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Flextec 350X Connect

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100% found this document useful (1 vote)

642 views180 pages

Flextec 350X Connect

Uploaded by

Rigoberto Delgado

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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PTC Servigistics InService

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Printed 2021-06-08 at 16:36:31

PTC Servigistics InService

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Printed 2021-06-08 at 16:36:31

Contents

AUXILIARY POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE ................................................................ 5

BOOST RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE ............................................................................... 8

BOOST RELAY REMOVAL AND REPLACEMENT PROCEDURE .................................................................................... 11

CASE COVER REMOVAL AND REPLACEMENT PROCEDURE ...................................................................................... 14

CHOKE REMOVAL AND REPLACEMENT PROCEDURE ............................................................................................... 17

CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE.................................................................... 23

FAN REMOVAL AND REPLACEMENT PROCEDURE.................................................................................................... 25

INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE .............................................................................. 30

INVERTER CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE ............................................................ 32

LINE SWITCH REMOVAL AND REPLACEMENT PROCEDURE..................................................................................... 35

MAIN CAPACITOR BOARD REMOVAL AND REPLACEMENT PROCEDURE ................................................................ 39

MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE ....................................................................... 43

MODE SELECT SWITCH REMOVAL AND REPLACEMENT PROCEDURE ...................................................................... 50

OUTPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE ........................................................................... 54

PFC BOOST BOARD REMOVAL AND REPLACEMENT PROCEDURE ........................................................................... 58

SCR (PRE-CHARGE) BOARD REMOVAL AND REPLACEMENT PROCEDURE................................................................ 63

SWITCHBOARD REMOVAL AND REPLACEMENT PROCEDURE ................................................................................. 67

THERMOSTAT #1 REMOVAL AND REPLACEMENT PROCEDURE ............................................................................... 71

USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE .................................................................. 74

AUXILIARY POWER BOARD TEST PROCEDURE......................................................................................................... 76

BOOST RECTIFIER TEST PROCEDURE ........................................................................................................................ 80

BOOST RELAY TEST PROCEDURE .............................................................................................................................. 85

CAPACITOR DISCHARGE PROCEDURE ...................................................................................................................... 88

CHOKE TEST PROCEDURE .......................................................................................................................................... 92

CURRENT TRANSDUCER (LEM) TEST PROCEDURE.................................................................................................... 94

FAN AND F.A.N. CIRCUIT TEST PROCEDURE ............................................................................................................ 98

INPUT RECTIFIER AND SCR (PRE-CHARGE) BOARD TEST PROCEDURE .................................................................. 102

INVERTER CONTROL BOARD TEST PROCEDURE..................................................................................................... 106

LINE SWITCH TEST PROCEDURE ............................................................................................................................. 111

MAIN CAPACITOR BOARD TEST PROCEDURE ........................................................................................................ 115

i
MAIN TRANSFORMER TEST PROCEDURE................................................................................................................ 118

MODE SELECT SWITCH TEST PROCEDURE .............................................................................................................. 122

OUTPUT RECTIFIER ASSEMBLY TEST PROCEDURE ................................................................................................. 126

PFC BOOST BOARD TEST PROCEDURE.................................................................................................................... 130

RETEST AFTER REPAIR ............................................................................................................................................. 134

SPECIAL TESTING MODES........................................................................................................................................ 136

SWITCHBOARD TEST PROCEDURE .......................................................................................................................... 146

THERMOSTAT #1 AND #2 CIRCUIT TEST PROCEDURE ........................................................................................... 154

USER INTERFACE BOARD TEST PROCEDURE .......................................................................................................... 160

General Description ................................................................................................................................................ 165

Input Section ........................................................................................................................................................... 166

Insulated Gate Bipolar Transistor (IGBT) Operation ........................................................................................... 167

Inverter Control Board And Switchboard............................................................................................................. 168

Main Transformer ................................................................................................................................................... 169

Output Rectifier And Choke................................................................................................................................... 170

Pulse Width Modulation......................................................................................................................................... 171

Thermal Protection ................................................................................................................................................. 173

User Interface (UI) Board....................................................................................................................................... 174

TROUBLESHOOTING GUIDE .................................................................................................................................... 176

USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS........................................................................ 179

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AUXILIARY POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE

WARNING:
Type of Hazard:
Service and repair should only be performed by 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.
How to avoid:
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 1-888-935-3877.

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Auxiliary Power Board.

MATERIALS NEEDED
○ 3/8” Nutdriver
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Label and disconnect plugs J45, J47 and J49 from the auxiliary power board. See Figure F.1. See Wiring
Diagram.
5. Using a 3/8” nutdriver, remove the four nuts securing the auxiliary power board to the PFC board bracket. See
Figure F.2.
6. The auxiliary power board can now be removed from it’s mounting posts and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Carefully position the new auxiliary power board into the machine.
2. Using a 3/8” nutdriver, attach the four nuts securing the auxiliary power board to the PFC board bracket.
3. Connect plugs J45, J47 and J49 to the auxiliary power board. See Wiring Diagram.
4. Perform the Case Cover Replacement Procedure.
5. Perform the Retest After Repair Procedure.

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Figure 1. Auxiliary power board plug locations

Auxiliary power board plug locations

0000178381_x.png

Figure 2. Auxiliary power board mounting nut locations

Auxiliary power board mounting nut locations

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0000178380_x.png

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BOOST RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Boost Rectifier.

MATERIALS NEEDED
○ Torx Nutdriver (Size T-20)
○ 7/64” Allen Wrench
○ Penetrox Heat Sink Compound (Lincoln Part #T12837-1)
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Using a torx nutdriver (size T-20), remove the four screws, lock washers and flat washers securing leads 202A,
202B, X21, POS and NEG to the boost rectifier. See Figure F.1. See Wiring Diagram. Label and disconnect
leads.
5. Using a 7/64” Allen wrench, remove the two screws and washers securing the boost rectifier to the heatsink.
See Figure F.2.
6. The boost rectifier can now be removed and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Apply a coating of Penetrox heat sink compound to the mating surfaces of the boost rectifier and the heatsink.
2. Carefully position the new boost rectifier into the machine.
3. Using a 7/64” Allen wrench, attach the two screws and washers securing the boost rectifier to the heatsink.
4. Using a torx nutdriver (size T-20), attach the four screws, lock washers and flat washers securing leads 202A,
202B, X21, POS and NEG to the boost rectifier. See Wiring Diagram.
5. Perform the Case Cover Replacement Procedure.
6. Perform the Retest After Repair Procedure.

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Figure 1. Boost rectifier lead locations

Boost rectifier lead locations

0000178468_x.png

Figure 2. Boost rectifier mounting screw locations

Boost rectifier mounting screw locations

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0000178467_x.png

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BOOST RELAY REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Boost Relay.

MATERIALS NEEDED
○ Pliers
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Label and disconnect plugs 227, 228, 110A, 110B, 202A and 202B from the boost relay terminals. See Figure
F.1. See Wiring Diagram.
5. Using pliers, remove the two cable ties securing the boost relay to the top rectifier bracket. See Figure F.2.
See Wiring Diagram.
6. The boost relay can now be removed and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Carefully position the new boost relay onto the top rectifier bracket.
2. Attach the two cable ties securing the boost relay to the top rectifier bracket.
3. Connect plugs 227, 228, 110A, 110B, 202A and 202B to the boost relay terminals. See Wiring Diagram.
4. Perform the Case Cover Replacement Procedure.
5. Perform the Retest After Repair Procedure.

