procedures used
and the combined duty cycle of the arcs are only limited by the 40,000 watt (36,000 watts on 50 Hz) rating of the
Multi-Source supply. The machine is IP-23S rated and is designed for outdoor applications.
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the Case Front Assembly of the MULTI-SOURCE. See
Figure B.1. below for the location of each control.
2
5
4
3
1
% Output
On
6
Output
Power
Thermal
OFF
Fan
FIGURE B.1. - CONTROL PANEL
4. WHITE LED: This LED indicates that the
1. ON/OFF TOGGLE SWITCH: This toggle
control board is energized.
switch turns the machine ON or OFF.
5. GREEN LED: This LED indicates that the
machines output voltage is within the safe
operating range.
2. CIRCUIT BREAKER: This 10 amp
breaker protects the 120 VAC fan circuit.
3. AMBER LED: This LED indicates that
the temperature of the machine is too
high.
6. DIGITAL METER: Provides the user with
an indication of the percentage of avail-
able power.
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Section C-1
Section C-1
TABLE OF CONTENTS
- ACCESSORIES -
Accessories...........................................................................................................................Section C
Factory Installed Options/Accessories.......................................................................................C-2
Field Installed Options/Accessories ...........................................................................................C-2
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C-2
C-2
ACCESSORIES
FACTORY INSTALLED OPTIONS / FIELD INSTALLED OPTIONS /
ACCESSORIES
ACCESSORIES
K1735-1 Multi-Weld 350, Multi-process controller.
There are no factory installed options.
K857, K857-1 Remote control, Control multi-weld
remotely (25 or 100 ft.)
K1736-1 Distribution box, Connects up to 10 Multi-
Welds.
K449
LN-25, Across the arc wire feeder.
K1788-1 Roll Cage, Protect power source, facilitate
moving, store cable.
K1806-1 Multi-Weld Four pack, Mounting / lift rack
for M-S and four M-Ws.
K1807-1 Multi-Weld Eight Pack, Mounting / lift rack
for M-S and eight M-Ws.
S20428 Paralleling Kit, Allows two machines to
equally share double load.
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D-1
D-1
TABLE OF CONTENTS
-MAINTENANCE-
Maintenance .........................................................................................................................Section D
Safety Precautions......................................................................................................................D-2
Routine and Periodic Maintenance ............................................................................................D-2
Major Component Locations......................................................................................................D-3
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D-2
D-2
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
Perform Periodically:
Clean the inside of the machine with low pressure air
stream. Clean the following parts. Refer to Figure
D.1.
ELECTRIC SHOCK can kill.
• Only
qualified
personnel
• Main Transformer.
should perform this mainte-
nance.
• Electrode and Work Cable connections.
• SCR rectifier bridge and heat sink fins.
• Control Board.
• Turn the input power OFF at
the disconnect switch or fuse box before working
on this equipment.
• Firing Board.
• Do not touch electrically charged hot parts.
• Fan Assembly.
ROUTINE AND PERIODIC MAINTE-
NANCE
NOTE: The fan motor has sealed bearings which
require no maintenance.
1. Disconnect input AC power supply lines to the
machine before performing periodic maintenance,
tightening, cleaning, or replacing parts. See
Figure D.1.
Perform the following daily:
1. Check that no combustible materials are in the
welding or cutting area around the machine.
2. Remove the debris, dust, dirt, or materials that
could block the air flow to the machine for cooling.
3. Inspect the welding cables for any splits or punc-
tures in the cable jacket, or any condition that
would affect the proper operation of the machine.
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D-3
D-3
MAINTENANCE
FIGURE D.1 – MAJOR COMPONENT LOCATION
1. Case Front Assembly
2. Case back Assembly
3. Fan
4. Base
5. Sides
6. Roof
7. Rectifier Assembly
7
6
2
3
4
%
O
UTPUT
OUTPUT
THERMAL
F
AN
PO
W
ER
M
ON
!
U
W
ARN
IN
L
G
TI
-
S
O
FF
O
U
R
C
E
URCE
TI-SO
L
MU
1
5
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D-4
D-4
NOTES
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Section E-1
Section E-1
TABLE OF CONTENTS
-THEORY OF OPERATION-
Theory of Operation Section ...............................................................................................Section E
General Description..............................................................................................................E-2
Input Voltage, Filter, Contactor and Control Transformer ....................................................E-2
Main Transformer, Control Board, Cooling Fan Motor, Digital Meter & LED’s.....................E-3
SCR Bridge, Resistor Bank, Firing Board, & Output Capacitor/Resistor ............................E-4
Protection Devices & Circuits...............................................................................................E-5
SCR Operation .....................................................................................................................E-6
FIGURE E.1 – MULTI-SOURCE BLOCK LOGIC DIAGRAM
T1
MAIN
TRANSFORMER
SURGE
NOISE
FILTER
WORK
TERMINAL
INPUT
CONTACTOR
SCR OUTPUT RECTIFIER
FILTER
CAPACITOR
R
E
LIMITING
RESISTOR
C
O
N
N
E
C
T
ELECTRODE
TERMINAL
SHUNT
T2
CONTROL
TRANSFORMER
TO CONTROL
BOARD
THERMOSTAT
TO CONTROL
BOARD
SWITCH
GATE SIGNALS
CONTROL
BOX
RECTIFIER
FIRING
BOARD
RESISTOR
BANK
CONTROL
BOARD
CONTROL
SIGNAL
THERMOSTAT
FAN
W
G
Y
DIGITAL
METER
LED LED LED
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 – INPUT VOLTAGE CIRCUIT
T1
MAIN
TRANSFORMER
SURGE
NOISE
FILTER
WORK
TERMINAL
INPUT
CONTACTOR
SCR OUTPUT RECTIFIER
FILTER
CAPACITOR
R
E
C
O
LIMITING
RESISTOR
ELECTRODE
TERMINAL
N
SHUNT
N
E
C
T
T2
CONTROL
TRANSFORMER
TO CONTROL
BOARD
THERMOSTAT
TO CONTROL
BOARD
SWITCH
GATE SIGNALS
CONTROL
BOX
RECTIFIER
FIRING
RESISTOR
BANK
BOARD
CONTROL
BOARD
CONTROL
SIGNAL
THERMOSTAT
FAN
W
G
Y
DIGITAL
METER
LED LED LED
has a single primary-to-secondary ratio (no taps) that
spans the full input range up to 600VAC. The sec-
ondary voltage developed on the secondary of the
control transformer is applied to the control box full
wave bridge rectifier via a thermostat and the input
power switch. The input contactor , which is activat-
ed and controlled by the control board, applies the
three phase AC input voltage to the primary windings
of the T1 main transformer.
GENERAL DESCRIPTION
The Multi-Source is designed to supply power to the
Multi-Weld Arc Converter welders. The Multi-Source
is an SCR controlled constant voltage (CV) DC power
supply that can operate with a wide range of three
phase input voltages. The machine's peak output
voltage helps regulate against wide variations in out-
put loading and/or variations in input line voltages.
This ability provides for a consistently high stable volt-
age applied to the Multi-Welds so as to provide good
manual electrode welding capability.
INPUT VOLTAGE, FILTER, CONTAC-
TOR AND CONTROL TRANS-
FORMER
The desired three phase power is connected to the
Multi-Source via a reconnect panel located in the input
box at the rear of the machine. The reconnect panel
allows the user to configure the machine for the
desired input voltage. The three phase input power is
also applied to a filter assembly that is located in the
input box. Two phases of the input voltage are applied
to the T2 control transformer. The control transformer
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
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E-3
E-3
TROUBLESHOOTING & REPAIR
FIGURE E.3 – MAIN TRANSFORMER, CONTROL BOARD, COOLING FAN MOTOR, & LEDs
T1
MAIN
TRANSFORMER
SURGE
NOISE
FILTER
WORK
TERMINAL
INPUT
CONTACTOR
SCR OUTPUT RECTIFIER
FILTER
CAPACITOR
R
E
C
O
N
N
E
C
T
LIMITING
RESISTOR
ELECTRODE
TERMINAL
SHUNT
T2
CONTROL
TRANSFORMER
TO CONTROL
BOARD
THERMOSTAT
TO CONTROL
BOARD
SWITCH
GATE SIGNALS
CONTROL
BOX
RECTIFIER
FIRING
BOARD
RESISTOR
BANK
CONTROL
CONTROL
SIGNAL
BOARD
THERMOSTAT
FAN
W
G
Y
DIGITAL
METER
LED LED LED
cooling fan motor and the input contactor.
MAIN TRANSFORMER, CONTROL
BOARD, COOLING FAN MOTOR,
DIGITAL METER AND INDICATOR
LIGHTS (LEDs)
The cooling fan is controlled by the control board. The
F.A.N. (fan as needed) will be activated with an output
current greater than 20 amps. It can also be activated
(via the control board) by a thermostat located on the
main transformer iron.
The main transformer changes the high voltage, low
current input power to a lower voltage, higher current
output. The finishes or "neutrals" of the main sec-
ondary coils are connected together and the six starts
of the secondary windings are connected to the SCR
output rectifier assembly. In addition the main trans-
former has an isolated 120VAC (nominal) winding the
supplies 120VAC, via the control board, to operate the
cooling fan motor. The three isolated 32VAC (nominal)
phase angle windings are also housed in the main
transformer assembly. These windings provide power
and "timing" information to the firing board.
A current sensing circuit on the control board controls
the digital meter display. This meter provides the user
with an indication of the percentage of available power
that is being drawn from the Multi-Source.
There are three indicator lights located on the front
panel of the Multi-Source. The green safe output light
indicates when the machine's output voltage is within
the safe operating range. Other indicator lights
include the amber thermal light that indicates the ther-
mostat, located on the negative output lead, has
opened due to an over temperature condition. The
white power light indicates when the control board is
energized.
The control board receives a widely-varying DC volt-
age from the control box rectifier. The switching
power supplies, that are housed on the control board,
supply DC current to the control circuits and the input
contactor. The control board receives current feed-
back information from the output shunt, voltage feed-
back information from the output terminals and tem-
perature information from several thermostats. This
feedback information is processed by the control
board. The control board then sends the appropriate
gate firing signals to the firing board, output informa-
tion to the digital meter and command signals to the
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E-4
E-4
TROUBLESHOOTING & REPAIR
FIGURE E.4 – SCR BRIDGE, RESISTOR BANK, FIRING BOARD, & OUTPUT CAPACITOR/RESISTOR
T1
SURGE
NOISE
FILTER
MAIN
TRANSFORMER
WORK
TERMINAL
INPUT
CONTACTOR
SCR OUTPUT RECTIFIER
FILTER
CAPACITOR
R
E
C
O
N
N
E
C
T
LIMITING
RESISTOR
ELECTRODE
TERMINAL
SHUNT
T2
CONTROL
TRANSFORMER
TO CONTROL
BOARD
THERMOSTAT
TO CONTROL
BOARD
SWITCH
GATE SIGNALS
CONTROL
BOX
RECTIFIER
FIRING
BOARD
RESISTOR
BANK
CONTROL
BOARD
CONTROL
SIGNAL
THERMOSTAT
FAN
W
G
Y
DIGITAL
METER
LED LED LED
SCR BRIDGE, RESISTOR BANK,
FIRING BOARD, AND OUTPUT
CAPACITOR/RESISTOR
The neutrals of the main transformer secondary wind-
ings are connected together and the six starts are con-
nected to the six SCR assemblies to form a six phase
output. This six phase AC output is rectified and con-
trolled through the SCR bridge.
