Lincoln Electric SVM152-A manuals
Power Tools > Welding System
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Lincoln Electric SVM152-A Service Manual
155 pages 3.91 Mb
SVM152-AJULY, 2000Copyright 2000 Lincoln Global Inc. World's Leader in Welding and Cutting Products View Safety Info View Safety Info View Safety Info View Safety InfoATTENTION INVERTEC V350-PRO For use with machine code numbers 10651, 10669 SERVICE MANUAL INVERTEC V350-PROWARNING REMOTEPOWER A VVOLTS OUTPUT LINCOLN ELECTRIC WARNING WARNING AVISO DE PRECAUCION RETURN TO MAIN INDEX Sales and Service through Subsidiaries and Distributors Worldwide i FOR ENGINE powered equipment. 2 WARNINGELECTRIC AND MAGNETIC FIELDS may be dangerous 3 ARC RAYS can burn.ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. 4 FOR ELECTRICALLY powered equipment.CYLINDER may explode if damaged. WELDING SPARKS can cause fire or explosion. 5 PRCAUTIONS DE SRETPRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 6 MASTER TABLE OF CONTENTS FOR ALL SECTIONS11 - OPERATION SECTION -17 - ACCESSORIES SECTION -CONNECTION OF LINCOLN ELEC- TRIC WIRE FEEDERS 18 + -NOTE: Illustation shows electrode connected for negative polarity. Figure C.1 V350-PRO/LN-25 ACROSS THE ARC CONNECTION DIAGRAM CONNECTION OF THE LN-25 TO THE V350-PRO ACROSS THE ARC WITH OPTIONAL 6 PIN K857 REMOTE CON- TROL. 19 + -To Wo rk Electrode Cable NOTE: Illustration shows electrode connected for negative polarity. Figure C.2 V350-PRO/LN-25 ACROSS THE ARC CONNECTION DIAGRAM WITH K857 REMOTE CONTROL 6 pin Amphenol LN-25 Wire Feeder Work Clip Lead To Wo rk K857 Remote Control CONNECTION OF THE LN-25 WITH K431 REMOTE OPTION TO THE V350-PRO. Figure C.3 LN-25 with K431 Remote Option to the V350-PRO 20 - +NOTE: Illustration shows electrode connected for positive polarity. CONNECTION OF THE K867 ADAPTER FOR USE WITH LN-25 WITH K431 OPTION/V350-PRO. Figure C.4 Connection of LN-25 to V350-PRO using K867 adapter. 21 - +CONNECTION OF THE LN-7 TO THE V350- PRO USING K480 CONTROL CABLE (SEE FIGURE C.5) Figure C.5 V350-PRO/LN-7 with K480 Control Cable Connection Diagram 22 - +K480 CONTROL CABLE TO WORK 6 PIN AMPHENOL TO LN-7 INPUT CABLE PLUG OPTIONAL K857 REMOTE CONTROL ELECTRODE CABLE TO WIRE FEED UNIT CONNECTION OF THE K867 ADAPTER FOR USE WITH THE K291 OR K404 INPUT CABLES AND LN-7. 1. Insulate each unused lead individually. 2. Splice leads and insulate. Figure C.6 Connection of LN-7 to V350-PRO using K867 adapter. 23 - +CONNECTION OF THE LN-742 TO THE V350-PRO (SEE FIGURE C.7) Figure C.7 V350-PRO/LN-742 Connection Diagram 24 + -14 PIN AMPHENOL TO WORK TO LN-742 INPUT CABLE PLUG K591 CONTROL CABLE ELECTRODE CABLE TO WIRE FEED UNIT(24/42VAC) AT REAR OF MACHINE CONNECTION OF THE LN-10 TO THE V350- PRO USING THE K1505 CONTROL CABLE. 