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Figure 1. Boost relay terminal locations

Boost relay terminal locations

0000178454_x.png

Figure 2. Boost relay cable tie locations

Boost relay cable tie locations

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0000178473_x.png

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CASE COVER REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Case Sheet Metal Covers.

MATERIALS NEEDED
○ 5/16" Nutdriver
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Using a 5/16” nutdriver, remove the four screws and washers securing the corner caps to the left and right
case sides. See Figure F.1. NOTE: It is not necessary to remove the corner caps completely at this time.
3. Using a 5/16” nutdriver, remove the nine screws (two on top, four on the left side and three on the right side)
securing the roof to the machine. See Figures F.1 and F.2.
4. Using a 5/16” nutdriver, remove the two screws securing the right case side to the machine. See Figure F.1.
5. The case covers can now be removed.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Carefully position the right case side onto the machine.
2. Using a 5/16” nutdriver, attach the two screws securing the right case side to the machine.
3. Carefully position the roof onto the machine.
4. Using a 5/16” nutdriver, attach the nine screws (two on top, four on the left side and three on the right side)
securing the roof to the machine.
5. Using a 5/16” nutdriver, attach the four screws and washers securing the corner caps to the left and right
case sides.

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Figure 1. Corner cap, right case side and roof mounting screw locations

Corner cap, right case side and roof mounting screw locations

0000178345_x.png

Figure 2. Roof mounting screw locations

Roof mounting screw locations

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0000178344_x.png

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CHOKE REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Choke.

MATERIALS NEEDED
○ 1/2” Nutdriver
○ 3/8” Nutdriver
○ 5/16” Nutdriver
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Perform the Main Capacitor Board Removal Procedure.
5. Using a 1/2” nutdriver, remove the bolt, lock washer and flat washer securing the choke lead and POS lead to
the heatsink. See Figure F.1. See Wiring Diagram. Label and disconnect POS lead.
6. Using a 1/2” nutdriver, remove the bolt, lock washer and flat washer securing the choke lead to the rear of the
positive output terminal. See Figure F.2. See Wiring Diagram.
7. Using a 3/8” nutdriver, remove the nut securing the cable holder closed. Remove the leads from the holders.
See Figure F.3. See Wiring Diagram.
8. Using a 3/8” nutdriver, remove the two nuts and washers securing the heatsink holder to the PFC board
bracket. See Figure F.3.
9. Using a 5/16” nutdriver, remove the two screws securing the bottom rectifier bracket to the base. See Figure
F.3.
10. Carefully maneuver the output rectifier assembly to allow for access and removal of the choke.
11. Using a 5/16” nutdriver, remove the two screws securing the choke to the base of the machine. See Figure
F.4. See Wiring Diagram.
12. The choke can now be removed and replaced.

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REPLACEMENT PROCEDURE
Procedure Steps:
1. Carefully position the new choke into the machine.
2. Using a 5/16” nutdriver, attach the two screws securing the choke to the base of the machine.
3. Carefully position the output rectifier assembly into the machine.
4. Using a 5/16” nutdriver, attach the two screws securing the bottom rectifier bracket to the base.
5. Using a 3/8” nutdriver, attach the two nuts and washers securing the heatsink holder to the PFC board
bracket.
6. Carefully position the previously removed leads into the cable holder. See Wiring Diagram.
7. Using a 3/8” nutdriver, attach the nut securing the cable holder closed.
8. Using a 1/2” nutdriver, attach the bolt, lock washer and flat washer securing the choke lead to the rear of the
positive output terminal. See Wiring Diagram.
9. Using a 1/2” nutdriver, attach the bolt, lock washer and flat washer securing the choke lead and POS lead to
the heatsink. See Wiring Diagram.
10. Perform the Main Capacitor Board Replacement Procedure.
11. Perform the Case Cover Replacement Procedure.
12. Perform the Retest After Repair Procedure.

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Figure 1. Choke lead and POS lead connection location

Choke lead and POS lead connection location

0000178427_x.png

Figure 2. Choke lead and mounting hardware location

Choke lead and mounting hardware location

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0000178426_x.png

Figure 3. Heatsink holder, cable holder and bottom rectifier bracket

locations

Heatsink holder, cable holder and bottom rectifier bracket locations

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0000178425_x.png

Figure 4. Choke mounting screw locations

Choke mounting screw locations

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0000178424_x.png

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CURRENT TRANSDUCER REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Current Transducer (LEM).

MATERIALS NEEDED
○ 7/16” Nutdriver
○ Pliers
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Using a 7/16” nutdriver, remove the two bolts, lock washers and flat washers securing the NEG lead and the
X13 leads to the copper bar. See Figure F.1. See Wiring Diagram.
5. Using pliers, remove the cable tie securing the current transducer (LEM) to the copper bar. See Wiring
Diagram.
6. Label and disconnect the plug from the rear of the current transducer. See Wiring Diagram.
7. The current transducer (LEM) can now be removed from the copper bar and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Carefully position the new current transducer (LEM) onto the copper bar.
2. Connect the plug to the rear of the current transducer. See Wiring Diagram.
3. Using a cable tie, secure the current transducer (LEM) to the copper bar. See Wiring Diagram.
4. Using a 7/16” nutdriver, attach the two bolts, lock washers and flat washers securing the NEG lead and the
X13 leads to the copper bar. See Wiring Diagram.
5. Perform the Case Cover Replacement Procedure.
6. Perform the Retest After Repair Procedure.

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Figure 1. NEG lead, X13 lead and mounting hardware locations

NEG lead, X13 lead and mounting hardware locations

0000178460_x.png

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FAN REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Fan Assembly.

MATERIALS NEEDED
○ 5/16” Nutdriver
○ Slotted Screwdriver
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Using a 5/16” nutdriver, remove the four screws securing the brickwork fan guard to the rear of the machine.
See Figure F.1.
5. Using a slotted screwdriver, remove the two screws and washers securing the fan bracket to the machine. See
Figure F.1.
6. Label and disconnect plugs J13 and J14 from the inverter control board. See Figure F.2. See Wiring Diagram.
7. Carefully route the plugs through the grommet to allow for the removal of the fans.
8. Using a 5/16” nutdriver, remove the four screws securing each fan to the fan bracket. See Figure F.3.
9. Each fan can now be removed and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Carefully position the new fan(s) into the fan bracket.
2. Using a 5/16” nutdriver, attach the four screws securing each fan to the fan bracket.
3. Carefully route plugs J13 and J14 through the grommet. See Wiring Diagram.
4. Connect plugs J13 and J14 to the inverter control board. See Wiring Diagram.
5. Using a slotted screwdriver, attach the two screws and washers securing the fan bracket to the machine.

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6. Using a 5/16” nutdriver, attach the four screws securing the brickwork fan guard to the rear of the machine.
7. Perform the Case Cover Replacement Procedure.
8. Perform the Retest After Repair Procedure.

