Lincoln Electric SVM155-A User Manual

SERVICE MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

SVM155-A

July, 2001

For use with machines having Code Numbers: 10668

MULTI-SOURCE

TM

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
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.

And, most importantly, think
before you act and be careful.

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Copyright © 2001 Lincoln Global Inc.

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SAFETY

i i

MULTI-SOURCE

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame weld­ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in posi­tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines

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SAFETY

ii ii

MULTI-SOURCE

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I 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.

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.

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.

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.

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:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

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.

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.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASES
can be dangerous.

5.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

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.

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 prod­ucts.

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.

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.

5.e. Also see item 1.b.

Mar ‘95

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SAFETY

iii iii

MULTI-SOURCE

FOR ELECTRICALLY
powered equipment.

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.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

• 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.

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.

Mar ‘95

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

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.

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.

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.

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).

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.

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.

6.h. Also see item 1.c.

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SAFETY

iv iv

MULTI-SOURCE

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

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 met­allique 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 defonc­tionnement.

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.

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.

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 rayon­nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

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.

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, pan­talons sans revers, et chaussures montantes.

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.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

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.

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.

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.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

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.

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 debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

v v

MULTI-SOURCE

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

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TABLE OF CONTENTS

- INSTALLATION SECTION -

Section A-1 Section A-1

MULTI-SOURCE

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

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INSTALLATION

A-2 A-2

MULTI-SOURCE

TECHNICAL SPECIFICATIONS - Multi-Source K1752-1

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

HEIGHT

30.8 in

781 mm

WIDTH

22.2in

565 mm

DEPTH

41 in

1040 mm

NET WEIGHT

992 lbs.

450.5 kg.

OPERATING TEMPERATURE RANGE

-40 to +122ºF

-40 to +50ºC

STORAGE TEMPERATURE RANGE

-40 to +185ºF

-40 to +85ºC

Volts at Rated Amperes

75

V

olts at Rated Amperes

75.8

Amps

533

Amps

475

Duty Cycle

100% Duty Cycle

@ 50°C (122°F)

0-650 A

INPUT - THREE PHASE ONLY

CURRENT RANGE OCV

RECOMMENDED INPUT WIRE AND FUSE SIZES

Standard Voltage/Frequency

380/415/50

400/60
440/50
460/60
550/50
575/60

99A
98A
79A
83A
66A
69A

Input Current at Rated Output

100% Duty Cycle

RATED OUTPUT

INPUT

VOLTAGE

380-415

460
575

FUSE

(SUPER

LAG)

OR

BREAKER

SIZE

(AMPS)

150 Amp
125 Amp
100 Amp

TYPE

75°C

GROUND

WIRE IN

CONDUIT

AWG(IEC-

MM2) SIZES

6 (16)
6 (16)
8 (10)

TYPE 75°C

COPPER

WIRE IN

CONDUIT
AWG(IEC-MM2)
SIZES 50°C

(122°F) Ambient

1/0 (70)

2 (35)
3 (35)

TYPE 75°C

COPPER

WIRE IN

CONDUIT
AWG(IEC-MM2)
SIZES 40°C

(104°F) Ambient

2 (35)
3 (35)
4 (25)

TYPE 90°C

COPPER

WIRE IN

CONDUIT

AWG(IEC-MM2)

SIZES 50°C

(122°F) Ambient

2 (35)
3 (35)
4 (25)

TYPE 90°C

COPPER

WIRE IN

CONDUIT

AWG(IEC-MM2)

SIZES 40°C

(104°F) Ambient

3 (35)
4 (25)
4 (25)

INPUT

AMPERE

RATING

99
83
69

HERTZ

50
60
60

Maximum Open Circuit Voltage

80V

60 Hz-40 kW

50 Hz-36 kW

SELECT PROPER LOCATION

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 mate­rial 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 nui­sance shut-downs.

STACKING

Two MULTI-SOURCE machines can be stacked.
Follow these guidelines when stacking:

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

INSTALLATION

A-3 A-3

MULTI-SOURCE

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the two holes in the base rails on the second
machine with the two pins on top at the front of the
bottom machine.

Note: The machines must be stacked with the Case

Front of each machine flush with each other.
See Figure A.1. below.

TILTING

The MUL TI-SOURCE must be placed on a stable, level
surface so it will not topple over.

ELECTRICAL INPUT
CONNECTIONS

Before installing the machine, check that the input sup­ply 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 volt­age machines.

Read entire Installation Section before installing the
MULTI-SOURCE.

SAFETY PRECAUTIONS

FIGURE A.1. - Stacking the MULTI-SOURCE

FIGURE A.2. - Input Power Supply Connection

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.

• 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.

-------------------------------------------------------------------

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.

---------------------------------------------------------------------

WARNING

STACKING HOLE

STACKING PIN

Rear Panel

W

V
U

INSTALLATION

A-4 A-4

MULTI-SOURCE

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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 ther­mal/magnetic circuit breakers.

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.

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 accom­modate 2" (trade size) conduit and fittings. This is more
than adequate for the largest conductors required.

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 volt­age supplied determines the position required for the
reconnect panel jumper. The three ranges on the stan­dard machine are 380-415, 440-460 and 550-575. The
machine is rated for 50 and 60 Hz operation. See the

Input Connection Diagram located on the inside of
Case Back Input Access Door.

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 mm

2

). National and
local codes must be consulted before connecting a
machine.

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 con­nected for the proper voltage.

Failure to follow these instructions can cause immedi­ate failure of components within the machine.

-----------------------------------------------------------

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.

CAUTION

WARNING

FIGURE A.3. - Input Connection Diagram

All input power must be electrically discon-

nected before touching reconnect panel.

1. Mount the movable reconnect bar to
the stationary reconnect panel as
shown, and secure firmly with the
three hex nuts provided.

2. Connect L1, L2, and L3 input supply
lines to the input side of the recon­nect panel as shown.

3. Connect terminal marked to ground
per national electrode code.

550-575V Connection

440-460V Connection

380-415V Connection

INPUT
LINES

L3
L2
L1

W

V

U

INPUT
LINES

L3
L2
L1

W

V

U

INPUT
LINES

L3
L2
L1

W

V

U

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.

Connection of Electrode and Work Leads to Output
terminals.

1. Set the POWER ON/OFF Toggle Switch to OFF.

2. Raise the hinged cover protecting the output termi­nals.

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 out­put 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 termi­nal following steps 3-5.

7. Lower the cover to protect the output terminals.

PARALLELING

Machines may be paralleled for increased output. The
S20428 paralleling kit permits paralleling of two MUL TI­SOURCE power supplies for supplying currents of up
to 1000 amps, 100% duty cycle.

MULTI-SOURCE OUTPUT LIMITATIONS

The number of Multi-Weld Converters that may be con­nected to a single Multi-Source Power Source is deter­mined by the following formula:

Power Source (Volts x Amps) capacity > 1.1 x Sum

of Converters’ (Volts x Amps) arcs

The number of Multi-Weld 350s, the procedures used
and the combined duty cycle of the arcs are only limit­ed 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.

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 Multi­Weld 350 converter. Six cable strain-relief ports are
provided for connection of up to (12) cables for distrib­ution or “daisy-chain” inter-connection to other boxes.
Four “pig-tail” leads (see below) are included with the
Box.

“PIG TAIL” LEADS AND CONNEC-
TIONS

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. Description:

CL012705 22in. (56cm) long 2/0 (70mm

2

) cable
with 0.5in. (13mm) hole lug and cut-off
ends.

K852-70 Twist-Mate male insulated plug for 1/0-

2/0 (50-70mm

2

) cable

K852-95 Twist-Mate male insulated plug for 2/0-

3/0 (70-95mm

2

) cable.

K1759-70 Twist-Mate female insulated recepta-

cle for 1/0-2/0 (50-70mm

2

) cable.

K1759-95 Twist-Mate female insulated recepta-

cle for 2/0-3/0 (70-95mm

2

) cable

INSTALLATION

A-5 A-5

MULTI-SOURCE

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FIGURE A.4. - Output Terminal Connections

NOTES

A-6 A-6

MULTI-SOURCE

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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

Section B-1 Section B-1

MULTI-SOURCE

OPERATION

B-2 B-2

MULTI-SOURCE

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SAFETY INSTRUCTIONS

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.

-----------------------------------------------------------

WARNING

Read and understand this entire section before
operating your machine.

OPERATION

B-3 B-3

MULTI-SOURCE

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GENERAL DESCRIPTION

The Multi-Source is designed to supply power to the
Multi-Weld welders. It has a wide range three phase
AC input and can be 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 man­ual electrode capability.

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 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 con­tactor if the limit is exceeded. The green Safe Output
light indicates when the machine output voltage is with­in the safe operating range.
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 thermo­stat 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 visi­bility in daylight.

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 nor­mal 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.

The only user controls are an on-off toggle Power
switch that energizes the machine and a 10 A cir­cuit breaker protecting the fan auxiliary against
short circuits.

RECOMMENDED
EQUIPMENT/PROCESSES

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.

The Multi-Weld 350 K1752-1 is the recommended
means by which to control the Multi-Source power sup­ply. Connections between Multi-Source and Multi­Weld 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)

is recommended for use in the Multi-Weld system.

DESIGN FEATURES AND ADVAN­TAGES

• 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 protec­tion.

• 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.

OPERATION

B-4 B-4

MULTI-SOURCE

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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.

1. ON/OFF TOGGLE SWITCH: This toggle

switch turns the machine ON or OFF.

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.

4. WHITE LED:

This

LED indicates that the

control board is energized.

5. GREEN LED:

This LED indicates that the

machines output voltage is within the safe
operating range.

6. DIGITAL METER: Provides the user with
an indication of the percentage of avail­able power.

For 1/0 Cable

K852-70

K1759-70

K852-90

K1759-90

Twist-Mate Male Connector

Twist-Mate Female Connector

Twist-Mate Male Connector

Twist-Mate Female Connector

For 3/0 Cable

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.

FIGURE B.1. - CONTROL PANEL

5

3

2

4

1

6

% Output

Output

Thermal

Fan

Power

On

OFF

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TABLE OF CONTENTS

- ACCESSORIES -

Accessories...........................................................................................................................Section C

Factory Installed Options/Accessories.......................................................................................C-2

Field Installed Options/Accessories ...........................................................................................C-2

Section C-1 Section C-1

MULTI-SOURCE

FACTORY INSTALLED OPTIONS /
ACCESSORIES

There are no factory installed options.

FIELD INSTALLED OPTIONS /
ACCESSORIES

K1735-1 Multi-Weld 350, Multi-process controller.

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.

ACCESSORIES

C-2 C-2

MULTI-SOURCE

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D-1 D-1

TABLE OF CONTENTS

-MAINTENANCE-

MULTI-SOURCE

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Maintenance .........................................................................................................................Section D

Safety Precautions......................................................................................................................D-2

Routine and Periodic Maintenance ............................................................................................D-2

Major Component Locations......................................................................................................D-3

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MAINTENANCE

D-2 D-2

MULTI-SOURCE

WARNING

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Only qualified personnel
should perform this mainte­nance.

• Turn the input power OFF at

the disconnect switch or fuse box before working
on this equipment.

• Do not touch electrically charged hot parts.

ROUTINE AND PERIODIC 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 punc­tures in the cable jacket, or any condition that
would affect the proper operation of the machine.

Perform Periodically:

Clean the inside of the machine with low pressure air
stream. Clean the following parts. Refer to Figure

D.1.

• Main Transformer.

• Electrode and Work Cable connections.

• SCR rectifier bridge and heat sink fins.

• Control Board.

• Firing Board.

• Fan Assembly.

NOTE: The fan motor has sealed bearings which

require no maintenance.

FIGURE D.1 – MAJOR COMPONENT LOCATION

MAINTENANCE

D-3 D-3

MULTI-SOURCE

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1. Case Front Assembly

2. Case back Assembly

3. Fan

4. Base

5. Sides

6. Roof

7. Rectifier Assembly

MULTI-SO

URCE

MULTI - SOURC E

OUTPUT

THERMAL FAN

POWER ON

OFF

%

OUTPUT

WARNING

!

1

2

3

4

5

6

7

NOTES

D-4 D-4

MULTI-SOURCE

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Section E-1 Section E-1

MULTI-SOURCE

FIGURE E.1 – MULTI-SOURCE BLOCK LOGIC DIAGRAM

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

TABLE OF CONTENTS

-THEORY OF OPERATION-

SURGE
NOISE
FILTER

T2

CONTROL
TRANSFORMER

T1
MAIN
TRANSFORMER

INPUT
CONTACTOR

THERMOSTAT

SWITCH

CONTROL
BOX
RECTIFIER

FAN

R
E
C
O
N
N
E
C
T

120 VAC

32 VAC

32 VAC

32 VAC

FAN VOLTAGE

CONTACTOR

CONTROL
BOARD

W

G

DIGITAL
METER

Y

LED LED LED

SCR OUTPUT RECTIFIER

GATE SIGNALS

RESISTOR
BANK

THERMOSTAT

SHUNT

TO CONTROL
BOARD

FIRING
BOARD

CONTROL
SIGNAL

FILTER
CAPACITOR

LIMITING
RESISTOR

TO CONTROL
BOARD

WORK
TERMINAL

ELECTRODE
TERMINAL

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 out­put loading and/or variations in input line voltages.
This ability provides for a consistently high stable volt­age applied to the Multi-Welds so as to provide good
manual electrode welding capability.

INPUT VOLTAGE, FILTER, CONTAC­TOR AND CONTROL TRANS­FORMER

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

has a single primary-to-secondary ratio (no taps) that
spans the full input range up to 600VAC. The sec­ondary 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 activat­ed and controlled by the control board, applies the
three phase AC input voltage to the primary windings
of the T1 main transformer.

THEORY OF OPERATION

E-2 E-2

MULTI-SOURCE

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FIGURE E.2 – INPUT VOLTAGE CIRCUIT

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

SURGE
NOISE
FILTER

T2

CONTROL
TRANSFORMER

INPUT
CONTACTOR

THERMOSTAT

SWITCH

CONTROL
BOX
RECTIFIER

FAN

T1
MAIN
TRANSFORMER

SCR OUTPUT RECTIFIER

R
E
C
O
N
N
E
C
T

120 VAC

32 VAC

32 VAC

32 VAC

CONTACTOR

DIGITAL
METER

FAN VOLTAGE

CONTROL
BOARD

G

LED LED LED

W

Y

RESISTOR
BANK

THERMOSTAT

SHUNT

TO CONTROL
BOARD

GATE SIGNALS

FIRING
BOARD

CONTROL
SIGNAL

FILTER
CAPACITOR

LIMITING
RESISTOR

TO CONTROL
BOARD

WORK
TERMINAL

ELECTRODE
TERMINAL

E-3 E-3

FIGURE E.3 – MAIN TRANSFORMER, CONTROL BOARD, COOLING FAN MOTOR, & LEDs

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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MAIN TRANSFORMER, CONTROL
BOARD, COOLING FAN MOTOR,
DIGITAL METER AND INDICATOR
LIGHTS (LEDs)

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 sec­ondary coils are connected together and the six starts
of the secondary windings are connected to the SCR
output rectifier assembly. In addition the main trans­former 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.

The control board receives a widely-varying DC volt­age 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 feed­back information from the output shunt, voltage feed­back information from the output terminals and tem­perature 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 informa­tion to the digital meter and command signals to the

cooling fan motor and the input contactor.

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.

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 ther­mostat, 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.

SURGE
NOISE
FILTER

T2

CONTROL
TRANSFORMER

INPUT
CONTACTOR

THERMOSTAT

SWITCH

CONTROL
BOX
RECTIFIER

FAN

T1
MAIN
TRANSFORMER

SCR OUTPUT RECTIFIER

R

E
C
O
N
N

E
C

T

120 VAC

32 VAC

32 VAC

32 VAC

CONTACTOR

DIGITAL
METER

FAN VOLTAGE

CONTROL
BOARD

G

LED LED LED

W

Y

RESISTOR
BANK

THERMOSTAT

SHUNT

TO CONTROL
BOARD

GATE SIGNALS

FIRING
BOARD

CONTROL
SIGNAL

FILTER
CAPACITOR

LIMITING
RESISTOR

TO CONTROL
BOARD

WORK
TERMINAL

ELECTRODE
TERMINAL

E-4 E-4

FIGURE E.4 – SCR BRIDGE, RESISTOR BANK, FIRING BOARD, & OUTPUT CAPACITOR/RESISTOR

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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SCR BRIDGE, RESISTOR BANK,
FIRING BOARD, AND OUTPUT
CAPACITOR/RESISTOR

The neutrals of the main transformer secondary wind­ings are connected together and the six starts are con­nected to the six SCR assemblies to form a six phase
output. This six phase AC output is rectified and con­trolled 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 cur­rent. 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 capac­itor ripple current (greatest with light resistive loads) is
limited by the resistor.

SURGE
NOISE
FILTER

T2

CONTROL
TRANSFORMER

INPUT
CONTACTOR

THERMOSTAT

SWITCH

CONTROL
BOX
RECTIFIER

FAN

T1
MAIN
TRANSFORMER

SCR OUTPUT RECTIFIER

R
E
C
O
N
N
E
C
T

120 VAC

32 VAC

32 VAC

32 VAC

CONTACTOR

DIGITAL
METER

FAN VOLTAGE

CONTROL
BOARD

G

LED LED LED

W

Y

RESISTOR
BANK

THERMOSTAT

SHUNT

TO CONTROL
BOARD

GATE SIGNALS

FIRING
BOARD

CONTROL
SIGNAL

FILTER
CAPACITOR

LIMITING
RESISTOR

TO CONTROL
BOARD

WORK
TERMINAL

ELECTRODE
TERMINAL

E-5 E-5

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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PROTECTION DEVICES AND CIR­CUITS

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 thermo­stat, located on the front of the main transformer iron,
should open.

Two additional thermostats (connected in series) pro­tect the machine in case of fan failure or blocked air­flow 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 trans­former iron, senses the lamination temperature (and
thus the coil insulation temperature) and will interrupt
power to the control board causing the input contac­tor to open until the iron cools.

A 10 amp circuit breaker protects the 120VAC fan cir­cuit. 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.

E-6 E-6

FIGURE E.5 SCR OPERATION

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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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 sup­ply. 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.

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 junc­tion 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 contin­ue the flow of gate current. As long as current contin­ues 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 volt­age passes through zero into the negative portion of
the sine wave. If the SCR is turned on early in the pos­itive 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.

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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

Section F-1 Section F-1

MULTI-SOURCE

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TROUBLESHOOTING & REPAIR

F-2 F-2

MULTI-SOURCE

HOW TO USE TROUBLESHOOTING GUIDE

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.

CAUTION

WARNING

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.

This Troubleshooting Guide is provided to help
you locate and repair possible machine malfunc­tions. Simply follow the three-step procedure
listed below.

Step 1. LOCATE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM (SYMP­TOMS). This column describes possible symp­toms that the machine may exhibit. Find the list­ing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into two main categories: Output Problems and
Function Problems.

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 con­ducted without removing the case wrap-around
cover.

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.

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 elec­trical wiring diagrams and schematics. Refer to
the Electrical Diagrams Section Table of Contents
to locate the appropriate diagram.

ELECTRIC SHOCK can kill.

Have an electrician install and ser­vice this equipment. Turn the
machine OFF before working on

equipment. Do not touch electrically hot parts.

Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob­lems when troubleshooting and replacing PC boards,
please use the following procedure:

1. Determine to the best of your technical ability that

the PC board is the most likely component causing
the failure symptom.

2. Check for loose connections at the PC board to

assure that the PC board is properly connected.

3. If the problem persists, replace the suspect PC

board using standard practices to avoid static elec­trical damage and electrical shock. Read the warn­ing inside the static resistant bag and perform the
following procedures.

PC Board can be damaged by
static electricity.

• Remove your body’s static
charge before opening the stat­ic-shielding bag. Wear an anti­static wrist strap. For safety,
use a 1 Meg ohm resistive cord
connected to a grounded part of
the equipment frame.

• If you don’t have a wrist strap,
touch an unpainted, grounded,
part of the equipment frame.
Keep touching the frame to pre­vent static build-up. Be sure not
to touch any electrically live
parts at the same time.

• Tools which come in contact with the PC Board
must be either conductive, anti-static or static-dis­sipative.

• 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 sta­tic-shielding bag.

• 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-shield­ing bag. This will prevent further damage and allow
proper failure analysis.

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.

NOTE: Allow the machine to heat up so that all elec-

trical components can reach their operating
temperature.

6. Remove the replacement PC board and substitute

it with the original PC board to recreate the original
problem. Recalibrate if required.

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 termi­nal strips.

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.

7. Always indicate that this procedure was followed

when warranty reports are to be submitted.

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.

TROUBLESHOOTING & REPAIR

F-3 F-3

MULTI-SOURCE

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PC BOARD TROUBLESHOOTING PROCEDURES AND REPLACEMENT

WARNING

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

Reusable
Container
Do Not Destroy

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TROUBLESHOOTING & REPAIR

F-4 F-4

MULTI-SOURCE

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

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 1­800-833-9353.

OUTPUT PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS

Major physical or electrical dam­age is evident.

1. Contact the Lincoln Electric
Service Dept.

1-800-833-9353 (WELD)

1. Contact the Lincoln Electric
Service Dept.

1-800-833-9353 (WELD)

Machine Multi-Source is dead and
the input contactor does not oper­ate. The white power light is NOT
lit.

The input contactor does not oper­ate. The white power light is ON.

1. Check for blown or missing
fuses in the input lines.

2. Check the three phase input line
voltage at the Multi-Source.
The input voltage must match
the rating plate and reconnect
panel.

1. Check the three phase input line
voltage at the Multi-Source.
The input line voltage must
match the rating plate and
reconnect panel.

2. Turn the power switch OFF and
wait a few seconds. Turn the
power switch back ON. If the
problem is not resolved, contin­ue with the “Recommended
Courses of Action”.

1. The ON/OFF switch may be
faulty. Check switch and asso­ciated leads. See the Wiring
Diagram.

2. The thermostat, located on the
rear of the main transformer
iron, may be faulty. This is nor­mally 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.

1. Perform the Input Contactor
Test.

2. Check leads #240 and #241
between the control board and
the input contactor for loose or
faulty connections. See the
Wiring Diagram.

3. Perform the Control Board

Test.

4. Perform the SCR Rectifier
Bridge Test.

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TROUBLESHOOTING & REPAIR

F-5 F-5

MULTI-SOURCE

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

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 1­800-833-9353.

OUTPUT PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS

The white power light is lit and the
input contactor activates but there
is no welding output. The amber
thermal light is NOT lit.

The Multi-Source operates but
does NOT have maximum welding
output. 40,000 watts on 60 Hz ­36,000 watts on 50HZ.

1. Check the welding cables for
loose or faulty connections.

2. Make certain the Multi-Weld(s)
are connected and operating
properly.

3. Check (at the output terminals
of the Multi-Source) for
approximately 75-80VDC open
circuit voltage. If this voltage
is present, the problem is most
likely external to the Multi­Source machine.

1. Check all three phases of the
input voltage at the Multi­Source machine. Make sure
the input voltages are present
and match the machine’s rat­ing and reconnect panel con­figuration.

2. Check for loose or faulty weld­ing cables.

1. Perform the Firing Board Test.

2. Perform the Control Board

Test.

3. Perform the SCR Rectifier
Bridge Test.

4. Perform the Main Transformer
(T1) Test.

5. Perform the Input Contactor
Test.

1. Perform the Main Transformer
(T1) Test.

2. Perform the SCR Rectifier
Bridge Test.

3. Perform the Input Contactor
Test.

4. Perform the Firing Board Test.

5. Perform the Control Board

Test.

6. The output shunt may be
faulty. See Display

Calibration Procedure.

TROUBLESHOOTING & REPAIR

F-6 F-6

MULTI-SOURCE

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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 1­800-833-9353.

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.

The Multi-Source has momentary output only. The green light is OFF and the input contactor opens.

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 ter­minals there may be a short
circuit external to the Multi­Source. Check the welding
cables and the Multi-Weld
machines.

2. If the problem is not resolved
with the welding cables
removed, there is a fault within
the Multi-Source machine.

1. Check the three phase input
voltage. Make certain it is not
too high for the machine’s rat­ing and the reconnect panel
configuration.

1. Check all heavy current carry­ing leads within the Multi­Source for possible “shorting”
conditions. See the Wiring
Diagram.

2. Perform the SCR Rectifier

Bridge Test.

3. Perform the Control Board
Test.

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.

TROUBLESHOOTING & REPAIR

F-7 F-7

MULTI-SOURCE

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TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

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 1­800-833-9353.

OUTPUT PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

OUTPUT PROBLEMS

The amber thermal light is lit. The
machine does not have welding
output, the fan runs and the digital
output display reads a value
greater than 100.

The amber thermal light is lit. The
machine does not have welding
output, and the fan runs. The dig­ital output display reads a value
greater than 100.

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 machine is being over­loaded and thus overheated.
Reduce the load to conform to
the rated output limits of the
Multi-Source machine. See
the Technical Specifications.

1. The machine may be internally
clogged with dirt and dust.
Clean the machine with clean
dry compressed air.

2. The cooling vents may be
obstructed or blocked.

3. The ambient cooling air may
be too hot.

1. Check the fan circuit breaker
located on the front panel.
Reset if tripped

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.

2. The control board may be
faulty.

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.

INSTALLATION

F-8 F-8

MULTI-SOURCE

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TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

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 1­800-833-9353.

OUTPUT PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

FUNCTIONS PROBLEMS

The Multi-Source machine will not shut off when the ON/OFF switch is in the OFF position.

1. Remove all external loading to
the Multi-Source and then
carefully remove the input
power.

1. The ON/OFF power switch
may be faulty. See the Wiring
Diagram.

2. The input contactor may be
stuck closed. Perform the

Input Contactor Test.

CONTROL TRANSFORMER (T2) VOLTAGE TEST

F-9 F-9

MULTI-SOURCE

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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 [phone] (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

WARNING

TROUBLESHOOTING & REPAIR

This procedure takes approximately 30 minutes to perform.

Control
Transformer (T2)

X3

H2

H1

X1

F-10 F-10

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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TEST PROCEDURE

1. Disconnect main AC input power to the
machine.

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.

4. Locate the Control Transformer primary
leads H1 & H2. See Wiring Diagram. See
Figure F.1.

5. Locate control transformer terminals X1 and
X3. See Figure F.1.

FIGURE F.1. CONTROL TRANSFORMER LOCATION & LEADS

CONTROL TRANSFORMER (T2) VOLTAGE TEST

F-11 F-11

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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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

Approximate Secondary

Resistance (X1-X3)

460 VAC

380 VAC

34.50 VAC

28.50 VAC

0.5 Ohms

60 Ohms

Approximate Primary

Resistance (H1-H2)

X2-X3 Thermostat

0 Ohms

43.0 VAC

CONTROL TRANSFORMER (T2) VOLTAGE TEST

F-12 F-12

CONTROL TRANSFORMER (T2) VOLTAGE TEST

MULTI-SOURCE

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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.

X3

Thermostat

X2

X1

Secondary

FIGURE F.2. Thermostat

TROUBLESHOOTING & REPAIR

F-13 F-13

INPUT CONTACTOR TEST

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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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 [phone] (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.

F-14 F-14

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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INPUT CONTACTOR TEST (Continued)

CONTACTOR
COIL

240

241

1. Disconnect the main input supply power to
the machine.

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 discon­nects may be located inside the loom (lead
covering).

4. Connect a DC ammeter to either lead #240
or #241.

Electric Shock can kill.

• 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.

5. Carefully apply the correct voltage to the

machine and turn the power switch (S1)
ON.

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.

If the current is present and the contactor
does NOT activate, then the input contac­tor coil may be faulty, or the contactor’s
moving parts may be stuck. The normal
coil resistance is approximately 4.0 ohms.

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.

The contactor may also be tested by dis­connecting leads #240 and #241 from the
coil and applying an external 120VAC sup­ply to the contactor coil. The contactor
should activate.

FIGURE F.3. INPUT CONTACTOR CONNECTIONS

WARNING

F-15 F-15

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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T3

T2

T1

U

V

W

TOP VIEW

Test Points

Test Points

Test Points

TEST FOR CONTACT
CONTINUITY

1. Disconnect the main input supply power to
the machine.

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.

4. With the contactor activated, check the
continuity across the contacts. (Zero ohms
or very low resistance is normal.) See

Figure F.4. If the resistance is high, the
input contactor is faulty. Replace the input
contactor.

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.

6. Reconnect any leads previously removed.
Replace any cable ties and loom previous­ly removed. Replace the roof and left case
side.

FIGURE F.4. INPUT CONTACTOR TEST CONNECTIONS

INPUT CONTACTOR TEST (Continued)

F-16 F-16

NOTES

MULTI-SOURCE

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F-17 F-17

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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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 [phone] (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.

F-18 F-18

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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MAIN TRANSFORMER (T1) VOLTAGE TEST (continued)

Reconnect Panel
Assembly

Input Contactor

TEST PROCEDURE

1. Disconnect main AC input power to the
machine.

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 trans­former for loose or faulty connections. See
Figure F.5.

4. Carefully apply input power, turn on and
make sure the input contactor (1CR) ener­gizes.

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

NOTE: If proper voltage is not present in any

or all of the three phases, check input
fuses and leads.

5. Test with an AC voltmeter for proper main
AC input voltage from the output side of

the input contactor (1CR). See Wiring
Diagram. See Figure F.5.

T1 to T2

T2 to T3

T1 to T3

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 con­tactor may be faulty. See Input

Contactor Test.

6. Test with an AC voltmeter for approximate­ly 97 VAC from each of the six main trans­former secondary leads to the common
buss connected to the negative output ter­minal. See Figure F.6.

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: A long wire with a clip or a long probe

may be required to reach the lower
middle lead.

FIGURE F.5. Input Contactor, Reconnect Panel, and Primary Leads to Main Transformer

Locations

T3

T2

T1

U

V

W

TOP VIEW

INPUT CONTACTOR

F-19 F-19

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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MAIN TRANSFORMER (T1) VOLTAGE TEST (continued)

Transformer
Secondary
Leads

Lift Bail

Common Buss

Transformer
Assembly

#250

#251

Phase Angle
Winding
Test Points

7. Test for 120 VAC between leads #250 to
#251. 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
entire harness. See the Wiring
Diagram.

b. If the wiring is good and the 120 VAC

is not present, then the main trans­former may be faulty.

9. Test with an AC voltmeter for 32 VAC for
each phase angle winding as shown. See
Figure F.6. See Wiring Diagram.

NOTE: If the main supply voltage varies, the

Main Transformer voltages will vary
proportionately.

10. Be sure to replace any and all insulation

materials that were removed for testing
purposes.

11. Replace roof and sides of case cover.

FIGURE F.6. Main Secondary Lead Test Points

F-20 F-20

NOTES

MULTI-SOURCE

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F-21 F-21

STATIC SCR TEST

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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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 [phone] (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.

F-22 F-22

STATIC SCR TEST (Continued)

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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1. Remove main supply power to the
machine.

2. Remove the roof and case sides.

3. Lower the front control panel.

4. Remove Plug J4 from the firing board. See
Figure F.7.

FIRING BOARD

J5
J6

J8

J4

J7

Plug J4

FIGURE F.7. FIRING BOARD LED & PLUG LOCATIONS

F-23 F-23

STATIC SCR TEST (Continued)

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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Leads

4. Using the 9/16” wrench, remove the two
positive output leads connecting the out­put bridge to the shunt. See Figure F.8.
This will partially electrically isolate the
SCR Bridge for testing purposes. See
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 resis­tance 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.

a. If a low resistance is indicated in either

direction, one of the SCRs may be
faulty. Further isolation will be neces­sary to determine which SCR is faulty.
This isolation can be accomplished by
disconnecting the transformer sec­ondary lead from the SCR under test.
See the Wiring Diagram.

FIGURE F.8. Shunt and Lead Connections

F-24 F-24

STATIC SCR TEST (Continued)

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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7. Repeat previous step(s) testing SCR 2,
SCR 3, SCR 4, SCR 5, and SCR 6.

To further check the SCRs’ functions use an
SCR tester and proceed to Active SCR Test.

8. When test is completed, reconnect the
positive bridge leads to the shunt.

9. Reconnect any secondary leads removed
from the SCRs.

10. Reconnect Plug J4 into the firing board.

11. Replace the case top, sides and control

panel.

Remove
Red Paint

Anode

Cathode

FIGURE F.9. SCR HEAT SINK TEST POINTS

F-25 F-25

ACTIVE SCR TEST

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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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 [phone] (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.

F-26 F-26

ACTIVE SCR TEST (Continued)

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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FIRING BOARD

J5

J6

J8

J4

J7

Plug J4

1. Remove main supply power to the Multi­Source.

2. Remove the roof and case sides.

3. Lower the front control panel and remove
Plug J4 from the Firing Board. See Figure
F.10.

FIGURE F.10. FIRING BOARD LED & PLUG LOCATIONS

F-27 F-27

ACTIVE SCR TEST (Continued)

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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Leads

4. Using a 9/16” wrench, remove the two
positive output leads connecting the out­put 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

F-28 F-28

ACTIVE SCR TEST (Continued)

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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Remove
Red Paint

Anode

Cathode

5. Remove the red insulating paint from heat
sink test points. See Figure F.12.

6. Perform test procedure as follows. Refer
to Figure F.13. Repeat test for all six
SCRs.

NOTE: Do not disassemble the heat sinks.

FIGURE F.12. SCR Heat Sink Test Points

F-29 F-29

ACTIVE SCR TEST (Continued)

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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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.

6 VOLT
LANTERN
BATTERY

SW1

R2

SW2

R1

G

A

V

SCR
UNDER
TEST

C

R1= 4 ohms/10 watts
R2= 3 ohms/10 watts

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, approxi­mately 0-5 or 0-10 volts.

BATTERY TEST

Check the battery by shorting leads (A) and
(C) and then close switch SW1. Replace bat­tery if voltage is less than 4.5 volts.

A. Connect SCR into the test circuit as

shown (A) lead to anode (C) lead to cath­ode and (G) lead to the gate.

B. Close switch SW1 (switch SW2 should

open), voltmeter should read zero. If the
voltmeter reads higher than zero than the
SCR is shorted.

NOTE: Do not disassemble the heat sinks.

8. With switch SW1 closed, close switch
SW2 for two seconds and release. The

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 bat­tery is defective (repeat battery Test
Procedure).

9. Open switch SW1, disconnect the gate
lead (G) and reverse the (A) and (C) leads
on the SCR. Close switch SW2. The volt­meter should read zero. If the voltage is
higher than zero, the SCR is shorted.

10. Replace any SCR assembly that does

not pass test.

11. When test is completed, reconnect the

positive bridge leads to the shunt.

12. Reconnect Plug J4 into the Firing Board.

13. Replace the case top, sides and control

panel.

FIGURE F.13. SCR Test Setup

F-30 F-30

NOTES

MULTI-SOURCE

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F-31 F-31

CONTROL BOARD TEST

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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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 [phone] (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.

F-32 F-32

CONTROL BOARD TEST (Continued)

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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J1

J2

J3

J5
J6

J8

Firing Board

Control Board

J4

J7

TEST PROCEDURE FOR NORMAL CON­TROL BOARD OPERATION

1. Remove main supply power to the Multi­Source.

2. Remove screws, loosen and lower the
front panel to access and inspect the con­trol 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.

WHEN THE MULTI-SOURCE IS
TURNED ON, THE OUTPUT
TERMINALS ARE ELECTRICAL­LY HOT.

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.

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(+)

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.

6. LED 2 indicates the level of the control sig­nal that is passed to the firing board. The
brightness of LED 2 is inversely propor­tional to the output of the machine. As the
control signal decreases (LED 2 gets dim­mer) the machine’s output increases. The
control signal can be measured at Plug J1­pin 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.

7. LED 3 indicates that the machine’s output
is greater than 10 amps and the control
board is developing a signal for the cool­ing fan to operate. This signal activates a
fan motor driver circuit that is incorporated
within the control board. See step 10 (LED

6).

8. LED 4 is an indication that either a ther­mostat, output current or output over-cur­rent 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.

FIGURE F.14. CONTROL BOARD LOCATION

WARNING

F-33 F-33

CONTROL BOARD TEST (Continued)

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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FIGURE F.15. Control Board with LED, Plug and Lead Locations

10. LED 6 indicates that the fan motor driver
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.

11. LED 7 will light if a positive voltage is pre­sent 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 con­trol 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 operat­ing 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.

This can be measured at Plug J1-pin 16(+)
lead #232 to Plug J1-pin 15(-) lead #233.
See Figure F.15.

13. The yellow (amber) light, located on the
front panel, will light if the “open thermo­stat” (secondary and SCR heat sink) sig­nal 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 Multi­Source. This voltage can be verified at
Plug J1-pin 3(+) lead #263 to Plug J1-pin
11(-) lead #264. This voltage will be pre­sent if only one of the thermostats are
open or an associated lead is disconnect­ed. 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.

CONTROL BOARD

J1

J2

J3

#222A

#201

#263

#231

#230
#215

#341

#232

#233
#234
#235
#264

#222D

#273

#274

F-34 F-34

NOTES

MULTI-SOURCE

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F-35 F-35

FIRING BOARD TEST

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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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 [phone] (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.

F-36 F-36

FIRING BOARD TEST (Continued)

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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J1

J2

J3

J5
J6

J8

Firing Board

Control Board

J4

J7

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.

3. Visually inspect the Firing Board for loose
or faulty connections and obvious physi­cal damage.

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.

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.

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.

7. Locate LEDs 1 thru 6. Each LED should
glow with equal brightness.

NOTE: LEDs 1 through 6 indicate that the
gate firing signals are being generated to
send to each of the output SCRs.

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.

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.

WARNING

FIGURE F.16. FIRING BOARD LOCATION

F-37 F-37

FIRING BOARD TEST (Continued)

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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TABLE F.2. - LED 7, 8 and 9 Check List

IF

LED 7 is ON

LED 7 is OFF or is DIM­MER than other LEDs

LED 8 is ON

LED 8 is OFF or is DIM­MER than other LEDs

LED 9 is ON

LED 9 is OFF or is DIM­MER than other LEDs

THEN

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.

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.

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.

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.

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.

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.

TROUBLESHOOTING & REPAIR

FIRING BOARD TEST (Continued)

F-38 F-38

MULTI-SOURCE

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FIRING BOARD

J6

J4

J7

Jumper
Plug

J5

J8

#284

#283

#286

#287

#285

#340

#215

#231

#288

FIGURE F.17. FIRING BOARD PLUG & PIN LOCATIONS

F-39 F-39

MULTI-SOURCE METER ACCURACY CHECK

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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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 [phone] (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.

F-40 F-40

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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MULTI-SOURCE METER ACCURACY CHECK (Continued)

METER ACCURACY CHECK

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.

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”.

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 sec­tion.

PROCEDURE TO RECALIBRATE IF
METER IS OUT OF RANGE

If the measured current is within the acceptable cur­rent range (approximately 533 amps DC) and the
Multi-Source digital display does not read approxi­mately “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 resis­tor R49 on the Control board may be adjusted. See
Figure F.18. for location of R49 trimmer.

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.

Note: The output shunt is rated at 50 mv @ 800 A.

J1

J2

J3

Control Board

R49

FIGURE F.18. R49 TRIMMER

F-41 F-41

NORMAL OPEN CIRCUIT VOLTAGE

WAVEFORM - NO LOAD

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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0 volts

2 ms

50 volts

This is the typical DC open circuit volt­age waveform generated from a properly
operating machine. Note that each ver­tical division represents 50 volts and that
each horizontal division represents 2 mil­liseconds in time.

Note: Scope probes connected at
machine output terminals: (+) probe to
positive terminal, (-) probe to negative
terminal.

Volts/Div.......................50 V/Div.

Horizontal Sweep......2 ms/Div.

Coupling..............................DC

Trigger..........................Internal

Scope Settings

F-42 F-42

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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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 volt­age waveform. One output SCR is not
functioning. Note the “gap” in the wave­form. One SCR gate is disconnected to
simulate an open or non-functioning out­put SCR. Each vertical division repre­sents 50 volts and each horizontal divi­sion represents 2 milliseconds in time.

Note: Scope probes connected at
machine output terminals: (+) probe to
positive terminal, (-) probe to negative
terminal.

Volts/Div.......................50 V/Div.

Horizontal Sweep......2 ms/Div.

Coupling..............................DC

Trigger..........................Internal

Scope Settings

F-43 F-43

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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TYPICAL SCR GATE VOLTAGE WAVEFORM - NO LOAD

0 volts

2 ms

1 volt

This is the typical SCR gate pulse volt­age waveform. The machine was in an
open circuit condition (no load) and
operating properly. Note that each verti­cal division represents 1 volt and that
each horizontal division represents 2 mil­liseconds in time.

Note: Scope probes connected at SCR
gate and cathode: (+) probe to gate, (-)
probe to cathode.

Volts/Div........................1 V/Div.

Horizontal Sweep......2 ms/Div.

Coupling..............................DC

Trigger..........................Internal

Scope Settings

F-44 F-44

NOTES

MULTI-SOURCE

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F-45 F-45

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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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 [phone] (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.

F-46 F-46

INPUT CONTACTOR CLEANING AND/OR REPLACEMENT (Continued)

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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T3

T2

T1

U

V

W

TOP VIEW

REMOVAL PROCEDURE

1. Disconnect input power to the machine.

2. Remove case sides and roof using a 3/8”
nut driver.

3. Label leads T1, T2, T3, U, V, W and their
respective terminals. See Figure F.19.

4. Using a 11/16” nut driver, remove the six
leads connected to the input contactor.

5. Using a 7/16” nut driver, remove the four
bolts mounting the input contactor to the
frame of the machine. Note washer posi­tions for replacement. See Figure F.20.

6. Disconnect leads 240 and 241 using quick
connects located in loom.

7. Carefully lift input contactor out of machine.

8. For contactor cleaning or inspection see

Figure F.21.

REPLACEMENT PROCEDURE

1. Mount input contactor to machine frame
using the four bolts, washers, and nuts
previously removed.

2. Reconnect leads #240 and #241.

3. Reconnect leads T1, T2, T3, U, V, W previ­ously removed.

4. Replace case sides and roof previously
removed.

FIGURE F.19. INPUT CONTACTOR (top view)

FIGURE F.20. 7/16” MOUNTING BOLTS

LEFT SIDELEFT SIDE

Mounting Bolts

F-47 F-47

INPUT CONTACTOR CLEANING AND/OR REPLACEMENT (Continued)

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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FIGURE F.21. INPUT CONTACTOR CLEANING/INSPECTION

CONTACTOR
COIL

240

241

F-48 F-48

NOTES

MULTI-SOURCE

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F-49 F-49

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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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 [phone] (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.

F-50 F-50

CONTROL BOARD REPLACEMENT PROCEDURE (Continued)

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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J1

J2

J3

J5
J6

J8

Firing Board

Control Board

J4

J7

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.

3. Disconnect plugs J2, J1, and J3 from the
control board.

4. Remove the four phillips head screws and
associated washers from the corners of
the control board. See Figure F.23.

5. Carefully remove the control board.

REPLACEMENT PROCEDURE

1. Replace the control board.

2. Mount the control board to the machine in
its proper position using the four phillips
head screws and associated washers pre­viously removed.

3. Reconnect plugs J3, J1, and J2 to the con­trol board.

4. Replace the four screws previously
removed from the front control panel.

FIGURE F.22. FRONT PANEL W/OUT COVER

J1

J2

J3

Control Board

MOUNTING SCREWS

FIGURE F.23. MOUNTING SCREW LOCATIONS

F-51 F-51

TROUBLESHOOTING & REPAIR

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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 [phone] (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.

F-52 F-52

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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FIRING BOARD REPLACEMENT PROCEDURE (Procedure)

J1

J2

J3

J5
J6

J8

Firing Board

Control Board

J4

J7

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
firing board on the left side of control box
while facing the machine. See Figure F.24.

3. Disconnect plugs J5, J8, and J4 from the
firing board.

4. Remove the four phillips head screws and
associated washers from the corners of
the firing board. See Figure F.25.

5. Carefully remove the firing board.

REPLACEMENT PROCEDURE

1. Replace the firing board.

2. Mount the firing board to the machine in its
proper position using the four phillips head
screws and associated washers previously
removed.

3. Reconnect plugs J4, J8, and J5 to the fir­ing board.

NOTE: Be sure plug J7 is installed in the new

board.

4. Replace the four screws previously
removed from the front access panel.

FIGURE F.24. FRONT PANEL W/OUT COVER

Firing Board

MOUNTING SCREWS

J5
J6

J8

J4

J7

FIGURE F.25. MOUNTING SCREW LOCATIONS

F-53 F-53

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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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 [phone] (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.

F-54 F-54

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE

REMOVAL PROCEDURE

1. Disconnect input power to the machine.

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.

4. Lower the control panel using a 3/8” nut
driver.

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.

LEFT SIDELEFT SIDE

9/16" Bolts

#264
#301

FIGURE F.26. Bolt and Lead Locations

Bridge
Assembly
Mount

F-55 F-55

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE

6. Using a 9/16” nut driver, remove the two
positive output leads connecting the out­put bridge to the shunt. See Figure F.27.

7. Using a 1/2” nut driver disconnect the six
copper transformer secondary leads con­nected to the SCR bridge from the main
transformer. Three leads are located on
the top and three on the bottom. See
Figure F.27.

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.

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 insula­tion, nut, bushing, and washer placement
upon removal. See Figure F.26.

12. Locate, label and remove lead #251 from
main transformer. The solder connection
must be broken to disconnect. See
Figure F.27.

FIGURE F.27. Bolt, Lead, and Shunt Locations

RIGHT SIDE

1/2" Bolts

Copper Leads

#251

Positive
Output
Leads

F-56 F-56

TROUBLESHOOTING & REPAIR

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SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE

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 alu­minum heat sinks.

UPON REASSEMBLY, THE SCR BRIDGE
ASSEMBLY MUST BE ELECTRICALLY
ISOLATED FROM GROUND. MINIMUM
ACCEPTABLE RESISTANCE TO GROUND
IS 500K OHMS.

---------------------------------------------------

FIGURE F.28. Mounting Bolt

J1

J2

J3

J5
J6

J8

Firing Board

Control Board

J4

J7

Mounting Bolt

CAUTION

F-57 F-57

TROUBLESHOOTING & REPAIR

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REMOVAL OF INDIVIDUAL
SCR HEAT SINK ASSEMBLIES

1. Using a 9/16” nut driver, remove the nuts

and respective washers securing the posi­tive buss bar in position. Remove buss
bar. See Figure F.29.

2. Using a 9/16” nut driver, remove the nut

and respective washers securing the snub­ber board and cathode heatsink to the
main assembly. See Figure F.29.

3. Carefully remove the SCR heatsink from

the mounting studs. Replacement will be
made with a new SCR assembly.

4. Replace snubber assembly if necessary.

DO NOT DISASSEMBLE THE SCR FROM
THE HEAT SINK. REPLACE THE SCR
ONLY AS AN ASSEMBLY.

---------------------------------------------------

INSTALLATION OF INDIVIDUAL
SCR HEAT SINK ASSEMBLIES

NOTE: Upon reassembly, apply a thin layer of

Lincoln T12837 (Dow Corning #340)
heat sink compound to all bolted elec­trical connections on the aluminum
heat sinks, including positive buss bar.

1. Carefully position new SCR assembly on to
heatsink mounting studs.

2. Place positive buss bar back in original
position.

3. Replace 9/16” nuts and washers previous­ly removed.

SCR BRIDGE / HEAT SINK ASSEMBLY REPLACEMENT PROCEDURE

FIGURE F.29. Individual Heatsink Removal

SCR Assembly
Mounting Studs

Anode
Heatsink

Cathode
Heatsink

Snubber
Assembly

Positive
Buss Bar

SCR
Bridge
Assembly

CAUTION

F-58 F-58

TROUBLESHOOTING & REPAIR

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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 elec­trical 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 pre­viously removed. Be sure to position insu­lation, 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 previ­ously 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 sec­ondary 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.

F-59 F-59

TROUBLESHOOTING & REPAIR

MULTI-SOURCE

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MAXIMUM OPEN CIRCUIT VOLTAGE

Open Circuit Volts

79.5/80 VDC

PERFORM METER ACCURACY TEST

RETEST AFTER REPAIR

Testing is required after the removal of any mechanical part that could affect the machine’s elec­trical characteristics, or if any electrical components are repaired or replaced.

NO LOAD READINGS (FAN OFF)

Input Volts/Phase/Hertz Maximum Idle Amps Maximum Idle KW

380/3/50 15.0 2.0
400/3/50 20.0 2.25
415/3/50 25.0 2.5
460/3/60 6.5 2.0
500/3/50 17.0 2.0
575/3/60 6.5 2.0

F-60 F-60

NOTES

MULTI-SOURCE

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MULTI-SOURCE

G-1

ELECTRICAL DIAGRAMS

G-1

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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ELECTRICAL DIAGRAMS

G-2

WIRING DIAGRAM -

G-2

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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MULTI-SOURCE WIRING DIAGRAM

INPUT SNUBBER

ASSEMBLY

L3

L2

3

POWER

L1

1

1

2

3

4

4

ELECTRICAL SYMBOLS PER E1537

CONNECTORS VIEWED FROM INSERTION END

INPUT

WELDER

BOX

PROTECTIVE BONDING CIRCUIT

H2

H1

L3

L2

L1

L3

L2

L1

BASE

W

V

U

550-575V CONNECTION

W

H2

V

H1

U

440-460V CONNECTION

W

H2

V

H1

U

380-415V CONNECTION

G

3

1

4

8

5

6

TRANSFORMER

BRACKET

L2

TO

9

6

TO T2

TO T1

12

9

6

TO T2

TO T1

11

9

6

5

10

10

11

7

8

4

5

11 10

87

54

10

7

8

4

5

1

9

CONTROL

BOX COVER

PRIMARY
COILS

10

TO
PRIMARY
COILS

TO
PRIMARY
COILS

8

16

THERMOSTAT

12

12

TO A SYSTEM GROUND PER
NATIONAL ELECTRIC CODE

1

6

H2

U

V

W

241

240

T2

X2

1CR

G4

302

REAR
TRANSFORMER

271

IRON

250

FAN

251
207

208

260

FRONT
TRANSFORMER
IRON

261

263

G1

G3

SCR5

253

SECONDARY LEAD

301

G5

215B

G6

341

LED (Y) (CENTER)

235

233

264

C1

215A

215

201

T1

1

4

7

301

264

SCR

5

8

11

2

203

204

SCR1

SCR2

T1

T1

3

205

6

206

9

12

SCR3

SCR4 SCR6

G2

1

H

X1

302

272

LED (W) (RIGHT)

230

234

LED (G) (LEFT)

232

OUTPUT
BYPASS

C2

-+

OUTPUT SHUNT

2

02

50 mV@800 A

POWER SWIT CH

S1

297

271

2

TP1

C3
820uF
500V

TP2

2

300W

222D

22C

92

294B

R9

273

+

AC

-

222A

222B

294A

CONTROL BOX
DIODE BRIDGE

274

+

AC

-

WORK

-

30

R1

300W

(BOTTOM)

293

30

R2

300W
(TOP)

+

ELECTRODE

+

L1

G1
G2
G3
G4
G5
G6

215
231

TO T1
AUXILIARIES

DIGITAL OUTPUT METER

M1M2M3M4M5M6M9

1 2 3 4 5 6 7 8 9 10

M1M2M3M4M5

1 2 3 4 5 6 7 8 9 10

201
261
263
231
202
215A
230
341
222A
260
264
235
234
215B
233
232

1
2
3
4
5
6
7
8

J1

9
10
11
12
13
14
15
16

CONTROL PC BOARD

1
2
3

J4

4
5
6

1
2
3
4
5
6
7
8

J5

9
10
11
12
13
14
15
16

FIRING PC BOARD

RESISTOR BANK

03

2

204

205

206

207

208

M7M8M9

M6

J3

J2

PARALLELING
CONNECTIONS

1 2 3 4

J6

J7

J8

R3

R4

R5

R6

R7

R8

M10

P11

J11

M10

222D

1

273

2

340

3

274

4

252

5

251

6

240

7

241

8

CB1

252
253

10 A FAN

CIRCUIT

BREAKER

1
2
3
4
5
6
7
8

284

1

283

2

286

3

285

4

288

5

287

6

240

7
8
9
10

283

284

285

286

287

288

10-13-2000

L11414

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ELECTRICAL DIAGRAMS

G-3

SCHEMATIC - CONTROL PC BOARD

G-3

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

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.

ELECTRICAL DIAGRAMS

G-4

PC BOARD ASSEMBLY-CONTROL

G-4

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PC BOARD DESIGNATORS

R33 1 S19400-6810 RESISTOR,MF,1/4W,681,1%
R34 1 S19400-3321 RESISTOR,MF,1/4W,3.32K,1%
R35,R116,R125,R153 4 S19400-2671 RESISTOR,MF,1/4W,2.67K,1%
R36 1 S24000-1500 RESISTOR,WW,3/4W,150,5%

LED3

C9

X13

C8

D1

C11

D5

T1

C10

R14

Q10

R13

R6

R 9

R10

C6

R8

C3

R7

C5

D4

C2

R 2

R 3

R4

DZ3

R5

DZ2

X11

C4

C1

R147

DZ9

D2

C7

R15

C12

X12

R 16

R 17

D3

DZ1

R129

R127

R126

R11

R12

R123

R149

R146

D48

D Z8

R1

C 63

R128

R75

X9

C53

R102

C41

C49

R131

X8

R130

C 48

R125

C 47

X7

R124

D42

Q9

D44

T P1

R120

R117

X4

C 27

C26

R83
R76

D25

D24

C35

D36

R90

C52

R122

Q2

Q8

LED7

R118

D29

R96

R95

R99

R100

C62

D35

R101

LED4

C33

X10

R121

C46

R112

R111

C44

Q5

R113

R116

D50

OCI1

R119

C45

R74
R73

R151

R81

D34

R 79

C 25

C58

R80

C 40

C54

R115

TRI1

R 84

C 29

R 93

R 67

R68

D 19

LED5

D26

D27

D30

R85

R91

R92

X5

C59

D31

R89

D32

R 32

R140

R 98

R 97

C36

R150

D 20

D 46

R145

D47

D49

Q1

X6

C50 C51

R135

C 37

R148

C38

C39

Q4

R133

LED6

D 43

DZ7

R136

R139

R64 R66

C24

C30

D21

D 33

C34

R86

R94

C32

R88
R87

R110

R144

R31

R 30

D 7

D41

D40

D 22

R52

R51

R50

R 49

R 69

R 70

D 45

R134

R138

D 23 R72

C31

Q7 Q3

R132

R71

D Z6

OCI2

R137

R60 R59

R56 R55

R57

DZ4

DZ5

R58

R62 R61

R65

R63

D17

R48

D18

C 61

R46

R47

D15

D16

C 23

R44

C57

R41
R107
R109

R143

R142

C60

D38

C56

R141

R29
R25

X1 X2 X3

C55

R40
R53

D14

R54

C21

R39
R37
R38

LED2

C 20

R114

D12

C13

R77

R78

R42

R45
R43

C43

D39

D37

R106

R108

R105

DZ10

R26 R27

C15

C16

D9

C22

R34
R35

R24

R23

C19

R21

D11

C 28

R20

D28

D6

R18

LED1

R19

G3726-2

C42

L

CONTRO

R104

R103

R28
R33

D8

C17

D13

D10

Q6

C18

D51

R152

R153

D52

R22

R36

R37,R39,R48,R89,R93 5 S19400-2211 RESISTOR,MF,1/4W,2.21K,1%
R38 1 S19400-10R0 RESISTOR,MF,1/4W,10.0,1%
R40 1 S19400-6812 RESISTOR,MF,1/4W,68.1K,1%
R41,R42,R88 3 S19400-1502 RESISTOR,MF,1/4W,15.0K,1%
R43 1 S19400-3923 RESISTOR,MF,1/4W,392K,1%
R44,R101,R107,R109,R130 5 S19400-1003 RESISTOR,MF,1/4W,100K,1%
R46,R150 2 S19400-2002 RESISTOR,MF,1/4W,20.0K,1%
R47 1 S19400-1211 RESISTOR,MF,1/4W,1.21K,1%
R49 1 S16296-3 TRIMMER,MT,1/2W,500, 10%,LINEAR
R50,R133,R134 3 S19400-7500 RESISTOR,MF,1/4W,750,1%
R51,R152 2 S19400-1001 RESISTOR,MF,1/4W,1.00K,1%
R52 1 S19400-3012 RESISTOR,MF,1/4W,30.1K,1%
R53,R73 2 S19400-2802 RESISTOR,MF,1/4W,28.0K,1%
R54,R64,R66,R123,R129 5 S19400-1000 RESISTOR,MF,1/4W,100,1%
R55,R56,R57,R58,R59,R60 8 S19400-8250 RESISTOR,MF,1/4W,825,1%
R61,R62
R67,R68,R70,R111,R112,R120 7 S19400-5621 RESISTOR,MF,1/4W,5.62K,1%
R122
R74,R79,R127 3 S19400-2001 RESISTOR,MF,1/4W,2.00K,1%
R77,R78,R103,R104,R115 5 S19400-5110 RESISTOR,MF,1/4W,511,1%
R84 1 S19400-6192 RESISTOR,MF,1/4W,61.9K,1%
R92 1 S19400-2673 RESISTOR,MF,1/4W,267K,1%
R95,R96,R97,R98 4 S19400-1623 RESISTOR,MF,1/4W,162K,1%
R99 1 S19400-5111 RESISTOR,MF,1/4W,5.11K,1%
R108 1 S19400-2213 RESISTOR,MF,1/4W,221K,1%
R119,R138 2 S19400-39R2 RESISTOR,MF,1/4W,39.2,1%
R121 1 S19400-2212 RESISTOR,MF,1/4W,22.1K,1%
R126 1 S19400-8251 RESISTOR,MF,1/4W,8.25K,1%
R128 1 T10812-62 TRIMMER,ST,1/2W,500, 10%,LINEAR
R136 1 S19400-3570 RESISTOR,MF,1/4W,357,1%
R137 1 S19400-4750 RESISTOR,MF,1/4W,475,1%
R146,R147 2 S19400-2430 RESISTOR,MF,1/4W,243,1%
R149 1 S19400-2210 RESISTOR,MF,1/4W,221,1%
T1 1 S20375-1 TRANSFORMER,PCB,PWM,FLYBACK
TP1 1 T13640-11 MOV,150VRMS,45J,14MM
TRI1 1 S18395-27 TRIAC,T220,8A,800V,WITH S18104-3HS
X1 1 S15128-16 IC,OP-AMP,QUAD,HIGH-PERF,1014
X2,X3,X4,X5 4 S15128-18 OP-AMP,QUAD, HIGH-PERF,33074
X6,X7 2 S15128-11 IC,COMPARATOR,QUAD,2901N
X8 1 S15018-9 IC,CMOS,MULTIVBRTR_MONO_DUAL_4538(SS)
X9,X10 2 S15018-13 IC,CMOS,TIMER,PROGRAMMABLE,4536(SS)
X11 1 M15458-4 IC,PWM-CONTROLLER,IMODE,2842A
X12 1 S15128-10 VOLTAGE REF,ADJ, PRECISION,431I
X13 1 S18395-3 REGULATOR,HEAT-SINKASBLY,S15128-5,S18104-3

UNLESS OTHERWISE SPECIFIED:
RESISTANCE = OHMS

ITEM

PART NO.

DESCRIPTION

J1 J2 J3

CT1

PC BOARD DESIGNATORS

C1 1 S13490-138 CAPACITOR,ALEL,1200,100V,+75/-20%
C2 1 S13490-73 CAPACITOR,ALEL,20,50V,+75/-10%
C3,C5,C6 3 S16668-4 CAPACITOR,CEMO, 2700PF, 50V,5%
C4,C16,C24,C27,C29,C31 22 S16668-11 CAPACITOR,CEMO,0.1, 50V,10%
C32,C35,C36,C44,C49,C50
C51,C52,C53,C54,C55,C56
C57,C58,C59
C7 1 S13490-121 CAPACITOR,ALEL,1000,35V,+30/-20%
C8,C9,C12,C25,C40 5 S13490-25 CAPACITOR,TAEL,4.7,35V 10%
C10 1 S13490-4 CAPACITOR,PEF,.022,200V,10%
C11 1 S13490-93 CAPACITOR,TAEL,27,35V,10%
C13,C19,C20 3 T11577-38 CAPACITOR,CD,.02,600V,+80/-20%
C15,C28,C42 3 S13490-94 CAPACITOR,PEMF,0.33,200V,10%
C17 1 S16668-3 CAPACITOR,CEMO,100P, 100V,5%
C18,C33,C34,C37,C41,C45 10 S16668-5 CAPACITOR,CEMO,.022, 50V,20%
C60,C61,C62,C63
C21 1 S16668-9 CAPACITOR,CEMO,150p, 100V,5%
C22 1 S13490-104 CAPACITOR,TAEL,39,20V,10%
C23 1 S13490-40 CAPACITOR,TAEL,2.7,50V,10%
C26 1 S13490-63 CAPACITOR,TAEL,.47,50V,10%
C30 1 S13490-66 CAPACITOR,TAEL,47,35V 10%
C38,C39 2 T11577-57 CAPACITOR,PEF,0.1,400V,10%
C43,C48 2 S13490-42 CAPACITOR,TAEL,1.0,35V,10%
C46 1 S16668-6 CAPACITOR,CEMO,4700p,50V,10%
C47 1 S16668-7 CAPACITOR,CEMO,820p,50V,5%
CT1 1 COSMETIC_TRACE COSMETIC TRACE
D1,D44 2 T12705-47 DIODE,AXLDS,4A,200V,UFR
D2,D6,D7,D8,D9,D10,D11,D12 44 T12199-1 DIODE,AXLDS,1A,400V
D13,D14,D15,D16,D17,D18
D19,D20,D21,D22,D23,D24
D25,D26,D27,D29,D30,D31
D32,D33,D34,D35,D36,D38
D39,D40,D41,D42,D45,D46
D47,D48,D49,D50,D51,D52
D3,D4,D5 3 T12705-34 DIODE,AXLDS,1A,400V,FR,1N4936
D28,D37,D43 3 T12199-2 DIODE,AXLDS,1A,1000V
DZ1,DZ8 2 T12702-11 ZENER DIODE, 1W,16V,5% 1N4745A
DZ2,DZ6,DZ9 3 T12702-52 ZENER DIODE, 1W,5.1V,5% 1N4733A
DZ3,DZ7 2 T12702-29 ZENER DIODE, 1W,15V,5% 1N4744A
DZ4,DZ5,DZ10 3 T12702-27 ZENER DIODE, 1W,10V,5% 1N4740A
J1 1 S24020-16 CONNECTOR,MOLEX,MINI,PCB,16-PIN,TIN
J2 1 S24020-8 CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN
J3 1 S24020-10 CONNECTOR,MOLEX,MINI,PCB,10-PIN,TIN
LED1,LED2,LED3,LED4,LED5 7 T13657-2 LED,T-1,3/4,RED,HLMP-3003
LED6,LED7
OCI1 1 S15000-8 OPTOCOUPLER,PHOTO-SCR,400V,MCS2401
OCI2 1 S15000-12 OPTOCOUPLER,TRIAC DRIVER,RANDM,3023
Q1,Q2,Q3,Q4,Q5,Q6,Q7 7 T12704-68 TRANSISTOR,NPN,TO226,0.5A,40V,2N4401
Q8 1 T12704-69 TRANSISTOR,PNP,TO226,0.5A, 40V,2N4403
Q9,Q10 2 S18395-5 MOSFET/HEATSINK ASBLY,T12704-61&S18104-3(SS)
R1 1 T14648-10 RESISTOR,WW,5W,1.2K,5%,SQ
R2,R3 2 S19400-3322 RESISTOR,MF,1/4W,33.2K,1%
R4,R72 2 S19400-2670 RESISTOR,MF,1/4W,267,1%
R5,R71 2 S19400-3010 RESISTOR,MF,1/4W,301,1%
R6,R80 2 S19400-6811 RESISTOR,MF,1/4W,6.81K,1%
R7,R18,R19,R23 4 S19400-1372 RESISTOR,MF,1/4W,13.7K,1%
R8 1 S19400-1503 RESISTOR,MF,1/4W,150K,1%
R9 1 S19400-1501 RESISTOR,MF,1/4W,1.50K,1%
R10,R132 2 S19400-1301 RESISTOR,MF,1/4W,1.30K,1%
R11 1 S19400-3320 RESISTOR,MF,1/4W,332,1%
R12 1 S19400-26R7 RESISTOR,MF,1/4W,26.7,1%
R13,R124 2 T12300-80 RESISTOR,WW,5W,0.5,5%
R14,R114 2 T14648-9 RESISTOR,WW,5W,2.5K,5%,SQ
R15,R139 2 S19400-1500 RESISTOR,MF,1/4W,150,1%
R16 1 S19400-6191 RESISTOR,MF,1/4W,6.19K,1%
R17,R117 2 S19400-2801 RESISTOR,MF,1/4W,2.80K,1%
R20,R21,R105 3 S19400-8252 RESISTOR,MF,1/4W,82.5K,1%
R22 1 S16296-5 TRIMMER,MT,1/2W,10K, 10%,LINEAR
R24,R25,R45,R69,R75,R76 22 S19400-1002 RESISTOR,MF,1/4W,10.0K,1%
R85,R86,R87,R90,R91,R94
R100,R102,R113,R118,R135
R141,R142,R143,R145,R148
R26,R27,R30,R81,R83,R106 6 S19400-1004 RESISTOR,MF,1/4W,1.00M,1%
R28 1 S19400-7501 RESISTOR,MF,1/4W,7.50K,1%
R29,R31,R32,R63,R65,R110 10 S19400-4751 RESISTOR,MF,1/4W,4.75K,1%
R131,R140,R144,R151

Chg. Sheet No.

XB

10-13-2000A

"X" INFO.

DESIGN INFORMATION

DRAWN BY:

MB/JB

ENGINEER:

MJK

APPROVED:

ITEM

REFERENCE:

G3742-1

SUPERSEDING:

PART NO.

EQUIPMENT TYPE:

SUBJECT:

SCALE:

CONTROL P.C. BOARD ASSEMBLY

MULTI-SOURCE

DATE:

4-20-2000

DRAWING No.:

1:1

DESCRIPTION

G

3726-2

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

ELECTRICAL DIAGRAMS

G-5

SCHEMATIC - FIRING PRINTED CIRCUIT BOARD

G-5

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

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.

ELECTRICAL DIAGRAMS

G-6

PC BOARD ASSEMBLY-FIRING

G-6

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

3742-1

G

C41

D9

SCR6

D39

D41

C22 C10 C2

LED5

R246

C29

R245

D60

D40

C21

LED6

R250

C28 C23

R249

D61

D56

D8

R220
R221
R222
R223
R224
R225 R173

D49 D29
R219

C26
R247 R186 R137
R248 R187 R138
R206

SCR5

D55
R208
R209

R210
R211
R212
R213

D47
R207

R238
R237
R202

D58

R82

R64

D42

D35

D57

D51
R168

R169
R170
R171
R172

R167

C12

R163

SCR3

R175
R176
R177
R178
R179
R180

D30

R174

R191
R190
R164

SCR4

D5

R185

C14

R184

D52

C11

R189

C15 C13

R188

D59

D6

LED3

LED4

R45

D68

LED8

D4

R46

D67

D7

D18

D17

R85
R86
R87
R88
R89
R90

D11

R84

C1

R83

SCR1

R93
R94
R95
R96
R97

R98
D12
R92

C3
R142
R141

R91

SCR2

R44

LED9

D1

D21

C43

D20

D14
R166

R165

R136

C5

R135

D15

R140

C6

R139

D36

LED7

LED1

C4

R193

LED2

G3742-1

R192

R240

D65

D66

R239

R262

R260

R256

R116

R134

C37

C35 C34

R261

R257

R264

R265

C8

Q5 Q4 Q3 Q2

C18

DZ15 DZ14

C24

D2

D3

Q7 Q6

DZ13

R258

R254

R36

C39

R18

DZ12

DZ11

DZ10

R263

R259

D50 D38

R255

R182

R194

R226 R228

R214 R196

D70

D69

D31

R195

R243 R200

R242 R199

R181

R227 R229

D53 D43

R183

C7

QU2

R201

C20

QU3

R244

C31

QU1

R160
D24
R161

C9

R162

D64

R197

C16

R198
D63

R215

C25

R216
D54

DZ2

D32

D44

DZ5

D62

DZ7

FIRING BOARD

R145 R144

SCR7

D71

R232
R233

R234

OCI1

D34

LED10

OCI2

OCI3

D16

D22

D33

R203

R143
R159
R251

DZ6

D27

D28

DZ3

R204

R230
R252

R231
R205
R266

C44

R236

DZ8

R241
R253
R235

C30

DZ1

C19

C17

C38

C40

C42

R37

R158

C32

C33

DZ4

R218

DZ9

R217

Q1

TP1

J6

J8 J5

J4 J7

C1,C3,C5,C6,C9,C12,C13,C14 19 S16668-5 .022/50
C15,C16,C23,C25,C26,C28
C29,C34,C35,C37,C44
C2,C4,C10,C11,C21,C22 6 S13490-95 .33/50
C7,C8,C18,C20,C24,C31,C33 7 S13490-108 .15/100
C17,C19 2 T11577-41 .022/400
C30 1 S13490-74 10/150
C32 1 S13490-73 20/50
C38,C40,C42 3 T11577-58 .0047/3000V
C39,C41,C43 3 T11577-46 .05/600V
D1,D4,D7,D11,D12,D14,D15 34 T12199-1 1N4004
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 26 T12199-2 1N4007
D18,D20,D21,D22,D39,D40,D41
D42,D55,D56,D57,D58,D65,D66
D67,D68,D69,D70
D71 1 T12705-46 1000V/3AMP DIODE
DZ1,DZ6,DZ9 3 T12702-52 1N4733A
DZ2,DZ5,DZ7 3 T12702-4 1N4747
DZ3 1 T12702-25 1N5357B
DZ4 1 T12702-33 1N5347B

DZ8,DZ10,DZ11,DZ12,DZ13 7 T12702-29 1N4744A
DZ14,DZ15
J4 1 S24020-6 HEADER, VERTICAL
J5 1 S24020-16 HEADER, VERTICAL

J6 1 S18248-4 HEADER
J7 1 S24020-8 HEADER, VERTICAL
J8 1 S24020-10 HEADER, VERTICAL
LED1,LED2,LED3,LED4,LED5 10 T13657-2 RED LED
LED6,LED7,LED8,LED9,LED10
OCI1,OCI3 2 S15000-10 OPTO ISOLATOR
OCI2 1 S15000-12 OPTO TRIAC DRIVER
Q1 1 T12704-80 HEXFET TRANS. (SS)
Q2,Q3,Q4,Q5,Q6,Q7 6 T12704-73 IC PKG MOSFET (SS)
QU1,QU2,QU3 3 T12707-4 2N6027
R18,R36,R64,R82,R116,R134 6 T14650-6 RESISTOR,WW,15W,5%,SQ
R37 1 T14648-15 700 5W
R44,R45,R46,R195,R227,R229 13 S19400-1002 10K 1/4W
R251,R254,R255,R258,R259
R262,R263
R83,R91,R135,R139,R163 13 S19400-1500 150 1/4W
R164,R184,R188,R202,R203
R206,R245,R249
R84,R92,R167,R174,R207,R219 6 S19400-1001 1K 1/4W

R85,R86,R87,R88,R89,R90 38 S19400-2000 200 1/4W
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

R136,R140,R160,R185,R189 9 S19400-2670 267 1/4W
R196,R214,R246,R250
R137,R138,R141,R142,R186 13 S19400-10R0 10 1/4W
R187,R190,R191,R237,R238
R247,R248,R253
R144,R145 2 T14650-1 1500 OHMS, 15W. RES
R158 1 T14648-1 5K 5W
R159,R234,R241 3 S19400-1003 100K 1/4W
R161,R197,R215 3 S19400-3323 332K 1/4W
R162,R198,R216 3 S19400-2671 2.67K 1/4W
R165,R166,R192,R193,R239 6 S19400-6190 619 1/4W
R240
R181,R199,R205,R231,R242 5 S19400-1501 1.5K 1/4W
R182,R200,R243 3 S19400-4750 475 1/4W
R183,R201,R244 3 T10812-67 100K 1/2W TRIMMER
R194,R226,R228 3 S19400-33R2 33.2 1/4W
R204,R235 2 S19400-1000 100 1/4W
R217,R232,R233 3 S19400-39R2 39.2 1/4W
R218 1 S24000-68R0 68 3/4W

R230 1 S19400-2001 2.0K 1/4W

R236 1 S19400-2002 20K 1/4W

R252 1 S19400-3321 3.32K 1/4W

R256,R260,R264 3 S19400-8251 8.25K 1/4W

R257,R261,R265 3 S19400-2211 2.21K 1/4W
SCR1,SCR2,SCR3,SCR4,SCR5 6 S15161-19 4A.,400V. SCR
SCR6
SCR7 1 S18395-21 SCR HS ASBLY
TP1 1 T13640-25 MOV,90J

CAPACITORS = MFD/VOLTS
RESISTORS = OHMS

DESCRIPTIONPART NO.ITEM REQ'D

UNLESS OTHERWISE SPECIFIED TOLERANCE

ON HOLE SIZES PER E-2056
ON 2 PLACE DECIMALS IS + .02
ON 3 PLACE DECIMALS IS + .002
ON ALL ANGLES IS + .5 OF A DEGREE

MATERIAL TOLERANCE (" ") TO AGREE
WITH PUBLISHED STANDARDS.

Ch'ge. Sht. No.

XD-UF

12-17-99

t

THE LINCOLN ELECTRIC CO.

FZ/DRS

DR.

CLEVELAND, OHIO U. S. A.

FULL

SCALE

DATE CHK. NO.

8-25-99

EQUIP.

DC-600/MULTI-SOURCE

TYPE

FIRING P.C. BOARD ASSEMBLY

SUBJECT

DRS

G2699-1,G3660-1,L9073-3

REF.

SHT.

3742-1

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.

ELECTRICAL DIAGRAMS

G-7

PC BOARD ASSEMBLY - SNUBBER

G-7

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14312-1

M

GND

NEG

M14312-1

TP7

TP8

POS

C7

C8

OUTPUT SNUBBER

CAD

Ch'ge. Sht. No.

2-19-93G

7-23-93C

THE LINCOLN ELECTRIC CO.

CLEVELAND, OHIO U.S.A.

FULL

SCALE

C.S.

DR

DATE

TRANSFORMER WELDERS

SUBJECT

8-18-92

CHK

EQUIP.

TYPE

OUTPUT SNUBBER P.C. BD. ASSEMBLY

REF.

SUP'S'D'G

SHT.

NO.

M

14312-1

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 col­umn 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 [phone]

SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________

Please give detailed description below:
___________________________________________________________________________

___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

SD287 01/99

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