25 + -31 -THEORY OF OPERATION SECTION-39 TROUBLESHOOTING & REPAIR SECTION56 - + - +60 #207AC B #207 #209A3/16" ALLEN BOLTS FRONT REAR 64 J42 J41 J4365 POWER BOARD TEST (CONTINUED)CHECK POINT LOCATION TEST OR IDENTITY PLUG PIN NO. LEAD NO. DESCRIPTION CONNECTOR NORMAL ACCEPTABLE VOLTAGE READING 408 (+) 410 (-) 411 (+) 410 (-) 403 (+) 401 (-) 406 (+) 405 (-) 402 (+) 401 (-) 438 (+) 431 (-) 412 (+) 410 (-) 15 VDC 65 (+) 66 (-) 38-42 VDC 67 OUTPUT DIODE MODULES TEST68 OUTPUT DIODE MODULES TEST (continued)CONTR OUTPUT TERMINALS WELD m LOCAL ONSELECT -FLUX CORED -WIRE TIG GT CC-STICK CRISP CC-STICK SOFT ARC CONTR WELD MODE T ST HO FIGURE F.5 Machine Output Terminals OFF ON HO T ST ARTWELD MODE ARC CONTR OLCC-STICK SOFT CC-STICK CRISP TIG GT AW -WIRE -FLUX CORED SELECT TE ON TE LOCAL WELD TERMINALS OUTPUT CONTR MPS A V NEGATIVE OUTPUT TERMINAL POSITIVE OUTPUT TERMINAL 69 - PROBE 70 LEFT SIDE 76 Plug J8802 801 804 806 80 Fan Lead Lead Com 2Fan Lead Lead 115 B Plug J22 81 Lead 716-FAN CONTROL AND MOTOR TEST (continued) Lead 715+ Plug J20 92 Right Side93 Right SideMounting Screws 96 Display BoardStatus Board Mode Board97 F-59 F-59FIGURE F.22 CASE FRONT SCREW LOCATIONTS MPS CONTR OUTPUT TERMINALS WELD m LOCAL ONSELECT -FLUX CORED -WIRE TIG GT CC-STICK CRISP CC-STICK SOFT OL ARC CONTR WELD MODE AR Input Power Switch Screws Welder Output Terminal Screws 5/16" ScrewsOFF ON HOT STAR TWELD MODE ARC CONTR OLCC-STICK SOFT CC-STICK CRISP TIG GT AW -WIRE -FLUX CORED SELECT ON LOCAL WELD TERMINALS OUTPUT CONTR MPS A V 99 MAIN SWITCH BOARD REMOVAL AND REPLACEMENTMAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued) 100 - + - +101 - + - +- + - +MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued) DEPRESS LOCKING TAB ON MOUNTING PIN 104 Display BoardStatus Board Mode BoardF-67 F-67 FIGURE F.27 CASE FRONT SCREW REMOVALVTS MPS CONTR OUTPUT TERMINALS WELD m LOCAL ONSELECT -FLUX CORED -WIRE TIG GT CC-STICK CRISP CC-STICK SOFT ON OFF 105 Input Power Switch ScrewsWelder Output Terminal Screws 5/16" ScrewsOFF ON HOT STARTWELD MODE ARC CONTROLCC-STICK SOFT CC-STICK CRISP TIG GT AW -WIRE -FLUX CORED SELECT ON LOCAL WELD TERMINALS OUTPUT CONTR MPS A 106 5/16" Screws 107 Small Flathead Screwdriver110 Display BoardStatus Board Mode BoardF-73 F-73 MPSmSELECT -FLUX CORED -WIRE TIG GT CC-STICK CRISP CC-STICK SOFT OL ARC CONTR WELD MODE AR T ST HO FIGURE F.31 FRONT SCREW REMOVAL 111 Input Power Switch ScrewsWelder Output Terminal Screws 5/16" ScrewsOFF ON HO T ST AR TWELD MODE ARC CONTR OLCC-STICK SOFT CC-STICK CRISP TIG GT AW -WIRE -FLUX CORED SELECT REMOTE ON REMOTE LOCAL WELD TERMINALS OUTPUT CONTROL SELECT SELECT A V 113 SNUBBER BOARD REMOVAL AND REPLACEMENTSNUBBER BOARD REMOVAL AND REPLACEMENT (continued) 114 LEFT SIDE116 LEFT SIDEPOWER BOARD 130 LEFT SIDE FOUR 3/8" MOUNTING BOLTS 134 +503 SNB N M MODE PANEL N M 610605 ~ + +J1 J2 J31 608 612 L1 REACTOR CHOKEELECTRICAL SYMBOLS PER E1537 _BRIDGECOLOR CODE: B = BLACK G = GREEN R = RED U = BLUE Y = YELLOW 903 XFMR AUXILIARY WIRING DIAGRAM - INVERTEC V350-PROJ11 C1,C3 804 C2,C4 +J8 J7 J6 J5 J4 J3 CB1 L CONTROL POT( 380-575VAC POSITION ) 6-2-2000A REAR OF MACHINE LEFT SIDE OF MACHINE FAN MAIN XFMR RECONNECTNOTES :N.A. 1. FOR MACHINES SUPPLIED WITH INPUT CABLE A B WIRING DIAGRAM INVERTEC