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Figure 1. Brickwork fan guard and fan bracket mounting screw locations

Brickwork fan guard and fan bracket mounting screw locations

0000178447_x.png

Figure 2. Inverter control board plug J13 and J14 locations

Inverter control board plug J13 and J14 locations

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0000178446_x.png

Figure 3. Fan mounting screw locations

Fan mounting screw locations

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0000178445_x.png

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INPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Input Rectifier.

MATERIALS NEEDED
○ Torx Nutdriver (Size T-25)
○ Penetrox Heat Sink Compound (Lincoln Part #T12837-1)
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Perform the SCR (Pre-Charge) Board Removal Procedure.
5. Using a Torx nutdriver (size T-25), remove the two screws and washers securing the input rectifier to the
heatsink. See Figure F.1.
6. The input rectifier can now be removed and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Apply a coating of Penetrox heat sink compound to the mating surfaces of the input rectifier and the heatsink.
2. Carefully position the new input rectifier into the machine.
3. Using a Torx nutdriver (size T-25), attach the two screws and washers securing the input rectifier to the
heatsink.
4. Perform the SCR (Pre-Charge) Board Replacement Procedure.
5. Perform the Case Cover Replacement Procedure.
6. Perform the Retest After Repair Procedure.

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Figure 1. Mounting hardware locations

Mounting hardware locations

0000178367_x.png

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INVERTER CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Inverter Control Board.

MATERIALS NEEDED
○ 3/8" Nutdriver
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Label and disconnect plugs J3, J4, J5, J6, J9, J10, J11, J12, J13 and J14 from the inverter control board. See Figure
F.1. See Wiring Diagram.
5. Using a 3/8” nutdriver, remove the two nuts securing the inverter control board to the switchboard etc panel.
See Figure F.2. Label and disconnect ground lead from lower mounting post prior to removing board. See
Wiring Diagram.
6. The inverter control board can now be removed from it’s mounting posts and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Carefully position the new inverter control board into the machine.
2. Attach ground lead to lower mounting post. See Wiring Diagram.
3. Using a 3/8” nutdriver, attach the two nuts securing the inverter control board to the switchboard etc panel.
4. Connect plugs J3, J4, J5, J6, J9, J10, J11, J12, J13 and J14 to the inverter control board. See Wiring Diagram.
5. Perform the Case Cover Replacement Procedure.
6. Perform the Retest After Repair Procedure.

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Figure 1. Inverter control board plug locations

Inverter control board plug locations

0000178422_x.png

Figure 2. Inverter control board mounting nut locations

Inverter control board mounting nut locations

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0000178421_x.png

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LINE SWITCH REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Line Switch.

MATERIALS NEEDED
○ Pliers
○ 3/8” Nutdriver
○ 5/16” Nutdriver
○ Phillips Screwdriver
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Carefully remove the cable tie, securing the plastic protective sleeve to the line switch. Move the plastic
protective sleeve flap to gain access to the rear of the line switch. See Wiring Diagram.
5. Using a 3/8” nutdriver, remove the nut, lock washer and flat washer securing the ground lead to the ground
stud on the front panel. See Figure F.1. See Wiring Diagram.
6. Using a 5/16” nutdriver, remove the two screws and washers securing the line switch to the front panel. See
Figure F.2.
7. Carefully maneuver the line switch out of the front panel. Do not remove completely from the machine.
8. Using a Phillips screwdriver, loosen the six screws securing leads L1, L2, L3 and the three input leads to the
terminals of the line switch. See Figure F.3. See Wiring Diagram.
9. The line switch can now be removed and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Using a Phillips screwdriver, attach the six screws securing leads L1, L2, L3 and the three input leads to the
terminals of the line switch. See Wiring Diagram.
2. Carefully position the new line switch into the front panel.

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3. Using a 5/16” nutdriver, attach the two screws and washers securing the line switch to the front panel.
4. Using a 3/8” nutdriver, attach the nut, lock washer and flat washer securing the ground lead to the ground
stud on the front panel. See Wiring Diagram.
5. Carefully attach the cable tie, securing the plastic protective sleeve to the line switch.
6. Perform the Case Cover Replacement Procedure.
7. Perform the Retest After Repair Procedure.

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Figure 1. Ground lead and ground stud locations

Ground lead and ground stud locations

0000178357_x.png

Figure 2. Line switch mounting screw locations

Line switch mounting screw locations

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0000178356_x.png

Figure 3. Line switch lead locations

Line switch lead locations

0000178355_x.png

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MAIN CAPACITOR BOARD REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Main Capacitor Board.

MATERIALS NEEDED
○ 7/16” Nutdriver
○ 3/8” Nutdriver
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Using a 7/16” nutdriver, remove the screw and lock washer securing leads B2 and B2A to terminal B2 on the
main capacitor board. See Figure F.1. See Wiring Diagram. Label and disconnect leads B2 and B2A from the
terminal.
5. Using a 7/16” nutdriver, remove the screw and lock washer securing leads B1 and B1A to terminal B1 on the
main capacitor board. See Figure F.1. See Wiring Diagram. Label and disconnect leads B1 and B1A from the
terminal.
6. Using a 3/8” nutdriver, remove the four nuts securing the main capacitor board to the brackets. See Figure
F.2.
7. The main capacitor board can now be removed from it’s mounting posts and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Carefully position the new main capacitor board into the machine.
2. Using a 3/8” nutdriver, attach the four nuts securing the main capacitor board to the brackets.
3. Using a 7/16” nutdriver, attach the screw and lock washer securing leads B1 and B1A to terminal B1 on the
main capacitor board. See Wiring Diagram.
4. Using a 7/16” nutdriver, attach the screw and lock washer securing leads B2 and B2A to terminal B2 on the
main capacitor board. See Wiring Diagram.

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5. Perform the Case Cover Replacement Procedure.

6. Perform the Retest After Repair Procedure.

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Figure 1. Main capacitor board terminal locations

Main capacitor board terminal locations

0000178374_x.png

Figure 2. Main capacitor board mounting nut locations

Main capacitor board mounting nut locations

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0000178393_x.png

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0000178431

MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Main Transformer.

MATERIALS NEEDED
○ Phillips Screwdriver
○ Small 3/8” Open End Wrench
○ 7/16” Nutdriver
○ Torx Nutdriver (Size T-15)
○ 5/16” Nutdriver
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Perform the SCR (Pre-Charge) Board Removal Procedure.
5. Perform the PFC Boost Board Removal Procedure.
6. Using a Phillips screwdriver and a small 3/8” open end wrench, remove the bolt, nut and two lock washers
securing the short transformer primary lead (201). See Figure F.1. See Wiring Diagram.
7. Using a 7/16” nutdriver, remove the bolt and lock washer securing lead 204 to terminal B3 of the switchboard.
See Figure F.2. See Wiring Diagram.
8. Using a 7/16” nutdriver, remove the two nuts, lock washers and flat washers securing the X11 leads to the top
output rectifier terminal. See Figure F.3. See Wiring Diagram.
9. Using a 7/16” nutdriver, remove the two nuts, lock washers and flat washers securing the X12 leads to the
bottom output rectifier terminal. See Figure F.3. See Wiring Diagram.
10. Using a torx nutdriver (size T-15), remove the screw, lock washer and flat washer securing lead X21 to the
boost rectifier. See Figure F.3. See Wiring Diagram.
11. Using a 7/16” nutdriver, remove the two bolts, lock washers and flat washers securing each pair of X13 leads
to the copper bar. See Figure F.4. See Wiring Diagram.
12. Label and disconnect leads 110 and 110A from the boost relay. See Figure F.5. See Wiring Diagram.