The firing board receives power through the current
limiting resistor bank. The firing board is a three phase
circuit. Each phase provides two firing pulses; one for
each of the two Silicon Controlled Rectifiers (SCRs)
controlled by that particular phase. The firing circuit
supplies the proper amount of energy to the gates of
the power SCRs. When the gate signal is applied, at
the correct time, the SCR will turn on and conduct cur-
rent. The amount of "ON" timer versus "OFF" time
determines the output of the machine. See SCR
Operation.
A capacitor filter and resistor are connected across the
output leads on the Multi-Source. This is required to
reduce and limit the output voltage peaks. The capac-
itor ripple current (greatest with light resistive loads) is
limited by the resistor.
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E-5
E-5
TROUBLESHOOTING & REPAIR
PROTECTION DEVICES AND CIR-
CUITS
Several thermostats protect the Multi-Source from
over temperature and /or excessive loading. High
transformer watts could cause the main transformer to
over heat so the cooling fan is activated if a thermo-
stat, located on the front of the main transformer iron,
should open.
Two additional thermostats (connected in series) pro-
tect the machine in case of fan failure or blocked air-
flow at normal output loads. The opening of either the
secondary or SCR heat sink thermostat(s) will disable
the machine's output and cause the amber thermal
light to glow.
The thermostat, located at the rear of the main trans-
former iron, senses the lamination temperature (and
thus the coil insulation temperature) and will interrupt
power to the control board causing the input contac-
tor to open until the iron cools.
A 10 amp circuit breaker protects the 120VAC fan cir-
cuit. This is located on the front panel of the machine
and may be reset if tripped.
An independent safety circuit on the control board
monitors the output voltage peaks and opens the input
contactor if the upper limit is exceeded for over 300
ms.
If the output current of the machine should exceed the
set limitations the control board will disable output for
about 75 seconds.
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E-6
E-6
TROUBLESHOOTING & REPAIR
FIGURE E.5 SCR OPERATION
An SCR is fired by a short burst of current into the
gate. This gate pulse must be more positive than the
cathode voltage. Since there is a standard PN junc-
tion between gate and cathode, the voltage between
these terminals must be slightly greater than 0.6V.
Once the SCR has fired, it is not necessary to contin-
ue the flow of gate current. As long as current contin-
ues to flow from anode to cathode the SCR will remain
on. When the anode to cathode current drops below
a minimum value, called holding current, the SCR will
shut off. This normally occurs as the AC supply volt-
age passes through zero into the negative portion of
the sine wave. If the SCR is turned on early in the pos-
itive half cycle, the conduction time is longer resulting
in greater SCR output. If the gate firing occurs later in
the cycle the conduction time is less resulting in lower
SCR output.
SCR OPERATION
A silicon controlled rectifier (SCR) is a three terminal
device used to control rather large currents to a load.
An SCR acts very much like a switch. When a gate
signal is applied to the SCR it is turned ON and there
is current flow from anode to cathode. In the ON state
the SCR acts like a closed switch. When the SCR is
turned OFF there is no current flow from anode to
cathode thus the device acts like an open switch. As
the name suggests, the SCR is a rectifier, so it passes
current only during positive half cycles of the AC sup-
ply. The positive half cycle is the portion of the sine
wave in which the anode of the SCR is more positive
than the cathode.
When an AC supply voltage is applied to the SCR, the
device spends a certain portion of the AC cycle time in
the on state and the remainder of the time in the off
state. The amount of time spent in the ON state is
controlled by the gate.
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Section F-1
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 ..........................................................................................................................F-9
Control Transformer (T2) Test ...............................................................................................F-9
Input Contactor Test...........................................................................................................F-13
Main Transformer (T1) Voltage Test ....................................................................................F-17
Static SCR Test...................................................................................................................F-21
Active SCR Test..................................................................................................................F-25
Control Board Test..............................................................................................................F-31
Firing Board Test.................................................................................................................F-35
Multi-Source Meter Accuracy Test.....................................................................................F-39
Normal Open Circuit Voltage Waveform - No Load...........................................................F-41
Abnormal Open Circuit Voltage Waveform 1 SCR Not Functioning - No Load.................F-42
Typical SCR Gate Voltage Waveform - No Load................................................................F-43
Replacement Procedures..........................................................................................................F-45
Input Contactor Cleaning and/or Replacement .................................................................F-45
Control Board Removal and Replacement.........................................................................F-49
Firing Board Removal and Replacement............................................................................F-51
SCR Bridge/Heat Sink Assembly Removal and Replacement...........................................F-53
Retest After Repair .............................................................................................................F-59
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F-2
F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
This Troubleshooting Guide is provided to help
you locate and repair possible machine malfunc-
tions. Simply follow the three-step procedure
listed below.
Step 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.
Step 1. LOCATE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM (SYMP-
TOMS). This column describes possible symp-
toms that the machine may exhibit. Find the list-
ing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into two main categories: Output Problems and
Function Problems.
All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced elec-
trical wiring diagrams and schematics. Refer to
the Electrical Diagrams Section Table of Contents
to locate the appropriate diagram.
Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S),” lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be con-
ducted without removing the case wrap-around
cover.
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.
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F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES AND REPLACEMENT
• Remove the PC Board from the static-shielding bag
and place it directly into the equipment. Don’t set
the PC Board on or near paper, plastic or cloth
which could have a static charge. If the PC Board
can’t be installed immediately, put it back in the sta-
tic-shielding bag.
WARNING
ELECTRIC SHOCK can kill.
Have an electrician install and ser-
vice this equipment.
machine OFF before working on
equipment. Do not touch electrically hot parts.
Turn the
• 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-shield-
ing bag. This will prevent further damage and allow
proper failure analysis.
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems when troubleshooting and replacing PC boards,
please use the following procedure:
4. Perform any necessary PC Board calibration pro-
cedures. See the flow chart on the next page.
5. Test the machine to determine if the failure symp-
tom has been corrected by the replacement PC
board.
1. Determine to the best of your technical ability that
the PC board is the most likely component causing
the failure symptom.
NOTE: Allow the machine to heat up so that all elec-
trical components can reach their operating
temperature.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
6. Remove the replacement PC board and substitute
it with the original PC board to recreate the original
problem. Recalibrate if required.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static elec-
trical damage and electrical shock. Read the warn-
ing inside the static resistant bag and perform the
following procedures.
a. If the original problem does not reappear
by substituting the original board, then the
PC board was not the problem. Continue
to look for bad connections in the control
wiring harness, junction blocks, and termi-
nal strips.
PC Board can be damaged by
static electricity.
• Remove your body’s static
charge before opening the stat-
ic-shielding bag. Wear an anti-
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, recalibrate if
required, and test the machine.
static wrist strap. For safety,
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
use a 1 Meg ohm resistive cord
connected to a grounded part of
the equipment frame.
7. Always indicate that this procedure was followed
when warranty reports are to be submitted.
• If you don’t have a wrist strap,
touch an unpainted, grounded,
part of the equipment frame.
Keep touching the frame to pre-
vent static build-up. Be sure not
to touch any electrically live
parts at the same time.
Workstations
NOTE: Following this procedure and write on the war-
ranty report, “INSTALLED AND SWITCHED
PC BOARDS TO VERIFY PROBLEM,” will help
avoid denial of legitimate PC board warranty
claims.
Reusable
Container
Do Not Destroy
• Tools which come in contact with the PC Board
must be either conductive, anti-static or static-dis-
sipative.
MULTI-SOURCE
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F-4
F-4
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
OUTPUT PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical dam- 1. Contact the Lincoln Electric 1. Contact the Lincoln Electric
age is evident.
Service Dept.
Service Dept.
1-800-833-9353 (WELD)
1-800-833-9353 (WELD)
Machine Multi-Source is dead and 1. Check for blown or missing 1. The ON/OFF switch may be
the input contactor does not oper-
ate. The white power light is NOT
lit.
fuses in the input lines.
faulty. Check switch and asso-
ciated leads. See the Wiring
Diagram.
2. Check the three phase input line
voltage at the Multi-Source.
The input voltage must match 2. The thermostat, located on the
the rating plate and reconnect
panel.
rear of the main transformer
iron, may be faulty. This is nor-
mally a closed device.
3. The control box diode bridge
may be faulty. Also check
associated wiring for loose or
faulty connections. See the
Wiring Diagram.
4. Perform the T2 Control
Transformer Test.
5. Perform the Control Board
Test.
The input contactor does not oper-
ate. The white power light is ON.
1. Perform the Input Contactor
1. Check the three phase input line
voltage at the Multi-Source.
Test.
The input line voltage must 2. Check leads #240 and #241
match the rating plate and
reconnect panel.
between the control board and
the input contactor for loose or
faulty connections. See the
Wiring Diagram.
2. Turn the power switch OFF and
wait a few seconds. Turn the
power switch back ON. If the 3. Perform the Control Board
problem is not resolved, contin-
ue with the “Recommended
Courses of Action”.
Test.
4. Perform the SCR Rectifier
Bridge Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
MULTI-SOURCE
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F-5
F-5
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
OUTPUT PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The white power light is lit and the 1. Check the welding cables for
1. Perform the Firing Board Test.
input contactor activates but there
is no welding output. The amber
thermal light is NOT lit.
loose or faulty connections.
2. Perform the Control Board
2. Make certain the Multi-Weld(s)
are connected and operating
properly.
Test.
3. Perform the SCR Rectifier
Bridge Test.
3. Check (at the output terminals
of the Multi-Source) for
4. Perform the Main Transformer
(T1) Test.
approximately 75-80VDC open
circuit voltage. If this voltage
is present, the problem is most
likely external to the Multi-
Source machine.
5. Perform the Input Contactor
Test.
The Multi-Source operates but
does NOT have maximum welding
output. 40,000 watts on 60 Hz -
36,000 watts on 50HZ.
1. Check all three phases of the
input voltage at the Multi-
Source machine. Make sure
the input voltages are present
and match the machine’s rat-
ing and reconnect panel con-
figuration.
1. Perform the Main Transformer
(T1) Test.
2. Perform the SCR Rectifier
Bridge Test.
3. Perform the Input Contactor
Test.
2. Check for loose or faulty weld-
ing cables.
4. Perform the Firing Board Test.
5. Perform the Control Board
Test.
6. The output shunt may be
faulty. See Display
Calibration Procedure.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
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F-6
F-6
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
OUTPUT PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The Multi-Source has only
momentary output after the input
contactor activates. Output
returns momentarily approximately
every 75 seconds.
1. Remove all external welding
cables from the Multi-Source
machine. If the open circuit
voltage (75-80VDC) is present
and constant at the output ter-
minals there may be a short
circuit external to the Multi-
Source. Check the welding
cables and the Multi-Weld
machines.
1. Check all heavy current carry-
ing leads within the Multi-
Source for possible “shorting”
conditions. See the Wiring
Diagram.
2. Perform the SCR Rectifier
Bridge Test.
3. Perform the Control Board
Test.
2. If the problem is not resolved
with the welding cables
removed, there is a fault within
the Multi-Source machine.
The Multi-Source has momentary
output only. The green light is
OFF and the input contactor
opens.
1. Check the three phase input
voltage. Make certain it is not
too high for the machine’s rat-
ing and the reconnect panel
configuration.
1. Check the output filter circuit.
(resistor R9, capacitor C3, and
leads 222C, 292, 294B. See
the Wiring Diagram.
2. Check the voltage feedback
leads 215B and 222A for loose
or faulty connections. See the
Wiring Diagram.
3. Perform the SCR Rectifier
Bridge Test.
4. Perform the Control Board
Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
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F-7
F-7
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
OUTPUT PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
The amber thermal light is lit. The 1. The machine is being over-
machine does not have welding
output, the fan runs and the digital
output display reads a value
greater than 100.
loaded and thus overheated.
Reduce the load to conform to
the rated output limits of the
Multi-Source machine. See
the Technical Specifications.
1. The secondary lead thermostat
or SCR heat sink thermostat
may be faulty. Check and
replace if necessary. These
are normally closed devices.
Also check associated leads
for loose or faulty connections.
See the Wiring diagram.
1. The machine may be internally
clogged with dirt and dust.
Clean the machine with clean
dry compressed air.
The amber thermal light is lit. The
machine does not have welding
output, and the fan runs. The dig-
ital output display reads a value
greater than 100.
2. The cooling vents may be
obstructed or blocked.
3. The ambient cooling air may
be too hot.
2. The control board may be
faulty.
1. Check the fan circuit breaker
located on the front panel.
Reset if tripped
The amber thermal light is lit. The
machine does not have welding
output, the fan does NOT run and
the digital output display never
reads a value greater than 100.
1. The fan motor may be faulty.
Disconnect and test using an
isolated 120VAC supply.
2. Check the leads #250, #253,
and #252 between the fan
motor, the circuit breaker and
the control board. See the
Wiring Diagram.
3. Make certain the 120VAC fan
voltage is being developed by
the main transformer. See the
Main Transformer Test.
4. Make sure the shunt and the
output display are operating
properly. See Display
Calibration Procedure.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
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F-8
F-8
INSTALLATION
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
OUTPUT PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTIONS PROBLEMS
The Multi-Source machine will not 1. Remove all external loading to
1. The ON/OFF power switch
may be faulty. See the Wiring
Diagram.
shut off when the ON/OFF switch
is in the OFF position.
the Multi-Source and then
carefully remove the input
power.
2. The input contactor may be
stuck closed. Perform the
Input Contactor Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
800-833-9353.
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F-9
F-9
TROUBLESHOOTING & REPAIR
CONTROL TRANSFORMER (T2) VOLTAGE TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment could result in danger to the technician or the
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical
shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call (800) 833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the correct voltage is being induced on the secondary winding of the
control transformer.
MATERIALS NEEDED
Volt/Ohm Meter (Multimeter)
MULTI-SOURCE wiring diagrams (See Electrical Diagram Section of Manual).
3/8” Nut Driver
This procedure takes approximately 30 minutes to perform.
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F-10
F-10
TROUBLESHOOTING & REPAIR
CONTROL TRANSFORMER (T2) VOLTAGE TEST
FIGURE F.1. CONTROL TRANSFORMER LOCATION & LEADS
Control
Transformer (T2)
X1
X3
H1
H2
4. Locate the Control Transformer primary
leads H1 & H2. See Wiring Diagram. See
Figure F.1.
TEST PROCEDURE
1. Disconnect main AC input power to the
machine.
5. Locate control transformer terminals X1 and
X3. See Figure F.1.
2. Remove the Top and Right case side.
3. Locate the Control Transformer (T2) on the
left side of the input box (facing the back of
the machine). See Figure F.1.
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F-11
F-11
TROUBLESHOOTING & REPAIR
CONTROL TRANSFORMER (T2) VOLTAGE TEST
6. Carefully apply primary power and test for
the correct secondary voltages. See Table
F.1.
NOTE: If the correct main AC input power to
the Control Transformer is present, and the
secondary voltages are not correct, the Control
Transformer may be faulty. Replace.
TABLE F.1.
Primary H1 & H2
Voltage
Approximate Secondary
Voltage X1-X3
575 VAC
460 VAC
380 VAC
43.0 VAC
34.50 VAC
28.50 VAC
0.5 Ohms
Approximate Secondary
Resistance (X1-X3)
Approximate Primary
Resistance (H1-H2)
60 Ohms
0 Ohms
X2-X3 Thermostat
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F-12
F-12
TROUBLESHOOTING & REPAIR
CONTROL TRANSFORMER (T2) VOLTAGE TEST
FIGURE F.2. Thermostat
Secondary
X3
X1
X2
Thermostat
NOTE: If the secondary voltage is not pre-
sent at terminal #X3 but is present at
terminal #X2 the internal thermostat
is faulty. See Figure F.2.
7. Replace any leads previously removed.
8. Replace right side and roof.
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F-13
F-13
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment could result in danger to the technician or the
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical
shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call (800) 833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the input contactor is receiving the correct coil voltage and if the
contacts are functioning correctly.
MATERIALS NEEDED
Ammeter
MULTI-SOURCE wiring diagrams (See Electrical Diagram Section of Manual).
3/8” Nut Driver
External 120VAC supply
This procedure takes approximately 30 minutes to perform.
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F-14
F-14
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR TEST (Continued)
FIGURE F.3. INPUT CONTACTOR CONNECTIONS
240
241
CONTACTOR
COIL
1. Disconnect the main input supply power to
the machine.
6. Check for approximately 1 amp of current
flow at the contactor coil. This current is
supplied by the Control Board. NOTE: The
pull-in coil current is designed to be about
5 amps for 100ms occurring about one
second after the power switch is closed.
Without this current pulse, the contactor
will not activate.
2. With the 3/8” nut driver, remove the case
top and the left case side.
3. Locate the two leads connected to the
input contactor coil, #240 and #241. See
Figure F.3 for location. Note: The discon-
nects may be located inside the loom (lead
covering).
If the current is present and the contactor
does NOT activate, then the input contac-
tor coil may be faulty, or the contactor’s
moving parts may be stuck. The normal
coil resistance is approximately 4.0 ohms.
4. Connect a DC ammeter to either lead #240
or #241.
WARNING
Electric Shock can kill.
If the 1 amp DC current is NOT present,
check the continuity of the leads between
the contactor and the control board. See
the Wiring Diagram.
• With the input power on,
there are high voltages inside
the machine. Do not reach
into the machine or touch any
internal part of the machine while the power
is on. High voltage is present at terminals.
The contactor may also be tested by dis-
connecting leads #240 and #241 from the
coil and applying an external 120VAC sup-
ply to the contactor coil. The contactor
should activate.
5. Carefully apply the correct voltage to the
machine and turn the power switch (S1)
ON.
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F-15
F-15
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR TEST (Continued)
FIGURE F.4. INPUT CONTACTOR TEST CONNECTIONS
Test Points
T3
W
Test Points
Test Points
T2
T1
V
U
TOP VIEW
Figure F.4. If the resistance is high, the
input contactor is faulty. Replace the input
contactor.
TEST FOR CONTACT
CONTINUITY
1. Disconnect the main input supply power to
the machine.
5. When the contactor is NOT activated, the
resistance should be infinite or very high
across the contacts. If the resistance is
low, the input contactor is faulty. Replace
the input contactor . See Input Contactor
Removal and Replacement Procedure.
2. Remove the two leads connected to the
input contactor coil, #240 and #241. See
Figure F.3 for location.
3. Using the external 120VAC supply, apply
120VAC to the leads of the input contactor
coil. If the contactor does NOT activate,
the input contactor is faulty. Replace the
input contactor.
6. Reconnect any leads previously removed.
Replace any cable ties and loom previous-
ly removed. Replace the roof and left case
side.
4. With the contactor activated, check the
continuity across the contacts. (Zero ohms
or very low resistance is normal.) See
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F-16
F-16
NOTES
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F-17
F-17
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER (T1) VOLTAGE TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment could result in danger to the technician or the
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical
shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call (800) 833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the correct voltages are being:
a. applied to the primary windings of the Main Transformer (T1).
b. induced on the secondary windings, fan winding, and phase angle windings.
MATERIALS NEEDED
Volt/Ohm Meter
MULTI-SOURCE wiring diagrams (See Electrical Diagram Section of Manual).
3/8” Nut Driver
This procedure takes approximately 45 minutes to perform.
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F-18
F-18
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER (T1) VOLTAGE TEST (continued)
FIGURE F.5. Input Contactor, Reconnect Panel, and Primary Leads to Main Transformer
Locations
Reconnect Panel
Assembly
T3
W
T2
T1
V
U
Input Contactor
TOP VIEW
INPUT CONTACTOR
the input contactor (1CR). See Wiring
Diagram. See Figure F.5.
TEST PROCEDURE
1. Disconnect main AC input power to the
machine.
T1 to T2
T2 to T3
T1 to T3
2. Using a 3/8” nutdriver, remove roof and
sides of case cover.
3. Inspect the input contactor, reconnect
panel, and primary leads to the main trans-
former for loose or faulty connections. See
Figure F.5.
a. If the correct voltage is present, the
contactor is working properly.
b. If the correct voltage is not present for
any or all of the three phases, the con-
tactor may be faulty. See Input
Contactor Test.
4. Carefully apply input power, turn on and
make sure the input contactor (1CR) ener-
gizes.
6. Test with an AC voltmeter for approximate-
ly 97 VAC from each of the six main trans-
former secondary leads to the common
buss connected to the negative output ter-
minal. See Figure F.6.
5. Carefully test with an AC voltmeter for the
proper main AC input voltage to the line
side of the input contactor (1CR). See
Wiring Diagram. See Figure F.5.
U to V
V to W
U to W
a. If one or more of the above voltage
tests are incorrect, check for loose or
faulty wiring. If the wiring is good,
then the main transformer may be
faulty.
NOTE: If proper voltage is not present in any
or all of the three phases, check input
fuses and leads.
NOTE: A long wire with a clip or a long probe
may be required to reach the lower
middle lead.
5. Test with an AC voltmeter for proper main
AC input voltage from the output side of
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F-19
F-19
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER (T1) VOLTAGE TEST (continued)
FIGURE F.6. Main Secondary Lead Test Points
Transformer
Secondary
Leads
Lift Bail
#250
Transformer
Assembly
Phase Angle
Common Buss
Winding
#251
Test Points
7. Test for 120 VAC between leads #250 to
#251. See Figure F.6. See Wiring Diagram.
9. Test with an AC voltmeter for 32 VAC for
each phase angle winding as shown. See
Figure F.6. See Wiring Diagram.
a. If the 120 VAC is not present, check
for loose or faulty wiring. If necessary,
untape and track the continuity of
leads #250 and #251 through the
NOTE: If the main supply voltage varies, the
Main Transformer voltages will vary
proportionately.
entire harness.
Diagram.
See the Wiring
10. Be sure to replace any and all insulation
materials that were removed for testing
purposes.
b. If the wiring is good and the 120 VAC
is not present, then the main trans-
former may be faulty.
11. Replace roof and sides of case cover.
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F-20
F-20
NOTES
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F-21
F-21
TROUBLESHOOTING & REPAIR
STATIC SCR TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment could result in danger to the technician or the
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical
shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call (800) 833-9353 (WELD).
TEST DESCRIPTION
The Static SCR Test is a quick check to determine if an SCR is shorted or “leaky”. See machine
waveform section for normal and abnormal output waveforms.
MATERIALS NEEDED
Analog Volt/Ohm Meter (Multimeter)
MULTI-SOURCE wiring diagrams (See Electrical Diagram Section of Manual).
3/8” Nut Driver
9/16” Wrench
This procedure takes approximately 45 minutes to perform.
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F-22
F-22
TROUBLESHOOTING & REPAIR
STATIC SCR TEST (Continued)
1. Remove main supply power to the
3. Lower the front control panel.
machine.