V350-PRORIGHT SIDE OF MACHINE D I S P L A Y C N T SWITCHH5 H6 H4 H1 901903 802 806 801 W = WHITE N = BROWN INPUT +B E FC D PRIMARY OUTPUT RECTIFIER CURRENT TRANSDUCER L2 REACTOR INPUT PER N.A. } M T P W GAS SOLENOID 115V WIRE FEEDER +CONTROL RECTIFIER 6 PIN 100 A CIRCUIT BREAKERN.C.A B C J K L D E H G F J21 J20 R1 S1CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD) J43, J331 J8, J20,J21 J9, J42, P53 J2,J5,J11, J22, J41, J311, P55 J31,J33, J34,J37 J1,J6,J7, P52 CB2S N U B B E R BASE CASE FRONT PROTECTIVE BONDING CIRCUIT A B C J K L D E H G F 24/42V WIRE FEEDERJ22 1001,1002, 1010,1020 21,21B,2A,4A, 75A,76A,77A 506 505 506 J10A, J10B G-2 135 ELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE206 208 202 RECONNECT SWITCH + MAIN TRANSFORMER206 208 202 RECONNECT SWITCH + MAIN TRANSFORMER POWER BOARDSWITCH BOARD 203 207 201 204 209 205 CONTROL BOARD POWER BOARDSWITCH BOARD 203 207 201 204 209 205 CONTROL BOARD 6 - 2 - 2000A G-3 ENHANCED WIRING DIAGRAM 136 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #13789-1D0/1BANK1R174 R21 R9 R36 R242 R257 R258 R259 R260 R261 C90 D77 D76 D115 D114 (2,3,4) Q9 Q10 LED7 Q4 Q7 Q5 Q6 GDATE: SCALE: SUBJECT: EQUIPMENT TYPE: DRAWING No.: INVERTER WELDERS DIGITAL CONTROL SCHEMATICD19 C110 C13 C46 C2 C107 C119 C104 C94 C12 Q1 J4MICRO_CONTROLLER X24 X25 CPLD (1) (1,4) (2,4) (3,4) (3,4) D8 D7 D5 D2 D24 D29 D6 D31 D9 D30 D17 D32 D15 D44 D18 D25 C135 C122 C123 C6 C72 C69 C5 C70 C71 C3 C74 C15 C18 C4 C43 C67 C25 C44 C22 C99 C108 C27 C68 C73 C105 C106 C120 C109 C93 C113 C111 C11 C14 C136 C143 D3 D4 Q15R84 R85 R168 R169 R35 R38 R100 R99 R33 R2 R3 R34 R16 R18 R10 R19 R17 R42 R14 R43 R37 R39 R81 R88 R87 R183 R20 R90 R8 R32 R47 R15 R46 R51 R11 R41 R187 R179 R172 R170 R171 G-4 137 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #23789-1D0/2C16 Q2 CAN COMMUNICATION CIRCUITRY ISOLATION BARRRIER FULL DUPLEX RS232 COMMUNICATION LINKSTATUS LED CIRCUITRY GROUND TIE POINT R195 R178 R177 R193 R190 R194 R191 R132 R133 R192 R167 R166 R165 R13 R12 R1 R31 R89 R82 R134 R163 R131 R52 R196 R198 R197 R30 Q17 Q16 Q13X29 C103 C121 C101 C118 C116 C117 C64 C89 C115 C88 C91 C92 D62 D61 D60 D53 D52 D58 D59 D27 D26 D14 D13 D12 D16 D43 D1 D46 D11 OCI4 OCI3 CAN AN82527 Y1 J2 4J2LED8 LED1 LED5 LED3 LED2 LED4 LED6 Q3C102 C66 C62 C65 C63 C1 C9 C10 C45 C39 C40 C61 PW1 PW2 G-5 138 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #33789-1D0/3D47 D28 D54 D34 Q18 X1 J10BD40 D42 D38 D36 DZ1 DZ4 DZ2 DZ3 D100 D98 D101 R160 R63 VOLTAGE FEEDBACK ON CONNECTOR SAWTOOTH GENERATOR PRIMARY CURRENT SENSE INPUT FROM 2nd LEM STT CURRENT FLOW I>56A = HI I<56A = LO 3500 VOLTS 1<GAIN<11 A/D CONVERSION CURRENT LIMIT SECONDARY CURRENT SENSE R25 R113 R27 R24 R28 R23 R26 R53 R22 R61 R29 R55 R111 R110 R146 R66 R67 R62 R106 R59 R48 R49 R108 R102 R44 R118 R122 R109 R139 R123 R115 R112 R60 R119 R117 R56 R57 R140 R130 R125 R126 R124 R45 R151 R154 R157 R148 R161 R158 R155 R152 R149 R70 R74 R76 R80 R78 R72 R107 R142 R143 R144 R103 R58 R213 R214 R216 R217 D56 D55 D51 D57 D99 C28 C82 C7 C85 C8 C80 C50 C23 C21 C17 C51 C19 C58 C56 C52 C32 C26 C35 C36 C38 C37 C60 C59 C127 C128 C129 D35 D37 D41 D39 J10A E1X31 X13 X20 Q12 C49 C54 D50 D33 D49 X12 X5 X7 G-6 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #43789-1D0/4(1,2) (2) (1) (3) BD ID=03 R83 R86 R182 R184 R104 R137 R221 R222 R251 C96 C98 C100 C48 C77 C76 C75 C79 C78 C130 D45 X22 XILINX XCS20-3PQ208I 139 X18FPGAC97 C47 D102BAV99LT1 D107BAV99LT1 D106BAV99LT1 D105BAV99LT1 D104BAV99LT1 D103BAV99LT1 X11 G-7 140 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-CONTROL V10 N.E. N.J. PART NO.OTHER COMPONENT SIDE (BACKSIDE) TEST PER E3856-C L11088-1D0 BUYPER E386711088-1APPROVED: NONE 4-6-99 F.V. T. O'DONNELUNLESS OTHERWISE SPECIFIED TOLERANCE Chg. Sheet No. INVERTER WELDERS CONTROL P.C. BOARD AS'BLYSUPERSEDING: "X" INFO. XE-UF BUY AS IDENTIFICATION CODECAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTANCE = OHMS N.B. N.A. N.J. N.J. G-8 141 ELECTRICAL DIAGRAMS SCHEMATIC - POWER SUPPLYPRINTED CIRCUIT BOARD.022/50V LABELSCOMMON CONNECTION FRAME CONNECTION VOLTAGE NETSUPPLY POWER SUPPLY SOURCE POINT EARTH GROUND CONNECTION 6-2-2000A NONE 11-30-98 GENGINEER: DATE:ON 3 PLACE DECIMALS IS .002 DO NOT SCALE THIS DRAWINGMANUFACTURING TOLERANCE PE R E2056 EN-170 Gate Drive.750 Amp 10-55 VDC Operation Machine Control DC Input (-) DC Input (+) RS232 Shutdown <30VDC Detect Undervoltage Overvoltage CAN +5Volts, .100 AmpShut Down Capacitor 15Volts, .250Amps SPI +5Volts, 3 Amps SPI +5Volts, .750 Amp Machine Control Power Supply+15Volts -15Volts, .100Amp .200 Amps Gate Drive +20Volts +20Volts .200 AmpsUNLESS OTHERWISE SPECIFIED TOLERANCE SCALE:DRAWN BY:WITH PUBLISHED STANDARDS. ON 2 PLACE DECIMALS IS .02 MATERIAL TOLERANCE (" ") TO AGREE ON ALL ANGLES IS .5 OF A DEGREE SUBJECT: EQUIPMENT TYPE: DRAWING No.: Digital Power SupplyREFERENCE:SUPERSEDING: Chg. Sheet No."X" INFO. XM5626 XBCAPACITORS = UNLESS OTHERWISE SPECIFIED) DIODES = FILENAME: G3631-2D0MFD ( GENERAL INFORMATIONUNLESS OTHERWISE SPECIFIED) RESISTORS = Ohms ( (UNLESS OTHERWISE SPECIFIED)1A, 400V ELECTRICAL SYMBOLS PER E1537 1/4W G-9 142 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-POWER SUPPLYReturn to Master TOC Return to Master TOC Return to Master TOC Retur n to Master TOCN.A. 2 (6.14) N.E. N.F. 55 45 51 56 HEATSINK MOUNTING DETAILPART NO. TEST PER E3856-P G3632-2D0 BUY PER E3867 GSUBJECT: DATE:DO NOT SCALE THIS DRAWING EN-170 SCALE: EQUIPMENT TYPE: DRAWING No.: DIGITAL POWER PC BD. ASBLY. BUY AS IDENTIFICATION CODECAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTANCE = OHMS V G-10 144 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-SWITCHITEM REQ'D PART NO. IDENTIFICATION N.P. N.L. A1 V35 G3830- A2 EYELET DETAIL .285 NON-COMPONENT SIDE G3830-1B16-2-2000A 3830-1B1APPROVED: FULL 5-11-2000 F.V./JB ON 3 PLACE DECIMALS IS .002 DO NOT SCALE THIS DRAWINGMANUFACTURING TOLERANCE PE R E2056 EN-170SOLID EDGEUNLESS OTHERWISE SPECIFIED TOLERANCE DRAWN BY:WITH PUBLISHED STANDARDS. ON 2 PLACE DECIMALS IS.02 MATERIAL TOLERANCE (" ") TO AGR EE ON ALL ANGLES IS .5 OF A DEGREE Chg. Sheet No. ENGINEER: SWITCH P.C. BOARD ASSEMBLYREFERENCE:SUPERSEDING: "X" INFO. XM5626 XA CAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTOR = OHMS MANUFACTURED AS: IDENTIFICATION CODE MAKE PER E1911 ENCAPSULATE WITH E1844, 3 COATS TEST PER E3817-SWPART NO.N.E., N.F. .105 HEIGHT .275 B205 T3 A1 B201 SWITCH 1 T2 0 5 4 3 1 2 N.N. (2 PLACES) N.H. (2 PLACES) N.D. (16 PLACES) N.K. (4 PLACES) N.K. (4 PLACES) N.B., N.G., N.M. (5 PLACES) N.C. N.J. (8 PLACES) G-12 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-DISPLAYITEM REQ'DPART NO. DESCRIPTION .80 1.78 .50 FULL 11-19-99 SPI DISPLAY P.C. BOARD ASSEMBLYG3443-1B2 UNLESS OTHERWISE SPECIF IED: CAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTANCE = OHMS BUY AS: 146 L11130-2C0IDENTIFICATION CODE PART NO. BUY PER E3867 TEST PER E3856-D VDO NOTMIX DIFFERENT VENDORS ON THE SAME BOARD ASSEMBLY. 1.90 1.45 .12 .31 3.50 6.14 6.20 6.45 12 N.C. G-14 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-STATUSReturn to Master TOC Retur n to Master TOC Return to Master TOC Return to Master TOC 11107-2NONE 9-30-99 SPI STATUS INPUT P.C. BOARD AS'BLYCAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTANCE = OHMS BUY AS: 148 L11107-2B0IDENTIFICATION CODE PART NO. BUY PER E3867 TEST PER E3856-ST V1NOTES: 33 .00 .18 2.78 4.38 6.88 7.58 7.80 1.11 .16 G-16 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-MODE SELECTITEM PART NO. REQ'D DESCRIPTION FOR ITEMS BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS N.B. A 0N.A., N.E. N.E. CONNECTOR MUST BE GREASED WITH ITEM 4 PRIOR TO ENCAPSULATIO N. 11110-1APPROVED: SUPERSEDING: FULL 2-23-99M.D.UNLESS OTHERWISE SPECIFIED TOLERANCE Chg. Sheet No. SPI MODE SELECT P.C. BD ASSEMBLYG3443-1B2 CAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTANCE = OHM S BUY AS: 150 L11110-1A1IDENTIFICATION CODE PART NO. BUY PER E3867 TEST PER E3856-MS VN.A. 6.90 G-18 ELECTRICAL DIAGRAMS 152 L11109-1A1PC BOARD ASSEMBLY-REMOTE6-2-2000A 11109-1SUBJECT: DATE:ON 3 PLACE DECIMALS IS .002 DO NOT SCALE THIS DRAWING EN-168 SCALE:DRAWN BY: Chg. Sheet No. ENGINEER: EQUIPMENT TYPE: DRAWING No.: CAPACITORS = MFD/VOLTS INDUCTANCE = HENRIES RESISTANCE = OHMS G-20 ELECTRICAL DIAGRAMS 154 MPC BOARD ASSEMBLY-SNUBBER M19532-1A01.92 .55 0 4 MAX. EYELET DETAIL .285 COPPER SIDE 19532-1APPROVED: NONE 10-6-99 F.V. SUBJECT: DATE:ON 3 PLACE DECIMALS IS .002 DO NOT SCALE THIS DRAWINGMANUFACTURING TOLERANCE PER E2056 SOLID EDGE EN-166UNLESS OTHERWISE SPECIFIED TOLERANCE SCALE:DRAWN BY:WITH PUBLISHED STANDARDS. ON 2 PLACE DECIMALS IS .02 MATERIAL TOLERANCE (" ") TO AGREE ON ALL ANGLES IS .5 OF A DEGREE Chg. Sheet No. ENGINEER: EQUIPMENT TYPE: DRAWING No.: INVERTER WELDERS SNUBBER P.C. BOARD ASSEMBLYREFERENCE:SUPERSEDING: "X" INFO. XM5626 XC-UF N.A., N.B. .105 HEIGHT .275R .0453 2.90 0 .60 1.75 2.90 3.50 +.04 1 2 MAKE PER E1911 ENCAPSULATE WITH E1844, 2 COATS TEST PER E3817-SN MANUFACTURED AS: IDENTIFICATION CODE G-22 155 SVM ERROR REPORTING FORM
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