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13. Using a 5/16” nutdriver, remove the two screws securing the main transformer to the base of the machine.
See Figure F.6. See Wiring Diagram.
14. Carefully route the transformer leads to allow for the removal. See Wiring Diagram.
15. The main transformer can now be removed and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Carefully position the new main transformer into the machine.
2. Using a 5/16” nutdriver, attach the two screws securing the main transformer to the base of the machine.
3. Connect leads 110 and 110A to the boost relay. See Wiring Diagram.
4. Using a 7/16” nutdriver, attach the two bolts, lock washers and flat washers securing each pair of X13 leads to
the copper bar. See Wiring Diagram.
5. Using a torx nutdriver (size T-15), attach the screw, lock washer and flat washer securing lead X21 to the boost
rectifier. See Wiring Diagram.
6. Using a 7/16” nutdriver, attach the two nuts, lock washers and flat washers securing the X12 leads to the
bottom output rectifier terminal. See Wiring Diagram.
7. Using a 7/16” nutdriver, attach the two nuts, lock washers and flat washers securing the X11 leads to the top
output rectifier terminal. See Wiring Diagram.
8. Using a 7/16” nutdriver, attach the bolt and lock washer securing lead 204 to terminal B3 of the switchboard.
See Wiring Diagram.
9. Using a Phillips screwdriver and a small 3/8” open end wrench, attach the bolt, nut and two lock washers
securing the short transformer primary lead (201). See Wiring Diagram.
10. Perform the PFC Boost Board Replacement Procedure.
11. Perform the SCR (Pre-Charge) Board Replacement Procedure.
12. Perform the Case Cover Replacement Procedure.
13. Perform the Retest After Repair Procedure.

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Figure 1. Short transformer primary lead location

Short transformer primary lead location

0000178417_x.png

Figure 2. Switchboard terminal B3 location

Switchboard terminal B3 location

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0000178416_x.png

Figure 3. Transformer leads X11, X12 and X21 locations

Transformer leads X11, X12 and X21 locations

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0000178415_x.png

Figure 4. X13 lead locations

X13 lead locations

0000178414_x.png

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Figure 5. Boost relay leads 110 and 110A locations

Boost relay leads 110 and 110A locations

0000178433_x.png

Figure 6. Main transformer mounting screw locations

Main transformer mounting screw locations

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0000178432_x.png

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MODE SELECT SWITCH REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Mode Select Switch.

MATERIALS NEEDED
○ 5/64" Allen Wrench
○ 9/16" Nutdriver
○ Molex Removal Tool
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Using a 5/64” Allen wrench, loosen the setscrew securing the knob to the shaft of the mode select switch. See
Figure F.1.
5. Using a 9/16” nutdriver, remove the nut securing the mode select switch to the front panel. See Figure F.1.
6. Label and disconnect plug J3 from the user interface board. See Figure F.2. See Wiring Diagram.
7. Using a molex removal tool, disconnect leads 301, 302, 303, 305, 306 and 308 from molex plug J3. See Figure
F.3. See Wiring Diagram.
8. The mode select switch can now be removed and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Using a molex removal tool, connect leads 301, 302, 303, 305, 306 and 308 to molex plug J3. See Wiring
Diagram.
2. Connect plug J3 to the user interface board. See Wiring Diagram.
3. Carefully position the new mode select switch into the machine.
4. Using a 9/16” nutdriver, remove the nut securing the mode select switch to the front panel.
5. Using a 5/64” Allen wrench, tighten the setscrew securing the knob to the shaft of the mode select switch.

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6. Perform the Case Cover Replacement Procedure.

7. Perform the Retest After Repair Procedure.

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Figure 1. Mode select switch knob location

Mode select switch knob location

0000178440_x.png

Figure 2. User interface board plug J3 location

User interface board plug J3 location

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0000178439_x.png

Figure 3. User interface board plug J3 lead locations

User interface board plug J3 lead locations

0000178438_x.png

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OUTPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Output Rectifier Assembly.

MATERIALS NEEDED
○ 1/2” Nutdriver
○ 7/16” Nutdriver
○ 3/8” Nutdriver
○ 5/16” Nutdriver
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Perform the Main Capacitor Board Removal Procedure.
5. Perform the Boost Rectifier Removal Procedure.
6. Perform the Thermostat #1 Removal Procedure.
7. Using a 1/2” nutdriver, remove the screw, lock washer and flat washer securing the choke lead and positive
boost lead to the heatsink. See Figure F.1. See Wiring Diagram. Label and disconnect the choke lead and
positive boost lead.
8. Using a 7/16” nutdriver, remove the two nuts, lock washers and flat washers securing the X11 leads to the top
rectifier module. See Figure F.1. See Wiring Diagram. Label and disconnect X11 leads.
9. Using a 7/16” nutdriver, remove the two nuts, lock washers and flat washers securing the X12 leads to the top
rectifier module. See Figure F.1. See Wiring Diagram. Label and disconnect X12 leads.
10. Using a 3/8” nutdriver, remove the nut securing the cable holder closed. See Figure F.2. Open the cable
holder and remove the leads. See Wiring Diagram.
11. Using a 5/16” nutdriver, remove the two screws securing the bottom rectifier bracket to the machine. See
Figure F.2. See Wiring Diagram.
12. Carefully remove the output rectifier assembly out of the machine.

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13. Using a 7/16” nutdriver, remove the two screws and washers securing the bottom rectifier bracket to the
heatsink. See Figure F.2.
14. The output rectifier assembly can now be removed and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Using a 7/16” nutdriver, attach the two screws and washers securing the bottom rectifier bracket to the
heatsink.
2. Carefully position the new output rectifier assembly into the machine.
3. Using a 5/16” nutdriver, attach the two screws securing the bottom rectifier bracket to the machine.
4. Open the cable holder and place the previously removed leads into the cable holder. See Wiring Diagram.
5. Using a 3/8” nutdriver, attach the nut securing the cable holder closed.
6. Using a 7/16” nutdriver, attach the two nuts, lock washers and flat washers securing the X12 leads to the top
rectifier module. See Wiring Diagram.
7. Using a 7/16” nutdriver, attach the two nuts, lock washers and flat washers securing the X11 leads to the top
rectifier module. See Wiring Diagram.
8. Using a 1/2” nutdriver, attach the screw, lock washer and flat washer securing the choke lead and positive
boost lead to the heatsink. See Wiring Diagram.
9. Perform the Thermostat #1 Replacement Procedure.
10. Perform the Boost Rectifier Replacement Procedure.
11. Perform the Main Capacitor Board Replacement Procedure.
12. Perform the Case Cover Replacement Procedure.
13. Perform the Retest After Repair Procedure.

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Figure 1. Choke lead, positive boost lead, X11 and X12 lead locations

Choke lead, positive boost lead, X11 and X12 lead locations

0000178493_x.png

Figure 2. Cable holder and bottom rectifier bracket location

Cable holder and bottom rectifier bracket location

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0000178492_x.png

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PFC BOOST BOARD REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the PFC Boost Board.