4. Remove Plug J4 from the firing board. See
Figure F.7.
2. Remove the roof and case sides.
FIGURE F.7. FIRING BOARD LED & PLUG LOCATIONS
FIRING BOARD
J5
J6
J7
Plug J4
J8
J4
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F-23
F-23
TROUBLESHOOTING & REPAIR
STATIC SCR TEST (Continued)
FIGURE F.8. Shunt and Lead Connections
Leads
4. Using the 9/16” wrench, remove the two
a.
If a low resistance is indicated in either
positive output leads connecting the out-
put bridge to the shunt. See Figure F.8.
This will partially electrically isolate the
SCR Bridge for testing purposes. See
Wiring Diagram.
direction, one of the SCRs may be
faulty. Further isolation will be neces-
sary to determine which SCR is faulty.
This isolation can be accomplished by
disconnecting the transformer sec-
ondary lead from the SCR under test.
See the Wiring Diagram.
5. Remove the red insulating paint from heat
sink test points. See Figure F.9.
NOTE: DO NOT DISASSEMBLE THE HEAT
SINKS.
6. Using an analog ohmmeter, test the resis-
tance from anode to cathode of SCR 1.
Reverse the meter leads and check from
cathode to anode of SCR 1 (R x 1000
scale). See Figure F.9.
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F-24
F-24
TROUBLESHOOTING & REPAIR
STATIC SCR TEST (Continued)
FIGURE F.9. SCR HEAT SINK TEST POINTS
Remove
Red Paint
Anode
Cathode
7. Repeat previous step(s) testing SCR 2,
SCR 3, SCR 4, SCR 5, and SCR 6.
9. Reconnect any secondary leads removed
from the SCRs.
To further check the SCRs’ functions use an
10. Reconnect Plug J4 into the firing board.
SCR tester and proceed to Active SCR Test.
11. Replace the case top, sides and control
panel.
8. When test is completed, reconnect the
positive bridge leads to the shunt.
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F-25
F-25
TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment could result in danger to the technician or the
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical
shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call (800) 833-9353 (WELD).
TEST DESCRIPTION
The active SCR Test will determine if the device is able to be gated “ON” and conduct current from
anode to cathode.
MATERIALS NEEDED
An SCR Tester (as outlined in this procedure)
Analog Volt/Ohm Meter (Multimeter)
MULTI-SOURCE wiring diagrams (See Electrical Diagram Section of Manual).
3/8” Nut Driver
9/16” Wrench
This procedure takes approximately 45 minutes to perform.
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F-26
F-26
TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST (Continued)
1. Remove main supply power to the Multi-
3. Lower the front control panel and remove
Plug J4 from the Firing Board. See Figure
F.10.
Source.
2. Remove the roof and case sides.
FIGURE F.10. FIRING BOARD LED & PLUG LOCATIONS
FIRING BOARD
J5
J6
J7
Plug J4
J8
J4
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F-27
F-27
TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST (Continued)
4. Using a 9/16” wrench, remove the two
positive output leads connecting the out-
put bridge to the shunt. See Figure F.11.
This will partially electrically isolate the
SCR bridge for testing purposes. See the
Wiring Diagram.
FIGURE F.11. Shunt and Lead Connections
Leads
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F-28
F-28
TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST (Continued)
FIGURE F.12. SCR Heat Sink Test Points
Remove
Red Paint
Anode
Cathode
5. Remove the red insulating paint from heat
sink test points. See Figure F.12.
NOTE: Do not disassemble the heat sinks.
6. Perform test procedure as follows. Refer
to Figure F.13. Repeat test for all six
SCRs.
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F-29
F-29
TROUBLESHOOTING & REPAIR
ACTIVE SCR TEST (Continued)
FIGURE F.13. SCR Test Setup
SW1
R2
V
R1
SW2
6 VOLT
LANTERN
BATTERY
A
R1= 4 ohms/10 watts
R2= 3 ohms/10 watts
G
SCR
UNDER
TEST
C
To test SCRs construct the circuit outlined above. Resistor values are plus or minus
ten percent. The voltmeter scale should be low, approximately 0-5 or 0-10 volts DC.
7. To test SCRs, construct the circuit outlined
in Figure F.13. Use one 6V lantern battery.
Resistor values are in ohms +/- 10%, The
voltmeter scale should be low, approxi-
mately 0-5 or 0-10 volts.
voltmeter should read 3 to 6 volts before
and after switch SW2 is released. If the
voltmeter does not read, or reads only
while SW2 is depressed, the SCR or bat-
tery is defective (repeat battery Test
Procedure).
BATTERY TEST
9. Open switch SW1, disconnect the gate
lead (G) and reverse the (A) and (C) leads
on the SCR. Close switch SW2. The volt-
meter should read zero. If the voltage is
higher than zero, the SCR is shorted.
Check the battery by shorting leads (A) and
(C) and then close switch SW1. Replace bat-
tery if voltage is less than 4.5 volts.
A. Connect SCR into the test circuit as
shown (A) lead to anode (C) lead to cath-
ode and (G) lead to the gate.
10. Replace any SCR assembly that does
not pass test.
B. Close switch SW1 (switch SW2 should
open), voltmeter should read zero. If the
voltmeter reads higher than zero than the
SCR is shorted.
11. When test is completed, reconnect the
positive bridge leads to the shunt.
12. Reconnect Plug J4 into the Firing Board.
NOTE: Do not disassemble the heat sinks.
13. Replace the case top, sides and control
panel.
8. With switch SW1 closed, close switch
SW2 for two seconds and release. The
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F-30
F-30
NOTES
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F-31
F-31
TROUBLESHOOTING & REPAIR
CONTROL BOARD TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment could result in danger to the technician or the
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical
shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call (800) 833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the control board is receiving the correct voltages and feedback signals.
MATERIALS NEEDED
Volt/Ohm Meter (Multimeter)
MULTI-SOURCE wiring diagrams (See Electrical Diagram Section of Manual).
This procedure takes approximately 45 minutes to perform.
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F-32
F-32
TROUBLESHOOTING & REPAIR
CONTROL BOARD TEST (Continued)
J2
J5
J6
J7
J1
J8
J3
J4
Firing Board
Control Board
FIGURE F.14. CONTROL BOARD LOCATION
TEST PROCEDURE FOR NORMAL CON-
TROL BOARD OPERATION
lead #201 to Plug J1-pin 9(-) lead #222A.
If the voltage is correct but LED1 is not lit,
the control may be faulty. See Figure
F.15.
1. Remove main supply power to the Multi-
Source.
6. LED 2 indicates the level of the control sig-
nal that is passed to the firing board. The
brightness of LED 2 is inversely propor-
tional to the output of the machine. As the
control signal decreases (LED 2 gets dim-
mer) the machine’s output increases. The
control signal can be measured at Plug J1-
pin 4(+) lead #231 to Plug J1-pin1(-) lead
#201. Normal range is about 12VDC at
open circuit to about 3VDC when high or
maximum output is required. See Figure
F.15.
2. Remove screws, loosen and lower the
front panel to access and inspect the con-
trol board located in the right side of the
control box. See Figure F.14.
3. Apply the correct three-phase input power
to the Multi-Source. Turn on the machine.
WARNING
WHEN THE MULTI-SOURCE IS
TURNED ON, THE OUTPUT
TERMINALS ARE ELECTRICAL-
LY HOT.
7. LED 3 indicates that the machine’s output
is greater than 10 amps and the control
board is developing a signal for the cool-
ing fan to operate. This signal activates a
fan motor driver circuit that is incorporated
within the control board. See step 10 (LED
6).
4. The white power light, located on the front
control panel, indicates the control board
is receiving the DC voltage that is supplied
from the rectified secondary voltage of the
control transformer. This voltage can
range from 38VDC with 345VAC applied to
the machines input, to 58VDC with
600VAC applied to the Multi-Source. This
voltage can be measured at Plug J2-pin4
(+) lead #274, to plug J2-pin2 (-) lead
#273. See Figure F.15. Normal voltage
on the white light is 3.5VDC. If 5.0VDC is
present the light may be open. This can
be measured at plug J1-pin 7(+) lead #230
to plug J1-pin 8(-) lead #341.
8. LED 4 is an indication that either a ther-
mostat, output current or output over-cur-
rent is calling for the fan motor to operate.
See Figure F.15.
9. LED 5 lights when the current feedback
signal from the output shunt is too high. If
LED 5 is lit for 5-8 seconds, the enable
signal from the control board to the firing
board is sent high (over 12VDC) (LED2). If
the output current overload is of a short
time duration LED 5 may only be lit briefly.
In either case the machine’s output will be
zero and the output will remain off for
about 75 seconds. See Figure F.15.
5. LED 1 is an indication of the machine’s
output voltage. At normal output voltages
LED1 should be brightly lit. Normal open
circuit voltage (OCV) at the welding output
terminals is approximately 80VDC. This
voltage can be checked at Plug J1-pin 1(+)
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F-33
F-33
TROUBLESHOOTING & REPAIR
CONTROL BOARD TEST (Continued)
10. LED 6 indicates that the fan motor driver
This can be measured at Plug J1-pin 16(+)
lead #232 to Plug J1-pin 15(-) lead #233.
See Figure F.15.
circuit has been activated and the fan
motor should be running. LED 6 and the
fan motor will be on for about 5 minutes
after LED 4 goes off. See Figure F.15.
13. The yellow (amber) light, located on the
front panel, will light if the “open thermo-
stat” (secondary and SCR heat sink) sig-
nal is sent to the fan control and output
disable circuits. The voltage on the two
thermostat circuit is from 24VDC to
38VDC. This voltage is dependent upon
the input voltage applied to the Multi-
Source. This voltage can be verified at
Plug J1-pin 3(+) lead #263 to Plug J1-pin
11(-) lead #264. This voltage will be pre-
sent if only one of the thermostats are
open or an associated lead is disconnect-
ed. See the Wiring Diagram. Normal
operating voltage for the amber light is
about 2.2VDC. A voltage reading of about
5.0VDC would indicate the amber light is
open and the control board is supplying
the correct signal. This can be verified at
Plug at Plug J1-pin 13(+) lead #234 to plug
J1-pin 12(-) lead #235. This light voltage
will normally be present ONLY when the
thermostat circuit is open. See the Wiring
Diagram. See Figure F.15.
11. LED 7 will light if a positive voltage is pre-
sent on the negative output terminal (AC
instead of DC). This is an indiction of a
shorted SCR in the output bridge rectifier.
See SCR Rectifier Bridge Test. The
input contactor will open and will remain
deenergized until the power switch is
turned off for a minimum of 1 second. See
Figure F.15.
12. The green light, located on the front con-
trol panel, is lit when the machine’s output
voltage is present and at a safe level. The
voltage range is from 40VDC to 113VDC
peak. This voltage can be measured at
the output terminals and verified at Plug
J1-pin 6(+) lead #215 to Plug J2-pin 1(-)
lead #222D. See Figure F.15. If the output
voltage is within range but the green light
is not lit either the green light is faulty or
the control board is faulty. Normal operat-
ing voltage for the green light is about
3.5VDC. A voltage of about 5.0VDC
would indicate the light is open and the
control board circuit is operating correctly.
FIGURE F.15. Control Board with LED, Plug and Lead Locations
CONTROL BOARD
#274
#273
#222D
J2
#232
#233
#234
#235
#264
#222A
#341
#230
#215
#231
#263
#201
J1
J3
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F-34
F-34
NOTES
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F-35
F-35
TROUBLESHOOTING & REPAIR
FIRING BOARD TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment could result in danger to the technician or the
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical
shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call (800) 833-9353 (WELD).
