Lincoln-electric MULTI-WELD SVM151-A User Manual

SVM151-ASeptember, 2002Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, your overall

Be sure to follow the safety practice touse the female connector on the cablewhich would normally be electrically "hot"(supply lead) if disc

TROUBLESHOOTING & REPAIRF-60 F-60MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

G-1ELECTRICAL DIAGRAMSG-1TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION-ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL DIAGRAMSG-2MULTI-WELD 350WIRING DIAGRAM - MULTI-WELD 3509-17-99AG3676MULTI-WELD 350 WIRING DIAGRAMREMOTE RECEPTACLEARC FORCEFAN(LEFT)(RIGHT

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ELECTRICAL DIAGRAMSG-7MULTI-WELD 350SCHEMATIC - CONTROL PC BOARD #5G-7NOTE: This diagram is for reference only. It may not be accurate for all machine

SOLID EDGEEN-170MANUFACTURING TOLERAN CE PER E2056UNLESS OTHERWISE SPECIFIED TOLERANCESCALE:DO NOT SCALE THIS DRAWINGON 3 PLACE DECIMALS IS ± .002TH

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A-5 A-5INSTALLATIONMULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

ELECTRICAL DIAGRAMSG-11MULTI-WELD 350SCHEMATIC - POWER PRINTED CIRCUIT BOARDG-11NOTE: This diagram is for reference only. It may not be accurate for a

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

SVM ERROR REPORTING FORMWe need to know if there are errors in our manuals. We also value any suggestions as toadditional tests or procedures that wo

For Converters (operating at rated output) less than200 ft. (61 m) from the power source, the following min-imum cable sizes are recommended for the i

Operation...Section BSafet

OPERATING INSTRUCTIONSRead and understand this entire section of operatinginstructions before operating the machine.SAFETY INSTRUCTIONSELECTRIC SHOCK

PRODUCT DESCRIPTIONThe Multi-Weld 350 Arc Converter (K1735-1) is part ofa Multi-Weld system, ideally suited for construction sitewelding. It uses a s

Simple• Easy installation with 10 ft. (3 m) work clip lead anduser preference quick-connect “pig-tails” for inputand electrode weld cables.• Easy se

REMOTE OUTPUT CONTROL OPTIONSThe Multi-Weld 350 is provided with a 6-pin remotereceptacle to permit use with the 25 ft.(7.6 m) K857 or100 ft. (30.4 m)

FRONT PANEL CONTROLSThe numbered items of Figure B.2 match the num-bered items described below:These few instruments and controls are basic to theoper

Average AMPS for about 7 seconds after weldingstops in CC and CV modes only.• The 5 second memory display is indicated by thedisplay’s left-most deci

i iSAFETYFOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be

Disconnecting the Remote plug from this recepta-cle automatically transfers output control back tothe panel Output Control (item (2) above).Remote out

TRANSPORTINGThe Converter may be carried by one or two personsusing the front and rear top and bottom handles. It canalso be set vertically on a two w

B-10 B-10NOTESMULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

Accessories ...Section COptions

OPTIONS/ACCESSORIESThe following options/accessories are available foryour Multi-Weld 350 from your local Lincoln Distributor.FIELD INSTALLED OPTIONSK

CONNECTION OF THE LN-25 TO THE MULTI-WELD 350 “ACROSS THE ARC”(SEE FIGURE C.1.) 1. Shut the welder off.2. Connect the electrode cable from the LN-25 t

C-4 C-4NOTESMULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

Maintenance...Section DSafety P

SAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Do not touch electrically live parts orelectrode with skin or wet clothing.• Insulate yourself from work a

SERVICEThe Multi-Weld 350 was designed for easy serviceusing quick-to-replace components and assemblymodules that can be simply swapped out at the job

ii iiSAFETYReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCARC RAYS can burn.4.a. Use a shield with the proper filt

D-4 D-4NOTESMULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

General Description ...E-2Input P

GENERAL DESCRIPTIONThe MULTI-WELD 350 Converter uses a single DCinput power source to provide up to 350 continuousamps for positive polarity stick, wi

POWER MODULES AND FEED-BACKThe external DC source voltage is applied to parallelcapacitors incorporated within each of the two Power(Chopper) Modules.

ANALOG CONTROL POWER SUPPLY BOARD AND WELD CONTROL BOARDThe Analog Control Power Supply Board, which is pow-ered by 40 VDC delivered from the DC Buss

MODE SELECTOR AND OUTPUTCONTROLSIn CC mode, machine output is at open circuit voltage.The OUTPUT control presets amps in the 30 to 350 Arange and then

PROTECTION FEATURESThe Multi-Weld 350 design features electronic protec-tion systems to help assure reliable operation evenunder adverse conditions.

INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATIONAn IGBT is a type of transistor. IGBTs are semicon-ductors well suited for high frequency switching

PULSE WIDTH MODULATIONThe term PULSE WIDTH MODULATION is used todescribe how much time is devoted to conduction in thecycle. Changing the pulse width

CHOPPER TECHNOLOGYFUNDAMENTALS The new era of welding machines such as the Multi-Weld 350 employ a technology whereby a DC sourceis turned on and off

iii iiiSAFETYReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCFOR ELECTRICALLYpowered equipment.8.a. Turn off input

E-10 E-10NOTESMULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

Troubleshooting & Repair Section...Section FHow to Use Troubles

This Troubleshooting Guide is provided to helpyou locate and repair possible machine malfunc-tions. Simply follow the three-step procedure list-ed be

ELECTRIC SHOCK can kill.Have an electrician install and servicethis equipment. Turn the machine OFFbefore working on equipment. Do nottouch electric

Observe Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced

TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced

Observe Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced

TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced

Observe Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced

TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced

iv ivSAFETYReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire e

Observe Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced

TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced

Observe Safety Guidelines TROUBLESHOOTING GUIDEdetailed in the beginning of this manual.CAUTIONIf for any reason you do not understand the test proced

TROUBLESHOOTING & REPAIRF-13 F-13MULTI-WELD 350CASE COVER ASSEMBLY REMOVALAND REPLACEMENT PROCEDUREWARNINGService and repair should be performed b

TROUBLESHOOTING & REPAIRF-14 F-14MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-15 F-15MULTI-WELD 350POWER MODULE CAPACITOR DISCHARGE PROCEDUREWARNINGService and repair should be performed by only Lin

TROUBLESHOOTING & REPAIRF-16 F-16MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-17 F-17MULTI-WELD 350INPUT CONTACTOR COIL RESISTANCE AND SUPPLY VOLTAGE TESTWARNINGService and repair should be performe

TROUBLESHOOTING & REPAIRF-18 F-18MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-19 F-19MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

v v- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -MULTI-WELD 350PageSafety...

TROUBLESHOOTING & REPAIRF-20 F-20MULTI-WELD 350ANALOG CONTROL POWER SUPPLY PC BOARD TESTWARNINGService and repair should be performed by only Linc

TROUBLESHOOTING & REPAIRF-21 F-21MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-22 F-22MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-23 F-23MULTI-WELD 350DC BUSS POWER SUPPLY PC BOARD TESTWARNINGService and repair should be performed by only Lincoln Ele

TROUBLESHOOTING & REPAIRF-24 F-24MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-25 F-25MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-26 F-26MULTI-WELD 350CHOPPER PC BOARD INPUT VOLTAGES AND RESISTANCE TESTWARNINGService and repair should be performed by

TROUBLESHOOTING & REPAIRF-27 F-27MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-28 F-28MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

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Installation...Section ATech

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TROUBLESHOOTING & REPAIRF-34 F-34MULTI-WELD 350CASE FRONT ASSEMBLY REMOVAL AND REPLACEMENTWARNINGService and repair should be performed by only Li

TROUBLESHOOTING & REPAIRF-35 F-35MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-36 F-36MULTI-WELD 350WELD CONTROL OR PERIPHERAL PC BOARD REMOVAL AND REPLACEMENTWARNINGService and repair should be perf

TROUBLESHOOTING & REPAIRF-37 F-37MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-38 F-38MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-39 F-39MULTI-WELD 350AMPS/VOLTS DIGITAL METER AND POTENTIOMETERREMOVAL AND REPLACEMENTWARNINGService and repair should b

A-2 A-2INSTALLATIONMULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to

TROUBLESHOOTING & REPAIRF-40 F-40MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-41 F-41MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-42 F-42MULTI-WELD 350INPUT CONTACTOR REMOVAL AND REPLACEMENTWARNINGService and repair should be performed by only Lincol

TROUBLESHOOTING & REPAIRF-43 F-43MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-44 F-44MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-45 F-45MULTI-WELD 350INPUT DIODE REMOVAL AND REPLACEMENTWARNINGService and repair should be performed by only Lincoln El

TROUBLESHOOTING & REPAIRF-46 F-46MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-47 F-47MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-48 F-48MULTI-WELD 350FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENTWARNINGService and repair should be performed by only Lin

TROUBLESHOOTING & REPAIRF-49 F-49MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

Read this entire installation section before youstart installation.SAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Do not touch electrically liveparts or

TROUBLESHOOTING & REPAIRF-50 F-50MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-51 F-51MULTI-WELD 350POWER CAPACITOR REMOVAL AND REPLACEMENTWARNINGService and repair should be performed by only Lincol

TROUBLESHOOTING & REPAIRF-52 F-52MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-53 F-53MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-54 F-54MULTI-WELD 350CHOPPER PC BOARD AND DIODE MODULEREMOVAL AND REPLACEMENTWARNINGService and repair should be perform

TROUBLESHOOTING & REPAIRF-55 F-55MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-56 F-56MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-57 F-57MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-58 F-58MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-59 F-59MULTI-WELD 350Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma