Lincoln Electric SVM151-A service manual Safety Precautions, Quick-Connect Pig-Tails

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Section TOC

Master TOC

A-3

 

A-3

INSTALLATION

 

Read this entire installation section before you

FIGURE A.1 – PIG-TAIL CONNECTIONS

start installation.

 

 

 

TO POWER

TO

 

SOURCE

WORK TO ELECT.

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SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

Do not touch electrically live parts or electrodes with your skin or wet clothing.

Insulate yourself from the work and ground.

Always wear dry insulating gloves.

IN

ELECT.

+

+

INPUT

+ +

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Only qualified personnel should install, use, or ser- vice this equipment.

QUICK-CONNECT “PIG-TAILS”

The Multi-Weld 350 is factory provided with two 21 in.(53 cm) long 2/0 AWG (70 mm2) “pig-tail” cables. Their 0.5" (13 mm) hole lug ends are routed through the “INPUT +” (on back) and “ELECTRODE +” (on front) cable channels of the Converter. They are attached to the bottom-accessed covered cable con- nection studs.

 

BOTTOM VIEW

IN

ELECT.

+

+

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Attach the preferred standard, user-provided Quick- connect terminal (such as Lincoln Twist-Mate or Tweco

2-MPC type) to the cut-off end of these cables. Use the female connector on the “ELECTRODE +” cable and the male connector on the “INPUT +” cable.

ATTACHMENT AND ARRANGEMENT OF “PIG-TAILS”

To best suit the desired inter-connection of the Converters, the “pig-tail” cables may be routed into the front or back cable channels. For single or double “pig- tail” cables, route through the bottom-accessed cov- ered cable connection studs. (See Figures A.1 and B.1.)

TO POWER

TO ELECT.

SOURCE

 

To connect the “pig-tail” cables to the Converter:

1.Stand the Converter vertically on its rear handle and skid to gain access to the bottom stud covers. Then remove the two 0.25"(6.3 mm) screws secur- ing each cover and fold out the cover insulation.

2.Route the appropriate “pig-tail” cable lug ends under the skid rail (for strain-relief) through the desired front and/or rear corner channels to the exposed 0.5" (13 mm) stud. Remove the flange nut with a .75" (19 mm) wrench.

NOTE: Input supply cable(s) must connect through “INPUT +” labeled channels, and output weld cable(s) must connect through “ELECTRODE +” labeled channels.

3.Slip the “pig-tail” cable lug(s) over the stud and re- secure the flange nut. Make sure that the lug(s) do not touch any sheetmetal of the stud housing. Fold back the cover insulation and replace the stud cover.

MULTI-WELD 350

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Contents Multi-Weld TM 350 Arc Converter California Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications MULTI-WELD 350 K1735-1 InstallationQUICK-CONNECT PIG-TAILS Safety PrecautionsCase Grounding Work ConnectionFixed Parallel Operation Converters Cable Size On Cable AWG mm2 Power Source SetupTable of Contents Operation Section Safety Instructions OperationOperating Instructions Product Description VersatilePortable PIG-TAIL Leads and Connectors MULTI-SYSTEM Power SourceRecommended Equipment and Processes Distribution BOXCV Mode Wire Welding CC Mode Stick Welding and GougingRemote Output Control Options Front Panel Controls Input Power/ Mode Switch has three positionsRecessed Panel Controls Paralleled Converters For CC STICK/GOUGE Mode onlyTransporting and Storage of the MULTI-WELD Cable HandlingProtection Features MULTI-WELD Table of Contents Accessories Section OPTIONS/ACCESSORIES AccessoriesSemiautomatic Welding Accessories Connection of Lincoln Electric Wire FeedersTo Work MULTI-WELD Table of Contents Maintenance SectionSection D-1 Maintenance MaintenanceSee additional warning information throughout this manual Figure D.2 Major Component Locations ServiceMULTI-WELD Table of Contents Theory of Operation Section General Description Theory of OperationFigure E.3 Power Modules and Feedback Power Modules and FEED- BackAnalog Control Power Supply Board and Weld Control Board Figure E.5 Mode Selector and Output Controls Mode Selector and Output ControlsOVER-VOLTAGE Protection Insulated Gate Bipolar Transistor Igbt Operation 8E-8 Pulse Width Modulation70-80VDC Chopper Technology FundamentalsMULTI-WELD Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board can be damaged by static electricity PC Board Troubleshooting ProceduresPower Supply Board Test Troubleshooting GuidePerform the DC Buss Supply Board TestPerform the Input Contactor SpecificationsCoil Resistance and Supply Voltage TestTest Input Voltage and ResistanceFunction Problems Analog Control Power Supply Board Test Tion and Adjustment TestSee the Digital Meter Calibra Perform the DC Buss Supply Welding Problems Troubleshooting & Repair Troubleshooting & Repair Case Cover Assembly Removal Replacement Procedure Test DescriptionMaterials Needed Replacement Procedure Removal ProcedurePower Module Capacitor Discharge Procedure Figure F.2 Power Module Capacitor Terminal Discharge ProcedureInput Contactor Coil Resistance and Supply Voltage Test Perform the Power Module Capacitor Discharge procedure Coil Test ProcedureInput Contactor Coil Resistance Supply Voltage Test Leads #303A #330Supply PC Board Test Test for Contact ContinuityAnalog Control Power Supply PC Board Test Figure F.4 Analog Control Power Supply PC Board Test ProcedurePower Supply PC Board Test DC Buss Power Supply PC Board Test P46 P47 DC Buss Power Supply PC BoardTable F.2 DC Buss Power Supply PC Board Voltage Table Chopper PC Board Input Voltages and Resistance Test Chopper PC Board Input Voltages Resistance Test Figure F.6 Power Module Assembly DetailsPower Module Capacitor Discharge Procedure Test Procedure for the Left Side Power ModuleCC Mode Input Voltage Applied 75 VDC Scope SettingsNormal Open Circuit Voltage Waveform CV Mode Output Control AT Maximum Normal Weld Voltage Waveform Machine Loaded to 350 Amps AT 34 Volts CC-STICK ModeMachine Loaded to 350 Amps AT 34 Volts CV Mode CV Mode Output Control AT Minimum Description Case Front Assembly Removal and ReplacementReplace the case cover Weld Control or Peripheral PC Board Removal and Replacement Figure F.8 Case Front Assembly Details Replacement Procedure Description Lens Bezel Spacer Seal Knob Digital Meter Removal ProcedureRefer to Figure F.9 Output Control Potentiometer Removal ProcedureInput Contactor Removal and Replacement Lead #331 Figure F.10 Input Contactor Assembly DetailsReplacement Procedure Input Diode Removal and Replacement Figure F.11 Input Diode Assembly Details Refer to Figure F.11 25-27 300-324FAN Motor Assembly Removal and Replacement Figure F.12 FAN Motor Assembly Details Perform the Input Diode Removal proce- dure Perform the Input Diode Replacement procedurePower Capacitor Removal and Replacement Figure F.13 Power Capacitor Mounting Details Reassembly Chopper PC Board and Diode Module Removal and Replacement Removal Chopper PC Board Removal and ReplacementRefer to Figure F.14 ReplacementFigure F.15 Diode Module Mounting Details Diode Module Removal and ReplacementRefer to Figure F.15 Figure F.16 Diode Module Tightening Sequence Idle Amps Retest After RepairOpen Circuit Voltages Load TestTable of Contents Electrical Diagrams Section Electrical DiagramsWiring Diagram MULTI-WELD MULTI-WELD 350 Wiring DiagramSchematic Control PC Board #1 Schematic Control PC Board #2 Schematic Control PC Board #3 Schematic Control PC Board #4 Schematic Control PC Board #5 RESISTOR,SMD,1W,243OHMS,1% PC Board ASSEMBLY-CONTROLSchematic Peripheral Printed Circuit Board PC Board Reference Description Designators PC Board ASSEMBLY-PERIPHERALSchematic Power Printed Circuit Board Return to Section Return to Section TOC To Section TOC PC Board ASSEMBLY-POWERSchematic Analog Printed Circuit Board PC Board ASSEMBLY-ANALOG Schematic BY-PASS Printed Circuit Board PC Board Assembly BY-PASS 19303 M Schematic Chopper Printed Circuit BoardPC Board Assembly Chopper SVM Error Reporting Form