TEST DESCRIPTION
The Test determines whether or not the Firing Board is receiving the correct voltages and gate
signals. The LEDs (Light Emitting Diodes) will help you determine if the Firing Board is Generating
gate signals to the main SCRs.
MATERIALS NEEDED
Volt/Ohm Meter (Multimeter)
MULTI-SOURCE Wiring Diagram and Firing Board Schematic Diagram (See Electrical Diagram
Section of Manual).
This procedure takes approximately 30 minutes to perform.
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F-36
F-36
TROUBLESHOOTING & REPAIR
FIRING BOARD TEST (Continued)
FIGURE F.16. FIRING BOARD LOCATION
J2
J5
J6
J7
J1
J8
J3
J4
Firing Board
Control Board
NOTE: To verify that the control board is
sending the correct output enable signal to
the firing board, check from plug J8, pin 7(+)
(lead #340) to plug J5, pin 12 (-) (lead #215).
See Figure F.17. See the wiring diagram.
Normal voltage is approximately less than 1.0
VDC. If not correct the control board may be
faulty.
TEST PROCEDURE FOR NORMAL
FIRING BOARD OPERATION
1. Disconnect main AC input power to the
machine.
2. Remove screws, loosen and lower the
front panel to access the firing board on
the left side of control box while facing
the machine. See Figure F.16.
7. Locate LEDs 1 thru 6. Each LED should
glow with equal brightness.
3. Visually inspect the Firing Board for loose
or faulty connections and obvious physi-
cal damage.
NOTE: LEDs 1 through 6 indicate that the
gate firing signals are being generated to
send to each of the output SCRs.
WARNING
8. If LED 2, located on the control board, is
bright along with LEDs 7,8 and 9 on the
Firing Board and LEDs 1 through 6 are
unequal in brightness, check to make
sure lead #231 is not loose or broken. See
the wiring diagram. Normal voltage range
at plug J5, pin 13 (+) (lead #231) to plug
J5, pin 12 (-) (lead #215) is 3 to 13 VDC.
At an open circuit condition the normal
voltage is approximately 10 VDC. See
Figure F.17.
Electric Shock can kill.
• With the input power on,
there are high voltages inside
the machine. Use caution
when reaching into the
machine or touching any internal part of the
machine while the power is on. High voltage
is present.
4. Reconnect the input power and turn the
MULTI-SOURCE on.
9. If one or two of the LEDs 1 through 6
are dimmer or brighter than the others,
this could indicate an open or shorted
gate on an output SCR. Perform the
Static and Active SCR Tests.
5. Locate LEDs 7, 8, and 9 on the Firing
Board. See Figure F.17. Each LED should
be ON and equally bright. Use Table F.2
to check LED operation.
6. Make certain that plug J7 (jumper plug) is
in place. See Figure F17. and the wiring
diagram.
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F-37
TROUBLESHOOTING & REPAIR
FIRING BOARD TEST (Continued)
TABLE F.2. - LED 7, 8 and 9 Check List
IF
THEN
LED 7 is ON
AC power is being supplied to the Firing Board from leads
#283 and #284 connected, through the resistor bank, to
the phase angle winding in the Main Transformer. See
Figure F.17.
Normal voltage at leads #283 to #284 is 25 VAC.
LED 7 is OFF or is DIM-
MER than other LEDs
The proper AC voltage may not be reaching the Firing
Board. Check for loose or faulty connections. Perform
Main Transformer Test. Also check resistors R3 and R4
located in the resistor bank. Normal resistance is 50
ohms.
LED 8 is ON
AC power is being supplied to the Firing Board from leads
#285 and #286 connected, through the resistor bank, to
the phase angle winding in the Main Transformer. See
Figure F.17.
Normal voltage at leads #285 to #286 is 25 VAC.
LED 8 is OFF or is DIM-
MER than other LEDs
The proper AC voltage may not be reaching the Firing
Board. Check for loose or faulty connections. Perform
Main Transformer Test. Also check resistors R5 and R6
located in the resistor bank. Normal resistance is 50
ohms.
LED 9 is ON
AC power is being supplied to the Firing Board from leads
#287 and #288 connected, through the resistor bank, to
the phase angle winding in the Main Transformer. See
Figure F.17.
Normal voltage at leads #287 to #288 is 25 VAC.
LED 9 is OFF or is DIM-
MER than other LEDs
The proper AC voltage may not be reaching the Firing
Board. Check for loose or faulty connections. Perform
Main Transformer Test. Also check resistors R7 and R8
located in the resistor bank. Normal resistance is 50
ohms.
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F-38
F-38
TROUBLESHOOTING & REPAIR
FIRING BOARD TEST (Continued)
FIGURE F.17. FIRING BOARD PLUG & PIN LOCATIONS
FIRING BOARD
#231
#215
J5
J6
Jumper
Plug
J7
#288
#285
#286
#283
#284
#340
#287
J8
J4
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F-39
F-39
TROUBLESHOOTING & REPAIR
MULTI-SOURCE METER ACCURACY CHECK
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment could result in danger to the technician or the
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical
shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call (800) 833-9353 (WELD).
TEST DESCRIPTION
This procedure will aid the technician in checking and calibrating the meter display.
MATERIALS NEEDED
DC ammeter and meter grade shunt, +/- 1% accuracy
Resistive load bank and/or Multi-Weld machines
This procedure takes approximately 30 minutes to perform.
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F-40
F-40
TROUBLESHOOTING & REPAIR
MULTI-SOURCE METER ACCURACY CHECK (Continued)
METER ACCURACY CHECK
PROCEDURE TO RECALIBRATE IF
METER IS OUT OF RANGE
1. With power off, connect a resistive load and the
meter grade shunt to the output terminals. Use
either a resistive grid, multisource welders or a
combination of both.
If the measured current is within the acceptable cur-
rent range (approximately 533 amps DC) and the
Multi-Source digital display does not read approxi-
mately “100” then the meter must be recalibrated. The
Multi-Source digital display is controlled by a current
sensing circuit on the Control board. The display
should read “100” when the machine output is a little
over 40 kW. To adjust the digital meter, trimmer resis-
tor R49 on the Control board may be adjusted. See
Figure F.18. for location of R49 trimmer.
2. Turn machine on.
3. Adjust the resistive load to approximately 533 amps
DC as read by the DC ammeter via the meter grade
shunt.
4. The Multi-Source digital display should read
approximately “100”.
If the meter can not be calibrated using this procedure
then the Control board or the output shunt may be
faulty. See the Wiring Diagram.
5. If the result is satisfactory the the test is over and
the machine may be reassembled. If the required
results are not obtained proceed to the next sec-
tion.
Note: The output shunt is rated at 50 mv @ 800 A.
FIGURE F.18. R49 TRIMMER
J2
R49
J1
J3
Control Board
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F-41
F-41
TROUBLESHOOTING & REPAIR
NORMAL OPEN CIRCUIT VOLTAGE
WAVEFORM - NO LOAD
0 volts
2 ms
50 volts
This is the typical DC open circuit volt-
age waveform generated from a properly
operating machine. Note that each ver-
tical division represents 50 volts and that
each horizontal division represents 2 mil-
liseconds in time.
Scope Settings
Volts/Div.......................50 V/Div.
Horizontal Sweep......2 ms/Div.
Coupling..............................DC
Trigger..........................Internal
Note: Scope probes connected at
machine output terminals: (+) probe to
positive terminal, (-) probe to negative
terminal.
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F-42
F-42
TROUBLESHOOTING & REPAIR
ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
ONE OUTPUT SCR NOT FUNCTIONING - NO LOAD
0 volts
2 ms
50 volts
This is NOT the typical DC output volt-
age waveform. One output SCR is not
functioning. Note the “gap” in the wave-
form. One SCR gate is disconnected to
simulate an open or non-functioning out-
put SCR. Each vertical division repre-
sents 50 volts and each horizontal divi-
sion represents 2 milliseconds in time.
Scope Settings
Volts/Div.......................50 V/Div.
Horizontal Sweep......2 ms/Div.
Coupling..............................DC
Trigger..........................Internal
Note: Scope probes connected at
machine output terminals: (+) probe to
positive terminal, (-) probe to negative
terminal.
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F-43
F-43
TROUBLESHOOTING & REPAIR
TYPICAL SCR GATE VOLTAGE WAVEFORM - NO LOAD
0 volts
2 ms
1 volt
This is the typical SCR gate pulse volt-
age waveform. The machine was in an
open circuit condition (no load) and
operating properly. Note that each verti-
cal division represents 1 volt and that
each horizontal division represents 2 mil-
liseconds in time.
Scope Settings
Volts/Div........................1 V/Div.
Horizontal Sweep......2 ms/Div.
Coupling..............................DC
Trigger..........................Internal
Note: Scope probes connected at SCR
gate and cathode: (+) probe to gate, (-)
probe to cathode.
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F-44
F-44
NOTES
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F-45
F-45
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR CLEANING AND/OR REPLACEMENT
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment could result in danger to the technician or the
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical
shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call (800) 833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the Input Contactor for maintenance,
repair, or cleaning.
MATERIALS NEEDED
3/8” Nut Driver
7/16” Nut Driver
11/16” Nut Driver
1/2” Nut Driver
This procedure takes approximately 40 minutes to perform.
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F-46
F-46
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR CLEANING AND/OR REPLACEMENT (Continued)
FIGURE F.19. INPUT CONTACTOR (top view)
T3
W
T2
T1
V
U
TOP VIEW
8. For contactor cleaning or inspection see
REMOVAL PROCEDURE
Figure F.21.
1. Disconnect input power to the machine.
REPLACEMENT PROCEDURE
2. Remove case sides and roof using a 3/8”
nut driver.
1. Mount input contactor to machine frame
using the four bolts, washers, and nuts
previously removed.
3. Label leads T1, T2, T3, U, V, W and their
respective terminals. See Figure F.19.
2. Reconnect leads #240 and #241.
4. Using a 11/16” nut driver, remove the six
leads connected to the input contactor.
3. Reconnect leads T1, T2, T3, U, V, W previ-
ously removed.
5. Using a 7/16” nut driver, remove the four
bolts mounting the input contactor to the
frame of the machine. Note washer posi-
tions for replacement. See Figure F.20.
4. Replace case sides and roof previously
removed.
6. Disconnect leads 240 and 241 using quick
connects located in loom.
7. Carefully lift input contactor out of machine.
FIGURE F.20. 7/16” MOUNTING BOLTS
Mounting Bolts
L E F T S I D E
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F-47
F-47
TROUBLESHOOTING & REPAIR
INPUT CONTACTOR CLEANING AND/OR REPLACEMENT (Continued)
FIGURE F.21. INPUT CONTACTOR CLEANING/INSPECTION
240
241
CONTACTOR
COIL
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F-48
F-48
NOTES
MULTI-SOURCE
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F-49
F-49
TROUBLESHOOTING & REPAIR
CONTROL BOARD REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment could result in danger to the technician or the
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical
shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call (800) 833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the control board for replacement.
MATERIALS NEEDED
3/8” Nut Driver
Phillips Head Screwdriver
Pliers (optional)
This procedure takes approximately 30 minutes to perform.