MATERIALS NEEDED
○ 3/8” Nutdriver
○ 5/16” Nutdriver
○ 7/16” Nutdriver
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Perform the Auxiliary Power Board Removal Procedure.
5. Using a 3/8” nutdriver, remove the two screws securing the PFC board bracket to the machine. See Figure F.1.
See Wiring Diagram.
6. Using a 5/16” nutdriver, remove the two screws (at the bottom of the bracket) securing the PFC board bracket
to the machine. See Figure F.1.
7. Label and disconnect plugs J53 and J46 from the PFC boost board. See Figure F.2. See Wiring Diagram.
8. Carefully route all leads through the PFC board bracket to allow for removal. See Wiring Diagram.
9. Using a 3/8” nutdriver, remove the two nuts and washers securing the heatsink holder to the PFC board
bracket. See Figure F.1.
10. Using a 7/16” nutdriver, remove the screw and lock washer securing lead B2 to terminal B2 on the PFC boost
board. See Figure F.2. See Wiring Diagram.
11. Using a 7/16” nutdriver, remove the screw and lock washer securing lead B1 to terminal B1 on the PFC boost
board. See Figure F.2. See Wiring Diagram.
12. Using a 7/16” nutdriver, remove the screw and lock washer securing lead B7 to terminal B7 on the PFC boost
board. See Figure F.2. See Wiring Diagram.
13. Using a 7/16” nutdriver, remove the screw and lock washer securing lead B5 to terminal B5 on the PFC boost
board. See Figure F.2. See Wiring Diagram.

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14. Label and disconnect plug J44 from the PFC boost board. See Figure F.2. See Wiring Diagram.
15. Carefully remove the PFC board bracket from the machine. Carefully route cables through the bracket as
necessary.
16. Using a 3/8” nutdriver, remove the four nuts securing the PFC boost board to the PFC board bracket. See
Figure F.3. See Wiring Diagram.
17. The PFC boost board can now be removed and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Carefully position the new PFC boost board onto the PFC board bracket.
2. Using a 3/8” nutdriver, attach the four nuts securing the PFC boost board to the PFC board bracket.
3. Carefully position the PFC board bracket into the machine. Route cables through the bracket as necessary.
4. Connect plug J44 to the PFC boost board. See Wiring Diagram.
5. Using a 7/16” nutdriver, attach the screw and lock washer securing lead B5 to terminal B5 on the PFC boost
board. See Wiring Diagram.
6. Using a 7/16” nutdriver, attach the screw and lock washer securing lead B7 to terminal B7 on the PFC boost
board. See Wiring Diagram.
7. Using a 7/16” nutdriver, attach the screw and lock washer securing lead B1 to terminal B1 on the PFC boost
board. See Wiring Diagram.
8. Using a 7/16” nutdriver, attach the screw and lock washer securing lead B2 to terminal B2 on the PFC boost
board. See Wiring Diagram.
9. Using a 3/8” nutdriver, attach the two nuts and washers securing the heatsink holder to the PFC board
bracket.
10. Carefully route all leads through the PFC board bracket. See Wiring Diagram.
11. Connect plugs J53 and J46 to the PFC boost board. See Wiring Diagram.
12. Using a 5/16” nutdriver, attach the two screws (at the bottom of the bracket) securing the PFC board bracket
to the machine.
13. Using a 3/8” nutdriver, attach the two screws securing the PFC board bracket to the machine.
14. Perform the Auxiliary Power Board Replacement Procedure.
15. Perform the Case Cover Replacement Procedure.
16. Perform the Retest After Repair Procedure.

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Figure 1. PFC board bracket and heatsink holder locations

PFC board bracket and heatsink holder locations

0000178388_x.png

Figure 2. PFC boost board plug and terminal locations

PFC boost board plug and terminal locations

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0000178387_x.png

Figure 3. PFC boost board mounting nut locations

PFC boost board mounting nut locations

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0000178386_x.png

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SCR (PRE-CHARGE) BOARD REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the SCR (Pre-Charge) Board.

MATERIALS NEEDED
○ Phillips Screwdriver
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Carefully remove the six cable ties securing the protective cover over the input rectifier and SCR (pre-charge)
board. See Figure F.1.
5. Label and disconnect leads 411, 412 and 417 from the input rectifier. See Figure F.2. See Wiring Diagram.
6. Using a Phillips screwdriver, remove the screw, lock washer and flat washer securing leads L1, L2, L3, B5 and
B6 to the terminals of the input rectifier. See Figure F.2. See Wiring Diagram. Note the board will be free of
the machine, use caution to prevent any damage to the board.
7. Label and disconnect plug J40 from the SCR (pre-charge) board. See Figure F.2. See Wiring Diagram.
8. The SCR (pre-charge) board can now be removed and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Carefully position the new SCR (pre-charge) board and protective cover into the machine.
2. Connect plug J40 to the SCR (pre-charge) board. See Wiring Diagram.
3. Using a Phillips screwdriver, attach the screw, lock washer and flat washer securing leads L1, L2, L3, B5 and
B6 to the terminals of the input rectifier. See Wiring Diagram.
4. Connect leads 411, 412 and 417 to the input rectifier. See Wiring Diagram.
5. Attach the six cable ties securing the protective cover over the input rectifier and SCR (pre-charge) board.

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6. Perform the Case Cover Replacement Procedure.

7. Perform the Retest After Repair Procedure.

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Figure 1. Protective cover cable tie locations

Protective cover cable tie locations

0000178370_x.png

Figure 2. SCR (pre-charge) board plug J40 and input rectifier lead and plug
locations

SCR (pre-charge) board plug J40 and input rectifier lead and plug locations

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0000178369_x.png

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SWITCHBOARD REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Switchboard.

MATERIALS NEEDED
○ 7/16” Nutdriver
○ Torx Nutdriver (Size T-25)
○ 3/8” Nutdriver
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Perform the PFC Boost Board Removal Procedure.
5. Using a 7/16” nutdriver, remove the bolt and lock washer securing lead 204 to terminal B3 of the switchboard.
See Figure F.1. See Wiring Diagram.
6. Using a torx nutdriver (size T-25), remove the screw and lock washer securing lead 201 to terminal B4 of the
switchboard. See Figure F.1. See Wiring Diagram.
7. Using a torx nutdriver (size T-25), remove the screw and lock washer securing lead B1A to terminal B1 of the
switchboard. See Figure F.1. See Wiring Diagram.
8. Using a torx nutdriver (size T-25), remove the screw and lock washer securing lead B2A to terminal B2 of the
switchboard. See Figure F.1. See Wiring Diagram.
9. Label and disconnect plugs J42 and J43 from the switchboard. See Figure F.1. See Wiring Diagram.
10. Using a 3/8” nutdriver, remove the four nuts securing the switchboard to the mounting bracket. See Figure
F.2.
11. The switchboard can now be removed and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:

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1. Carefully position the new switchboard into the machine.