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F-50
F-50
TROUBLESHOOTING & REPAIR
CONTROL BOARD REPLACEMENT PROCEDURE (Continued)
FIGURE F.22. FRONT PANEL W/OUT COVER
J2
J5
J6
J7
J1
J8
J3
J4
Firing Board
Control Board
5. Carefully remove the control board.
REPLACEMENT PROCEDURE
1. Replace the control board.
REMOVAL PROCEDURE
1. Disconnect input power to the machine.
2. Using a 3/8” nut driver, remove screws and
lower the front control panel to access the
control board on the right side of control
box while facing the machine. See Figure
F.22.
2. Mount the control board to the machine in
its proper position using the four phillips
head screws and associated washers pre-
viously removed.
3. Disconnect plugs J2, J1, and J3 from the
control board.
3. Reconnect plugs J3, J1, and J2 to the con-
trol board.
4. Remove the four phillips head screws and
associated washers from the corners of
the control board. See Figure F.23.
4. Replace the four screws previously
removed from the front control panel.
FIGURE F.23. MOUNTING SCREW LOCATIONS
MOUNTING SCREWS
J2
J1
J3
Control Board
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F-51
F-51
TROUBLESHOOTING & REPAIR
FIRING BOARD REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment could result in danger to the technician or the
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical
shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call (800) 833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the firing board for replacement.
MATERIALS NEEDED
3/8” Nut Driver
Phillips Head Screwdriver
Pliers (optional)
This procedure takes approximately 30 minutes to perform.
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F-52
F-52
TROUBLESHOOTING & REPAIR
FIRING BOARD REPLACEMENT PROCEDURE (Procedure)
FIGURE F.24. FRONT PANEL W/OUT COVER
J2
J5
J6
J7
J1
J8
J3
J4
Firing Board
Control Board
REPLACEMENT PROCEDURE
REMOVAL PROCEDURE
1. Replace the firing board.
1. Disconnect input power to the machine.
2. Mount the firing board to the machine in its
proper position using the four phillips head
screws and associated washers previously
removed.
2. Using a 3/8” nut driver, remove screws and
lower the front control panel to access the
firing board on the left side of control box
while facing the machine. See Figure F.24.
3. Reconnect plugs J4, J8, and J5 to the fir-
ing board.
3. Disconnect plugs J5, J8, and J4 from the
firing board.
NOTE: Be sure plug J7 is installed in the new
board.
4. Remove the four phillips head screws and
associated washers from the corners of
the firing board. See Figure F.25.
4. Replace the four screws previously
removed from the front access panel.
5. Carefully remove the firing board.
FIGURE F.25. MOUNTING SCREW LOCATIONS
MOUNTING SCREWS
J5
J6
J7
J8
J4
Firing Board
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F-53
F-53
TROUBLESHOOTING & REPAIR
SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment could result in danger to the technician or the
machine operator and will invalidate your factory warranty. For your safety and to avoid electrical
shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call (800) 833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the SCR bridge and/or an individual
heat sink assembly for repair or replacement.
MATERIALS NEEDED
3/8” Nut Driver
9/16” Nut Driver
1/2” Nut Driver
Solder
Solder Gun/Iron
T12837 (Dow Corning 340) Heatsink Compound
This procedure takes approximately 2 Hours to perform.
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F-54
F-54
TROUBLESHOOTING & REPAIR
SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE
FIGURE F.26. Bolt and Lead Locations
9/16" Bolts
#264
#301
L E F T S I D E
Bridge
Assembly
Mount
4. Lower the control panel using a 3/8” nut
driver.
REMOVAL PROCEDURE
1. Disconnect input power to the machine.
5. Remove plug J4 from the firing board and
feed the disconnected plug down through
the hole in the bottom of the P.C. board
control box.
2. Using a 3/8” nut driver, remove the case
sides and roof.
3. Locate, label, and remove leads #301 and
#264 from the thermostat. See Figure F.26.
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F-55
F-55
TROUBLESHOOTING & REPAIR
SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE
FIGURE F.27. Bolt, Lead, and Shunt Locations
Copper Leads
1/2" Bolts
Positive
Output
Leads
R I G H T S I D E
#251
6. Using a 9/16” nut driver, remove the two
positive output leads connecting the out-
put bridge to the shunt. See Figure F.27.
11. Using a 9/16” nut driver, remove two bolts
covered in red insulating paint on the left
side of the machine only. These two bolts
are located above leads #301 and #264.
See Figure F.26. Note position of insula-
tion, nut, bushing, and washer placement
upon removal. See Figure F.26.
7. Using a 1/2” nut driver disconnect the six
copper transformer secondary leads con-
nected to the SCR bridge from the main
transformer. Three leads are located on
the top and three on the bottom. See
Figure F.27.
12. Locate, label and remove lead #251 from
main transformer. The solder connection
must be broken to disconnect.
Figure F.27.
See
8. Using a 3/8” nut driver remove the right
bolt mounting the SCR bridge to the front
assembly. The bolt is located below the
control board. See Figure F.28.
9. Cut any necessary cable ties.
10. Using a 1/2” nut driver, remove the two
mounting bolts on the right side of the
machine mounting the SCR bridge to the
main transformer.
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F-56
F-56
TROUBLESHOOTING & REPAIR
SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE
FIGURE F.28. Mounting Bolt
J2
J5
J6
J7
J1
J8
J3
J4
Firing Board
Control Board
Mounting Bolt
13. Clear all leads and carefully maneuver
SCR bridge out of the right side of the
machine.
NOTE: Upon reassembly, apply a thin layer of
Lincoln Electric T12837 (Dow Corning
340) heat sink compound to all bolted
electrical connections on the alu-
minum heat sinks.
CAUTION
UPON REASSEMBLY, THE SCR BRIDGE
ASSEMBLY MUST BE ELECTRICALLY
ISOLATED FROM GROUND. MINIMUM
ACCEPTABLE RESISTANCE TO GROUND
IS 500K OHMS.
---------------------------------------------------
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F-57
F-57
TROUBLESHOOTING & REPAIR
SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE
FIGURE F.29. Individual Heatsink Removal
Positive
Snubber
Buss Bar
Assembly
SCR
Bridge
Anode
Assembly
Heatsink
Cathode
Heatsink
SCR Assembly
Mounting Studs
REMOVAL OF INDIVIDUAL
SCR HEAT SINK ASSEMBLIES
INSTALLATION OF INDIVIDUAL
SCR HEAT SINK ASSEMBLIES
1. Using a 9/16” nut driver, remove the nuts
and respective washers securing the posi-
tive buss bar in position. Remove buss
bar. See Figure F.29.
NOTE: Upon reassembly, apply a thin layer of
Lincoln T12837 (Dow Corning #340)
heat sink compound to all bolted elec-
trical connections on the aluminum
heat sinks, including positive buss bar.
2. Using a 9/16” nut driver, remove the nut
and respective washers securing the snub-
ber board and cathode heatsink to the
main assembly. See Figure F.29.
1. Carefully position new SCR assembly on to
heatsink mounting studs.
2. Place positive buss bar back in original
position.
3. Carefully remove the SCR heatsink from
the mounting studs. Replacement will be
made with a new SCR assembly.
3. Replace 9/16” nuts and washers previous-
ly removed.
4. Replace snubber assembly if necessary.
CAUTION
DO NOT DISASSEMBLE THE SCR FROM
THE HEAT SINK. REPLACE THE SCR
ONLY AS AN ASSEMBLY.
---------------------------------------------------
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F-58
F-58
TROUBLESHOOTING & REPAIR
SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE
INSTALLATION OF SCR OUTPUT
BRIDGE
NOTE: Upon reassembly, apply a thin layer of
Lincoln T12837 (Dow Corning #340)
heat sink compound to all bolted elec-
trical connections on the aluminum
heat sinks, including positive buss bar.
1. Carefully maneuver SCR bridge back into
original position.
2. Using a solder iron, reconnect lead #251 to
the main transformer and insulate.
3. Replace the two 9/16” mounting bolts pre-
viously removed. Be sure to position insu-
lation, bushing, washer, and nut correctly.
See Figure F.26.
4. Replace the two 1/2” mounting bolts on
the right side of the machine previously
removed. These bolts mount the SCR
bridge to the main transformer. See
Figure F.27.
5. Replace any previously removed cable
ties.
6. Replace the 3/8” mounting screw previ-
ously removed from the front of the
machine located behind the control panel.
7. Reconnect plug J4 to the firing board.
8. Replace the four screws previously
removed from the front control panel.
9. Reconnect the six copper transformer sec-
ondary leads previously removed.
10. Reconnect the two positive output leads
to the shunt.
11. Reconnect leads #264 and #301 previous-
ly removed from the thermostat.
12. Replace the case sides and roof.
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F-59
F-59
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
Testing is required after the removal of any mechanical part that could affect the machine’s elec-
trical characteristics, or if any electrical components are repaired or replaced.
NO LOAD READINGS (FAN OFF)
Input Volts/Phase/Hertz
380/3/50
Maximum Idle Amps
Maximum Idle KW
15.0
20.0
25.0
6.5
2.0
2.25
2.5
2.0
2.0
2.0
400/3/50
415/3/50
460/3/60
500/3/50
17.0
6.5
575/3/60
MAXIMUM OPEN CIRCUIT VOLTAGE
Open Circuit Volts
79.5/80 VDC
PERFORM METER ACCURACY TEST
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F-60
F-60
NOTES
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G-1
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
CONTROL PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
CONTROL PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
FIRING PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
FIRING PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
SNUBBER PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
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G-2
G-2
ELECTRICAL DIAGRAMS
WIRING DIAGRAM -
MULTI-SOURCE WIRING DIAGRAM
INPUT SNUBBER
ASSEMBLY
DIGITAL OUTPUT METER
L2
H2
1
H
POWER SWITCH
CONTROL BOX
DIODE BRIDGE
274
S1
T2
241
P11
J11
U
W
V
297
1 2 3 4 5 6 7 8 9 10
+
AC
X2
AC
X1
-
240
302
271
272
1CR
273
302
271
250
T1
T1
T1
1 2 3 4 5 6 7 8 9 10
REAR
TRANSFORMER
IRON
1
201
261
263
231
202
215A
230
341
222A
260
264
235
234
215B
233
232
J3
222D
273
340
274
252
251
240
241
1
2
3
4
5
6
7
8
2
LED (W) (RIGHT)
230
H2
L3
253
3
FAN
4
1
2
3
341
5
TO
J2
10
7
12
9
W
V
11
6
PRIMARY
COILS
L2
LED (Y) (CENTER)
234
203
205
3
7
8
POWER
8
5
J1
251
235
9
L1
4
5
8
6
207
10
11
12
13
14
15
16
4
LED (G) (LEFT)
232
6
U
H1
204
206
CB1
252
253
10 A FAN
CIRCUIT
BREAKER
233
550-575V CONNECTION
7
9
208
260
FRONT
TRANSFORMER
IRON
261
TO T2
TO T1
CONTROL PC BOARD
10
11
12
L3
L2
L1
PARALLELING
CONNECTIONS
222A
11 10
12
9
W
V
TO
H2
222D
L1
PRIMARY
COILS
263
SECONDARY LEAD
8
5
7
4
H1
1 2 3 4
1
2
3
4
5
6
G1
G2
G3
G4
G5
G6
J6
-
6
U
J4
WORK
1
2
3
4
5
6
7
8
440-460V CONNECTION
TO T2
301
-
264
C1
222B
J7
222C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
TO T1
TP1
C3
820uF
500V
30
300W
L3
+
(BOTTOM)
10
7
11
8
12
W
284
1
2
TO
PRIMARY
COILS
H2
L2
L1
283
286
285
288
287
240
J5
92
293
G1
3
9
V
U
H1
OUTPUT
BYPASS
4
G3
5
G5
J8
215
231
4
6
5
6
30
300W
(TOP)
7
SCR1
TP2
SCR5
SCR3
2
8
C2
380-415V CONNECTION
300W
9
10
G
TO A SYSTEM GROUND PER
NATIONAL ELECTRIC CODE
FIRING PC BOARD
+
294B
TO T1
AUXILIARIES
301
294A
RESISTOR BANK
1
1
3
2
4
3
6
1
5
1
9
4
1
6
8
ELECTRODE
5
+
-
+
R3
R4
R5
R6
R7
R8
203
283
284
285
286
287
288
8
4
10
16
264
ELECTRICAL SYMBOLS PER E1537
204
205
206
207
208
OUTPUT SHUNT
50 mV@800 A
202
CONNECTORS VIEWED FROM INSERTION END
215A
215
215B
201
SCR
THERMOSTAT
TRANSFORMER
BRACKET
SCR2
INPUT WELDER
BOX
CONTROL
BOX COVER
SCR4
SCR6
BASE
G4
G6
G2
PROTECTIVE BONDING CIRCUIT
10-13-2000
L11414
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.
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G-3
G-3
ELECTRICAL DIAGRAMS
SCHEMATIC - CONTROL PC BOARD
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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G-4
G-4
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-CONTROL
PC BOARD DESIGNATORS
PC BOARD DESIGNATORS
C1
ITEM
1
PART NO.
ITEM
1
PART NO.
S13490-138
S13490-73
DESCRIPTION
RESISTOR,MF,1/4W,681,1%
DESCRIPTION
CAPACITOR,ALEL,1200,100V,+75/-20%
R33
S19400-6810
S19400-3321
S19400-2671
S24000-1500
S19400-2211
S19400-10R0
S19400-6812
S19400-1502
S19400-3923
S19400-1003
S19400-2002
S19400-1211
S16296-3
C2
1
CAPACITOR,ALEL,20,50V,+75/-10%
CAPACITOR,CEMO, 2700PF, 50V,5%
CAPACITOR,CEMO,0.1, 50V,10%
R34
1
RESISTOR,MF,1/4W,3.32K,1%
RESISTOR,MF,1/4W,2.67K,1%
RESISTOR,WW,3/4W,150,5%
RESISTOR,MF,1/4W,2.21K,1%
RESISTOR,MF,1/4W,10.0,1%
RESISTOR,MF,1/4W,68.1K,1%
RESISTOR,MF,1/4W,15.0K,1%
RESISTOR,MF,1/4W,392K,1%
RESISTOR,MF,1/4W,100K,1%
RESISTOR,MF,1/4W,20.0K,1%
RESISTOR,MF,1/4W,1.21K,1%
TRIMMER,MT,1/2W,500, 10%,LINEAR
RESISTOR,MF,1/4W,750,1%
RESISTOR,MF,1/4W,1.00K,1%
RESISTOR,MF,1/4W,30.1K,1%
RESISTOR,MF,1/4W,28.0K,1%
RESISTOR,MF,1/4W,100,1%
RESISTOR,MF,1/4W,825,1%
C3,C5,C6
3
S16668-4
R35,R116,R125,R153
4
C4,C16,C24,C27,C29,C31
22
S16668-11
R36
1
C32,C35,C36,C44,C49,C50
R37,R39,R48,R89,R93
5
C51,C52,C53,C54,C55,C56
R38
1
D 1 7
R 4 8
D 1 8
C57,C58,C59
R40
1
X 1 3
C7
1
5
S13490-121
S13490-25
S13490-4
S13490-93
T11577-38
S13490-94
S16668-3
S16668-5
CAPACITOR,ALEL,1000,35V,+30/-20%
CAPACITOR,TAEL,4.7,35V 10%
CAPACITOR,PEF,.022,200V,10%
CAPACITOR,TAEL,27,35V,10%
R41,R42,R88
3
C8,C9,C12,C25,C40
R43
1
C10
1
R44,R101,R107,R109,R130
5
C11
1
R46,R150
2
C 5 8
R 8 0
R 8 3
R 7 6
8
C
C13,C19,C20
3
CAPACITOR,CD,.02,600V,+80/-20%
CAPACITOR,PEMF,0.33,200V,10%
CAPACITOR,CEMO,100P, 100V,5%
CAPACITOR,CEMO,.022, 50V,20%
R47
1
7 C
C15,C28,C42
3
R49
1
D 2 9
D 2 6
D 2 7
D 2 5
D 2 4
C17
1
R50,R133,R134
3
S19400-7500
S19400-1001
S19400-3012
S19400-2802
S19400-1000
S19400-8250
1
D
R 7 4
R 7 3
C18,C33,C34,C37,C41,C45
10
R51,R152
2
R 4 2
C60,C61,C62,C63
R52
1
C 1 1
C 5 7
R 4 1
D 3 0
R 8 5
C21
1
1
S16668-9
S13490-104
S13490-40
S13490-63
S13490-66
T11577-57
S13490-42
S16668-6
S16668-7
CAPACITOR,CEMO,150p, 100V,5%
CAPACITOR,TAEL,39,20V,10%
CAPACITOR,TAEL,2.7,50V,10%
CAPACITOR,TAEL,.47,50V,10%
CAPACITOR,TAEL,47,35V 10%
CAPACITOR,PEF,0.1,400V,10%
CAPACITOR,TAEL,1.0,35V,10%
CAPACITOR,CEMO,4700p,50V,10%
CAPACITOR,CEMO,820p,50V,5%
R53,R73
2
R 1 5
C 1 2
R 4 5
R 4 3
C22
R54,R64,R66,R123,R129
5
5
D
R 1 0 7
R 1 0 9
C23
1
R55,R56,R57,R58,R59,R60
8
C26
1
R61,R62
R 1 4 3
R 1 4 2
C 6 0
C30
1
R67,R68,R70,R111,R112,R120
7
S19400-5621
RESISTOR,MF,1/4W,5.62K,1%
R 9 9
C38,C39
2
R122
R 1 0 0
C 6 2
C43,C48
2
R74,R79,R127
3
5
1
1
4
1
1
2
1
1
1
1
1
2
1
1
1
1
1
4
2
1
2
1
1
1
S19400-2001
S19400-5110
S19400-6192
S19400-2673
S19400-1623
S19400-5111
S19400-2213
S19400-39R2
S19400-2212
S19400-8251
T10812-62
RESISTOR,MF,1/4W,2.00K,1%
RESISTOR,MF,1/4W,511,1%
1
T
C 5 3
D 3 8
C46
1
R77,R78,R103,R104,R115
D 3 5
C 3 2
C47
1
R84
RESISTOR,MF,1/4W,61.9K,1%
RESISTOR,MF,1/4W,267K,1%
R 1 0 1
C 5 9
D 3 1
R 8 8
R 8 7
CT1
1
COSMETIC_TRACE COSMETIC TRACE
R92
D1,D44
2
T12705-47
T12199-1
DIODE,AXLDS,4A,200V,UFR
R95,R96,R97,R98
R99
RESISTOR,MF,1/4W,162K,1%
D2,D6,D7,D8,D9,D10,D11,D12
44
DIODE,AXLDS,1A,400V
R 8 9
D 3 2
RESISTOR,MF,1/4W,5.11K,1%
RESISTOR,MF,1/4W,221K,1%
D13,D14,D15,D16,D17,D18
C 1 0
R108
R 1 0 5
D Z 1 0
D19,D20,D21,D22,D23,D24
R119,R138
R121
RESISTOR,MF,1/4W,39.2,1%
D25,D26,D27,D29,D30,D31
RESISTOR,MF,1/4W,22.1K,1%
RESISTOR,MF,1/4W,8.25K,1%
TRIMMER,ST,1/2W,500, 10%,LINEAR
RESISTOR,MF,1/4W,357,1%
C 5 6
D32,D33,D34,D35,D36,D38
R 1 4
R126
R 1 4 1
R 2 9
R 2 5
D39,D40,D41,D42,D45,D46
R128
D47,D48,D49,D50,D51,D52
R136
S19400-3570
S19400-4750
S19400-2430
S19400-2210
S20375-1
D3,D4,D5
3
3
2
3
2
3
1
1
1
7
T12705-34
T12199-2
T12702-11
T12702-52
T12702-29
T12702-27
S24020-16
S24020-8
S24020-10
T13657-2
DIODE,AXLDS,1A,400V,FR,1N4936
DIODE,AXLDS,1A,1000V
R137
RESISTOR,MF,1/4W,475,1%
D28,D37,D43
R146,R147
R149
RESISTOR,MF,1/4W,243,1%
DZ1,DZ8
ZENER DIODE, 1W,16V,5% 1N4745A
ZENER DIODE, 1W,5.1V,5% 1N4733A
ZENER DIODE, 1W,15V,5% 1N4744A
ZENER DIODE, 1W,10V,5% 1N4740A
CONNECTOR,MOLEX,MINI,PCB,16-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,10-PIN,TIN
LED,T-1,3/4,RED,HLMP-3003
RESISTOR,MF,1/4W,221,1%
Q 1 0
DZ2,DZ6,DZ9
T1
TRANSFORMER,PCB,PWM,FLYBACK
MOV,150VRMS,45J,14MM
C 5 2
C 5 4
R 1 5 1
DZ3,DZ7
TP1
T13640-11
R 1 2 0
DZ4,DZ5,DZ10
TRI1
S18395-27
TRIAC,T220,8A,800V,WITH S18104-3HS
IC,OP-AMP,QUAD,HIGH-PERF,1014
OP-AMP,QUAD, HIGH-PERF,33074
IC,COMPARATOR,QUAD,2901N
R 2 8
R 3 3
J1
X1
S15128-16
J2
X2,X3,X4,X5
X6,X7
X8
S15128-18
C 5 5
8 D
J3
S15128-11
1
Q
C 1 7
D 1 3
LED1,LED2,LED3,LED4,LED5
S15018-9
IC,CMOS,MULTIVBRTR_MONO_DUAL_4538(SS)
IC,CMOS,TIMER,PROGRAMMABLE,4536(SS)
IC,PWM-CONTROLLER,IMODE,2842A
VOLTAGE REF,ADJ, PRECISION,431I
REGULATOR,HEAT-SINKASBLY,S15128-5,S18104-3
R 4 0
R 5 3
LED6,LED7
X9,X10
X11
S15018-13
8
R
OCI1
1
1
7
1
2
1
2
2
2
2
4
1
1
2
1
1
2
2
2
1
2
3
1
22
S15000-8
OPTOCOUPLER,PHOTO-SCR,400V,MCS2401
OPTOCOUPLER,TRIAC DRIVER,RANDM,3023
TRANSISTOR,NPN,TO226,0.5A,40V,2N4401
TRANSISTOR,PNP,TO226,0.5A, 40V,2N4403
MOSFET/HEATSINK ASBLY,T12704-61&S18104-3(SS)
RESISTOR,WW,5W,1.2K,5%,SQ
RESISTOR,MF,1/4W,33.2K,1%
RESISTOR,MF,1/4W,267,1%
M15458-4
D 1 4
R 1 2 8
3 C
7
OCI2
S15000-12
X12
S15128-10
R 5 4
C 2 1
R 3 9
R 3 7
R 3 8
C 5 1
C 5 0
R
Q1,Q2,Q3,Q4,Q5,Q6,Q7
T12704-68
X13
S18395-3
R 1 2 2
R 1 4 8
Q
5 C
Q8
T12704-69
2
Q
5
Q
3
4
Q
7
Q
Q9,Q10
S18395-5
6
Q
R1
T14648-10
8
Q
X 1 1
C
UNLESS OTHERWISE SPECIFIED:
RESISTANCE = OHMS
R2,R3
S19400-3322
S19400-2670
S19400-3010
S19400-6811
S19400-1372
S19400-1503
S19400-1501
S19400-1301
S19400-3320
S19400-26R7
T12300-80
C 1 8
D 5 1
R4,R72
4
R5,R71
RESISTOR,MF,1/4W,301,1%
R 3 4
R 3 5
R6,R80
RESISTOR,MF,1/4W,6.81K,1%
RESISTOR,MF,1/4W,13.7K,1%
RESISTOR,MF,1/4W,150K,1%
R 1 5 2
R7,R18,R19,R23
R 1 5 3
D 5 2
R8
R9
RESISTOR,MF,1/4W,1.50K,1%
RESISTOR,MF,1/4W,1.30K,1%
RESISTOR,MF,1/4W,332,1%
R 2 4
R 2 3
R10,R132
R11
R12
RESISTOR,MF,1/4W,26.7,1%
R 2 2
R13,R124
RESISTOR,WW,5W,0.5,5%
9
Q
R14,R114
T14648-9
RESISTOR,WW,5W,2.5K,5%,SQ
RESISTOR,MF,1/4W,150,1%
1 C
1
R I
T
R15,R139
S19400-1500
S19400-6191
S19400-2801
S19400-8252
S16296-5
R16
RESISTOR,MF,1/4W,6.19K,1%
RESISTOR,MF,1/4W,2.80K,1%
RESISTOR,MF,1/4W,82.5K,1%
TRIMMER,MT,1/2W,10K, 10%,LINEAR
RESISTOR,MF,1/4W,10.0K,1%
R17,R117
D 4 4
R20,R21,R105
R22
C 3 8
C 3 9
R24,R25,R45,R69,R75,R76
R85,R86,R87,R90,R91,R94
R100,R102,R113,R118,R135
R141,R142,R143,R145,R148
R26,R27,R30,R81,R83,R106
R28
S19400-1002
1
R
R 1 4 7
D Z 9
6
1
S19400-1004
S19400-7501
S19400-4751
RESISTOR,MF,1/4W,1.00M,1%
RESISTOR,MF,1/4W,7.50K,1%
RESISTOR,MF,1/4W,4.75K,1%
6
D
5 R
R 6 5
R 1 8
R 1 9
R 6 6
R 6 4
D Z 2
R 6 3
R29,R31,R32,R63,R65,R110
R131,R140,R144,R151
10
2 J
1 J
3 J
C T 1
Chg. Sheet No.
XB
"X" INFO.
DESIGN INFORMATION
DRAWN BY: MB/JB
REFERENCE:
EQUIPMENT TYPE:
SUBJECT:
MULTI-SOURCE
CONTROL P.C. BOARD ASSEMBLY
G3742-1
10-13-2000A
ENGINEER:
SUPERSEDING:
MJK
4-20-2000
1:1
APPROVED:
SCALE:
DATE:
DRAWING No.:
3726-2
G
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 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.
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G-5
G-5
ELECTRICAL DIAGRAMS
SCHEMATIC - FIRING PRINTED CIRCUIT BOARD
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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G-6
G-6
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY-FIRING
3 7 4 2 - 1
G
ITEM
C1,C3,C5,C6,C9,C12,C13,C14
C15,C16,C23,C25,C26,C28
C29,C34,C35,C37,C44
C2,C4,C10,C11,C21,C22
C7,C8,C18,C20,C24,C31,C33
C17,C19
C30
C32
C38,C40,C42
C39,C41,C43
D1,D4,D7,D11,D12,D14,D15
D24,D27,D28,D29,D30,D31
D32,D33,D34,D35,D36,D38,D43
D44,D47,D49,D50,D51,D52,D53
D54,D59,D60,D61,D62,D63,D64
D2,D3,D5,D6,D8,D9,D16,D17
D18,D20,D21,D22,D39,D40,D41
D42,D55,D56,D57,D58,D65,D66
D67,D68,D69,D70
REQ'D
19
PART NO.
S16668-5
DESCRIPTION
.022/50
6
7
2
1
1
3
3
34
S13490-95
S13490-108
T11577-41
S13490-74
S13490-73
T11577-58
T11577-46
T12199-1
.33/50
.15/100
.022/400
10/150
20/50
.0047/3000V
.05/600V
1N4004
26
T12199-2
1N4007
C38
C40
R36
R82
R64
D71
DZ1,DZ6,DZ9
1
3
3
1
1
T12705-46
T12702-52
T12702-4
T12702-25
T12702-33
1000V/3AMP DIODE
1N4733A
R116
R134
DZ2,DZ5,DZ7
DZ3
DZ4
1N4747
1N5357B
1N5347B
C39
TP1
C41
C43
C42
DZ8,DZ10,DZ11,DZ12,DZ13
DZ14,DZ15
J4
J5
J6
7
T12702-29
1N4744A
R18
1
1
S24020-6
S24020-16
S18248-4
S24020-8
S24020-10
T13657-2
HEADER, VERTICAL
HEADER, VERTICAL
HEADER
1
DZ1
DZ9
D16
J7
J8
1
1
10
HEADER, VERTICAL
HEADER, VERTICAL
RED LED
D2
D3
D70
D69
D65
D66
LED1,LED2,LED3,LED4,LED5
LED6,LED7,LED8,LED9,LED10
OCI1,OCI3
OCI2
Q1
D22
R160
D24
D35
D57
D51
R37
2
1
1
S15000-10
S15000-12
T12704-80
OPTO ISOLATOR
OPTO TRIAC DRIVER
HEXFET TRANS. (SS)
R232
R233
R234
R161
C9
R162
D20
D14
D17
R85
R86
R87
R88
R89
R90
Q2,Q3,Q4,Q5,Q6,Q7
QU1,QU2,QU3
6
3
T12704-73
T12707-4
IC PKG MOSFET (SS)
2N6027
R220
R221
R222
R223
R224
R168
R169
R170
R171
R172
R173
R158
R18,R36,R64,R82,R116,R134
R37
6
1
T14650-6
T14648-15
S19400-1002
RESISTOR,WW,15W,5%,SQ
700 5W
D64
R166
R165
OCI1
R44,R45,R46,R195,R227,R229
R251,R254,R255,R258,R259
R262,R263
13
10K 1/4W
R144
R145
D27
D28
C22
C10
C2
DZ4
R83,R91,R135,R139,R163
R164,R184,R188,R202,R203
R206,R245,R249
13
S19400-1500
150 1/4W
R183
C7
R225
D33
D34
D11
D49
D29
R84,R92,R167,R174,R207,R219
6
S19400-1001
S19400-2000
1K 1/4W
R85,R86,R87,R88,R89,R90
R93,R94,R95,R96,R97,R98
R143,R168,R169,R170,R171
R172,R173,R175,R176,R177
R178,R179,R180,R208,R209
R210,R211,R212,R213,R220
R221,R222,R223,R224,R225
R266
38
200 1/4W
R219
R246
C26
R247
R245
R248
R167
C12
R186
R187
R163
R84
C1
R137
R138
R83
C32
C8
R185
C14
R184
R136
C5
R135
C29
R197
C16
R198
R230
R252
D60
D52
D15
R206
LED10
QU2
D63
C19
R136,R140,R160,R185,R189
R196,R214,R246,R250
R137,R138,R141,R142,R186
R187,R190,R191,R237,R238
R247,R248,R253
R144,R145
9
S19400-2670
S19400-10R0
267 1/4W
10 1/4W
D44
13
R201
C20
R203
C17
2
1
3
3
3
6
T14650-1
T14648-1
S19400-1003
S19400-3323
S19400-2671
S19400-6190
1500 OHMS, 15W. RES
5K 5W
R93
R94
R95
R96
R97
R98
R175
R176
R177
R178
R179
R180
D55
R158
DZ3
R204
R217
R218
C18
R159,R234,R241
R161,R197,R215
R162,R198,R216
R165,R166,R192,R193,R239
R240
R181,R199,R205,R231,R242
R182,R200,R243
R183,R201,R244
R194,R226,R228
R204,R235
100K 1/4W
332K 1/4W
2.67K 1/4W
619 1/4W
R208
R209
R210
R211
R212
R213
D40
C21
OCI2
OCI3
R215
C25
R216
C4
SCR7
C11
R231
R205
R266
C44
5
3
3
3
2
3
S19400-1501
S19400-4750
T10812-67
S19400-33R2
S19400-1000
S19400-39R2
1.5K 1/4W
475 1/4W
D54
D12
D30
QU3
100K 1/2W TRIMMER
33.2 1/4W
R236
R92
C3
R142
R141
R91
D47
R174
C13
R191
R190
R164
R189
C15
R188
R140
C6
R139
C33
Q1
DZ8
100 1/4W
39.2 1/4W
R207
C23
R238
R237
R202
R250
C28
R249
R143
R159
R251
R217,R232,R233
R241
R253
R235
R218
R230
R236
R252
1
1
1
1
3
3
6
S24000-68R0
S19400-2001
S19400-2002
S19400-3321
S19400-8251
S19400-2211
S15161-19
68 3/4W
2.0K 1/4W
20K 1/4W
R244
C31
D36
D59
D61
3.32K 1/4W
8.25K 1/4W
2.21K 1/4W
4A.,400V. SCR
C24
R256,R260,R264
R257,R261,R265
SCR1,SCR2,SCR3,SCR4,SCR5
C30
SCR6
SCR7
TP1
1
1
S18395-21
T13640-25
SCR HS ASBLY
MOV,90J
G3742-1
FIRING BOARD
CAPACITORS
RESISTORS
=
MFD/VOLTS
=
OHMS
UNLESS OTHERWISE SPECIFIED TOLERANCE
ON HOLE SIZES PER E-2056
Ch'ge. Sht. No.
EQUIP.
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U. S. A.
DC-600/MULTI-SOURCE
TYPE
XD-UF
ON
ON
2
3
PLACE DECIMALS IS
PLACE DECIMALS IS
+
+
.02
12-17-99
.002
FIRING P.C. BOARD ASSEMBLY
SUBJECT
DRS
ON ALL ANGLES IS
+
.5 OF
A
DEGREE
FULL
SCALE
SHT.
NO.
t
MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.
FZ/DRS
8-25-99
G2699-1,G3660-1,L9073-3
REF.
3742-1
DR.
DATE
CHK.
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 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.
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - SNUBBER
M
1 4 3 1 2 - 1
C7
TP7
C8
TP8
OUTPUT SNUBBER
Ch'ge. Sht. No.
EQUIP. TRANSFORMER WELDERS
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
TYPE
2-19-93G
7-23-93C
OUTPUT SNUBBER P.C. BD. ASSEMBLY
SUBJECT
FULL
SCALE
SHT.
NO.
C.S.
8-18-92
REF.
DATE
SUP'S'D'G
14312-1
CHK
DR
M
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 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.
Download from Www.Somanuals.com. All Manuals Search And Download.
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 with us. Please include the
machine’s code number and how the problem was resolved.
Thank You,
Technical Services Group
Lincoln Electric Co.
22801 ST. Clair Ave.
Cleveland, Ohio 44117-1199
FAX 216-481-2309
SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________
Please give detailed description below:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
SD287 01/99
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