2. Using a 3/8” nutdriver, attach the four nuts securing the switchboard to the mounting bracket.
3. Connect plugs J42 and J43 to the switchboard. See Wiring Diagram.
4. Using a torx nutdriver (size T-25), attach the screw and lock washer securing lead B2A to terminal B2 of the
switchboard. See Wiring Diagram.
5. Using a torx nutdriver (size T-25), attach the screw and lock washer securing lead B1A to terminal B1 of the
switchboard. See Wiring Diagram.
6. Using a torx nutdriver (size T-25), attach the screw and lock washer securing lead 201 to terminal B4 of the
switchboard. See Wiring Diagram.
7. Using a 7/16” nutdriver, attach the bolt and lock washer securing lead 204 to terminal B3 of the switchboard.
See Wiring Diagram.
8. Perform the PFC Boost Board Replacement Procedure.
9. Perform the Case Cover Replacement Procedure.
10. Perform the Retest After Repair Procedure.

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Figure 1. Switchboard terminal and plug locations

Switchboard terminal and plug locations

0000178401_x.png

Figure 2. Switchboard mounting nut locations

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Switchboard mounting nut locations

0000178400_x.png

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THERMOSTAT #1 REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Thermostat #1.

MATERIALS NEEDED
○ 7/64” Allen Wrench
○ Penetrox Heat Sink Compound (Lincoln Part #T12837-1)
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Label and disconnect leads 224 and 225 from thermostat #1. See Figure F.1. See Wiring Diagram.
5. Using a 7/64” Allen wrench, remove the two screws securing thermostat #1 to the output rectifier heatsink.
See Figure F.2. See Wiring Diagram.
6. Thermostat #1 can now be removed and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Clean the mating surface of the output rectifier heatsink.
2. Apply a coating of Penetrox heat sink compound to the rear of thermostat #1.
3. Carefully position the new thermostat #1 onto the output rectifier heatsink.
4. Using a 7/64” Allen wrench, attach the two screws securing thermostat #1 to the output rectifier heatsink.
5. Connect leads 224 and 225 to thermostat #1. See Wiring Diagram.
6. Perform the Case Cover Replacement Procedure.
7. Perform the Retest After Repair Procedure.

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Figure 1. Thermostat #1 lead locations

Thermostat #1 lead locations

0000178476_x.png

Figure 2. Thermostat #1 mounting screw locations

Thermostat #1 mounting screw locations

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0000178475_x.png

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USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE

TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the User Interface Board.

MATERIALS NEEDED
○ Phillips Screwdriver
○ Wiring Diagram

REMOVAL PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Label and disconnect plugs J1, J2, J3 and J4 from the user interface board. See Figure F.1. See Wiring Diagram.
5. Using a Phillips screwdriver, remove the two screws securing the user interface board to the front panel. See
Figure F.2.
6. Carefully pry the user interface board off the mounting posts.
7. The user interface board can now be removed and replaced.

REPLACEMENT PROCEDURE
Procedure Steps:
1. Carefully position the new user interface board into the machine.
2. Carefully press the user interface board onto it’s mounting posts.
3. Using a Phillips screwdriver, attach the two screws securing the user interface board to the front panel.
4. Connect plugs J1, J2, J3 and J4 to the user interface board. See Wiring Diagram.
5. Perform the Case Cover Replacement Procedure.
6. Perform the Retest After Repair Procedure.

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Figure 1. User interface board plug locations

User interface board plug locations

0000178412_x.png

Figure 2. User interface board mounting screw locations

User interface board mounting screw locations

0000178411_x.png

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AUXILIARY POWER BOARD TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Auxiliary Power Board is functioning properly.

MATERIALS NEEDED
○ Volt/Ohmmeter
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the auxiliary power board. See Figure F.1. See Wiring Diagram.
5. Using a volt/ohmmeter, perform the diode drop tests outlined in Table F.1. See Figures F.2 and Figures F.3.
See Wiring Diagram.
6. Carefully apply the correct input power to the machine and turn ON the machine.
7. Using a volt/ohmmeter, perform the voltage tests outlined in Table F.2. See Figures F.2 and Figures F.3. See
Wiring Diagram.
8. If any of the tests fail, the auxiliary power board may be faulty.
9. If faulty, perform the Auxiliary Power Board Removal And Replacement Procedure.
10. Perform the Case Cover Replacement Procedure.

Auxiliary power board diode drop tests

TEST POINT TEST POINT EXPECTED READING

PLUG J49 PIN 6 (LEAD B1C) PLUG J49 PIN 1 (LEAD B2C) 0.6 TO 2.0 VDC

PLUG J47 PIN 9 (LEAD 51A) PLUG J47 PIN 5 (LEAD 51) 0.3 TO 1.0 VDC

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Auxiliary power board voltage tests

TEST POINT TEST POINT EXPECTED READING

PLUG J49 PIN 1 (LEAD B2C) PLUG J49 PIN 6 (LEAD B1C) 860 VDC

PLUG J49 PIN 12 (LEAD 444) PLUG J49 PIN 11 (LEAD 441) 18 VDC

PLUG J45 PIN 2 (LEAD 465) PLUG J45 PIN 1 (LEAD 466) 5 VDC

PLUG J47 PIN 7 (LEAD 52C) PLUG J47 PIN 10 (LEAD 51C) 42 VDC

PLUG J47 PIN 2 (LEAD 52A) PLUG J47 PIN 9 (LEAD 51A) 42 VDC

PLUG J47 PIN 3 (LEAD 52) PLUG J47 PIN 5 (LEAD 51) 42 VDC

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Figure 1. Auxiliary power board location

Auxiliary power board location

0000178378_x.png

Figure 2. Auxiliary power board plug locations

Auxiliary power board plug locations

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0000178377_x.png

Figure 3. Auxiliary power board lead locations

Auxiliary power board lead locations

0000178376_x.png

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BOOST RECTIFIER TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Boost Rectifier is functioning properly.

MATERIALS NEEDED
○ 7/16" Nutdriver
○ 1/2" Nutdriver
○ Torx Nutdriver (Size T-20)
○ Volt/Ohmmeter
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the boost rectifier. See Figure F.1. See Wiring Diagram.
5. Using a 7/16” nutdriver, remove the bolt and associated washers securing the transformer leads (X11 and
X12) to the output rectifier. Label and disconnect the transformer leads (X11 and X12) from the output
rectifier assembly. See Figure F.2. See Wiring Diagram.
6. Using a 1/2” nutdriver, remove the bolt securing the positive boost lead to the output rectifier heatsink. See
Figure F.2. Label and disconnect positive boost lead.
7. Using a Torx nutdriver (Size T-20), remove the screw, lock washer and flat washer securing the leads to the
four rectifier terminals. See Figure F.3. See Wiring Diagram. Label and disconnect leads.
8. Using a volt/ohmmeter, perform the diode drop tests outlined in Table F.1. See Figure F.3. See Wiring
Diagram.
9. Connect all previously disconnected leads.
10. If any of the tests fail, the boost rectifier may be faulty.
11. If faulty, perform the Boost Rectifier Removal And Replacement Procedure.
12. Perform the Case Cover Replacement Procedure.

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Table F.1 - Boost rectifier diode drop tests

TEST POINT TEST POINT EXPECTED READING

AC TERMINAL (LEAD X21) POSITIVE TERMINAL (POS) 0.3 VDC – 1.0 VDC

NEGATIVE TERMINAL (NEG) AC TERMINAL (LEAD X21) 0.3 VDC – 1.0 VDC

NEGATIVE TERMINAL (NEG) AC TERMINAL (LEADS 202A AND 202B) 0.3 VDC – 1.0 VDC

AC TERMINAL (LEADS 202A AND 202B) POSITIVE TERMINAL (POS) 0.3 VDC – 1.0 VDC

POSITIVE TERMINAL (POS) AC TERMINAL (LEAD X21) OL

AC TERMINAL (LEAD X21) NEGATIVE TERMINAL (NEG) OL

AC TERMINAL (LEADS 202A AND 202B) NEGATIVE TERMINAL (NEG) OL

POSITIVE TERMINAL (POS) AC TERMINAL (LEADS 202A AND 202B) OL

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Figure 1. Boost rectifier location

Boost rectifier location

0000178465_x.png

Figure 2. Transformer and positive boost lead connection locations

Transformer and positive boost lead connection locations

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0000178464_x.png

Figure 3. Boost rectifier terminal and lead locations

Boost rectifier terminal and lead locations

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0000178483_x.png

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0000178469

BOOST RELAY TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Boost Relay is functioning properly.

MATERIALS NEEDED
○ Volt/Ohmmeter
○ External 15 VDC Power Supply
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the boost relay. See Figure F.1. See Wiring Diagram.
5. Label and disconnect leads #228 and #227 from the boost relay. See Figure F.2. See Wiring Diagram.
6. Using a volt/ohmmeter, measure the resistance of the boost relay coil. See Figure F.2. The resistance should
be approximately 83 ohms.
7. Label and disconnect the remaining leads from the boost relay. See Figure F.2. See Wiring Diagram.
8. Using a volt/ohmmeter, measure the resistance of the contacts (terminals 2 to 4 and terminals 6 to 8). See
Figure F.2. See Wiring Diagram. The resistance between contacts should be infinite (open).
9. Using an external 15 VDC power supply, apply voltage to the coil terminals. An audible click should be heard
as the contacts close. See Wiring Diagram.
10. Using a volt/ohmmeter, test the contacts again (terminals 2 to 4 and terminals 6 to 8), resistance should be
very low (less than one ohm).
11. If any of the tests fail, the boost relay may be faulty.
12. If faulty, perform the Boost Relay Removal And Replacement Procedure.
13. Connect all previously removed leads.
14. Perform the Case Cover Replacement Procedure.

NOTE: The boost relay is only activated when the machine is in SMAW mode and welding current is being
drawn.

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Figure 1. Boost relay location

Boost relay location

0000178471_x.png

Figure 2. Boost relay terminal and lead locations

Boost relay terminal and lead locations

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0000178470_x.png

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CAPACITOR DISCHARGE PROCEDURE

TEST DESCRIPTION
This procedure will help determine if the capacitors have been discharged.

MATERIALS NEEDED
○ Resistor (1000 ohms and 25 watts minimum)
○ Electrical Insulating Gloves
○ Analog Voltmeter or Digital Multimeter
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Locate the SCR (pre-charge) board and input rectifier. See Figure F.1. See Wiring Diagram.
4. Locate the main capacitor board. See Figure F.1. See Wiring Diagram.
5. Using a volt/ohmmeter, measure the voltage between terminals B5 and B6 on the input rectifier. See Figure
F.2. See Wiring Diagram. If no voltage is present, proceed with step 8. If any voltage is present continue with
this procedure.
6. Using a 25 watt or more (25 to 1000 ohm) resistor connected to two test leads, carefully discharge the
capacitors at terminals B5 and B6 on the input rectifier. See Figure F.2. See Wiring Diagram.
7. Locate the two large bolted connections labeled B1 and B2 on the main capacitor board. See Figure F.3. See
Wiring Diagram.
8. Using a volt/ohmmeter, measure the voltage between terminals B1 and B2 on the main capacitor board. See
Figure F.3. See Wiring Diagram. If no voltage is present, this procedure is complete. If any voltage is present
continue with this procedure.
9. Using a 25 watt or more (25 to 1000 ohm) resistor connected to two test leads, carefully discharge the
capacitors at terminals B1 and B2 on the main capacitor board. See Figure F.3. See Wiring Diagram.
10. Using a volt/ohmmeter, ensure the capacitors are discharged by connecting the positive meter probe to
terminal B1 and the negative meter probe to terminal B2 on the main capacitor board. The voltage should be
zero, if not repeat the discharge procedure. See Wiring Diagram.
11. Perform desired test(s) / repair procedure(s).
12. When testing is complete, perform the Case Cover Replacement Procedure.
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Figure 1. SCR (pre-charge) board, input rectifier and main capacitor board
locations

SCR (pre-charge) board, input rectifier and main capacitor board locations

0000178362_x.png

Figure 2. Input rectifier terminals B5 and B6

Input rectifier terminals B5 and B6

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0000178361_x.png

Figure 3. Main capacitor board terminals B1 and B2

Main capacitor board terminals B1 and B2

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0000178360_x.png

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CHOKE TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Choke is shorted turn to turn or grounded.

MATERIALS NEEDED
○ Volt/Ohmmeter
○ 1/2" Nutdriver
○ 1/2" Open End Wrench
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the choke. The choke is attached to the base near the transformer. See Figure F.1. See Wiring Diagram.
5. OPEN: No weld output. Using a volt/ohmmeter, test the resistance from the choke lead connected to the
heatsink of the output rectifier to the positive output terminal. See Wiring Diagram. The resistance should be
very low (less than one ohm).
6. Turn To Turn Short: Reduced inductance, arc instability, excessive heating of the choke. Check for any
physical signs of arcing within the choke assembly.
7. Choke Coil Grounded: Reduced inductance, alternate weld current path. Electrically isolate the choke coil by
disconnecting both choke leads. To electrically isolate the choke coil, using a 1/2” nutdriver and 1/2” open end
wrench, remove the bolt, nut and associated washers securing the top choke lead to the positive output
terminal. Using the 1/2” nutdriver, remove the other choke flex lead from the output rectifier heatsink. Take
note of Positive white lead. Using a volt/ohmmeter, check the resistance from choke coil to chassis ground.
Resistance should be at least 500,000 ohms. See Wiring Diagram.
8. If any of the tests fail, the line switch may be faulty.
9. Connect all previously removed leads. See Wiring Diagram.
10. If faulty, perform the Choke Removal And Replacement Procedure.
11. Perform the Case Cover Replacement Procedure.

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Figure 1. Choke location

Choke location

0000178442_x.png

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CURRENT TRANSDUCER (LEM) TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Current Transducer (LEM) is functioning properly

MATERIALS NEEDED
○ Volt/Ohmmeter
○ Load Bank
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. The current transducer is located behind the negative output stud. See Wiring Diagram.
5. Locate the inverter control board. See Figure F.1. See Wiring Diagram.
6. Locate plug J11 on the inverter control board. See Figure F.2. See Wiring Diagram.
7. Carefully apply the correct input power to the machine and turn the machine ON.
8. Using a volt/ohmmeter, carefully check for the DC supply voltages to the current transducer per Table F.1.
See Figures F.2 and F.3. See Wiring Diagram.

NOTE: Do not attempt to check the voltages at the current transducer connector. The terminals are small and
delicate and may be damaged if probed with meter leads.
9. If the correct voltages are NOT present at the inverter control board, perform the Inverter Control Board
Test Procedure.
10. Place the machine into a constant current output mode. Using a load bank, load the machine according to
Table F.2.
11. Using a volt/ohmmeter, test the current transducer feedback versus actual output current. See Table F.2. See
Figures F.2 and F.3. See Wiring Diagram.
12. If the DC supply voltages are correct but the feedback voltages are incorrect the current transducer may be
faulty.
13. If faulty, perform the Current Transducer (LEM) Removal And Replacement Procedure.

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14. Perform the Case Cover Replacement Procedure.

Table F.1 - DC supply voltages from inverter control board

DESCRIPTION TEST POINT (POS) TEST POINT (NEG) EXPECTED

READING

POSITIVE VOLTAGE SUPPLY PLUG J11 PIN 4 (LEAD 216A) PLUG J11 PIN 9 (LEAD 218A) +15 VDC

NEGATIVE VOLTAGE PLUG J11 PIN 5 (LEAD 217A) PLUG J11 PIN 9 (LEAD 218A) -15 VDC
SUPPLY

Table F.2 - Current transducer feedback versus actual output current

ACTUAL OUTPUT TEST POINT (POS) TEST POINT (NEG) CURRENT TRANSDUCER
CURRENT (AMPS) FEEDBACK VOLTAGE

500 PLUG J11 PIN 10 PLUG J11 PIN 9 4.0 VDC

(LEAD 215A) (LEAD 218A)

450 PLUG J11 PIN 10 PLUG J11 PIN 9 3.6 VDC

(LEAD 215A) (LEAD 218A)

400 PLUG J11 PIN 10 PLUG J11 PIN 9 3.2 VDC

(LEAD 215A) (LEAD 218A)

350 PLUG J11 PIN 10 PLUG J11 PIN 9 2.8 VDC

(LEAD 215A) (LEAD 218A)

300 PLUG J11 PIN 10 PLUG J11 PIN 9 2.4 VDC

(LEAD 215A) (LEAD 218A)

250 PLUG J11 PIN 10 PLUG J11 PIN 9 2.0 VDC

(LEAD 215A) (LEAD 218A)

200 PLUG J11 PIN 10 PLUG J11 PIN 9 1.6 VDC

(LEAD 215A) (LEAD 218A)

150 PLUG J11 PIN 10 PLUG J11 PIN 9 1.2 VDC

(LEAD 215A) (LEAD 218A)

100 PLUG J11 PIN 10 PLUG J11 PIN 9 0.8 VDC

(LEAD 215A) (LEAD 218A)

50 PLUG J11 PIN 10 PLUG J11 PIN 9 0.4 VDC

(LEAD 215A) (LEAD 218A)

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Figure 1. Inverter control board location

Inverter control board location

0000178458_x.png

Figure 2. Plug J11 location on inverter control board

Plug J11 location on inverter control board

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0000178457_x.png

Figure 3. Plug J11 lead locations

Plug J11 lead locations

0000178456_x.png

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FAN AND F.A.N. CIRCUIT TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Fan and F.A.N. Circuit are functioning properly.

MATERIALS NEEDED
○ Volt/Ohmmeter
○ Wiring Diagram

TEST PROCEDURE
NOTE: The fans should turn on briefly when the machine is turned on. The fans turn on during OCV or when
welding current is present. The fans also turn on in the event of an over temperature condition.

Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the inverter control board. See Figure F.1. See Wiring Diagram.
5. Locate the plugs J13 and J14 on the inverter control board. With the two plugs still connected to the inverter
control board carefully insert the meter probes into pin 4 (red wire +) and pin 3 (black wire -) of plug J13 and
test per Table F.1. See Figure F.2. See Wiring Diagram.
6. Carefully apply the correct input power to the machine.
7. Repeat the above step for plug J14.
8. If the 42 VDC is present at the red and black leads and the fan does not run, the fan may be faulty.
9. If faulty, perform the Fan Removal And Replacement Procedure.
10. Perform the Case Cover Replacement Procedure.

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Table F.1 - Fan voltage tests

TEST TEST POINT TEST POINT CONDITIONS EXPECTED

DESCRIPTION READING

BOTTOM FAN PLUG J13 PLUG J13 PIN FAN NOT RUNNING 0 VDC
PIN 4 (RED 3 (BLACK
WIRE +) WIRE -)

TOP FAN PLUG J14 PLUG J14 PIN FAN NOT RUNNING 0 VDC
PIN 4 (RED 3 (BLACK
WIRE +) WIRE -)

BOTTOM FAN PLUG J13 PLUG J13 PIN FAN RUNNING – FANS SHOULD RUN IF 42 VDC
PIN 4 (RED 3 (BLACK THERMOSTAT CIRCUIT IS OPENED. SEE
WIRE +) WIRE -) WIRING DIAGRAM AND Figure F.2.

TOP FAN PLUG J14 PLUG J14 PIN FAN RUNNING – FANS SHOULD RUN IF 42 VDC
PIN 4 (RED 3 (BLACK THERMOSTAT CIRCUIT IS OPENED. SEE
WIRE +) WIRE -) WIRING DIAGRAM AND Figure F.2.

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Figure 1. Inverter control board location

Inverter control board location

0000178463_x.png

Figure 2. Inverter control board plugs J13 and J14 locations

Inverter control board plugs J13 and J14 locations

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0000178462_x.png

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INPUT RECTIFIER AND SCR (PRE-CHARGE) BOARD TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Input Rectifier and the SCR (Pre-Charge) Board are functioning properly.

MATERIALS NEEDED
○ Volt/Ohmmeter
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the input rectifier and SCR (pre-charge) board. See Figure F.1. See Wiring Diagram.
5. Carefully remove the six cable ties securing the protective cover over the input rectifier and SCR (pre-charge)
board. The cover can be lifted to perform tests. Do not completely remove the protective cover. See Figure
F.2.
6. Using a volt/ohmmeter, perform the diode drop tests outlined in Table F.1. See Figure F.2. See Wiring
Diagram.
7. If any of the tests fail, label and disconnect all leads connected to the input rectifier terminals and retest. See
Wiring Diagram.
8. If any of the tests still fail, the input rectifier may be faulty.
9. If faulty, perform the Input Rectifier Removal And Replacement Procedure.
10. Connect any previously disconnected leads. See Wiring Diagram.
11. Carefully apply the correct input power to the machine and turn ON the machine.
12. Using a volt/ohmmeter, measure the voltage from SCR (pre-charge) board plug J40 pin 8 (lead 446) to plug J40
pin 16 (lead 445). See Figures F.2 and Figures F.3. See Wiring Diagram. Normal reading is 15 VDC.
13. When testing is complete, close protective cover and secure with six cable ties.
14. If the test fails, the SCR (pre-charge) board may be faulty.
15. If faulty, perform the SCR (Pre-Charge) Board Removal And Replacement Procedure.
16. Perform the Case Cover Replacement Procedure.

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Table F.1 - Input rectifier diode drop tests

TEST POINT TEST POINT EXPECTED READING

TERMINAL L1 POSITIVE TERMINAL (B6) 0.3 VDC – 1.0 VDC

TERMINAL L2 POSITIVE TERMINAL (B6) 0.3 VDC – 1.0 VDC

TERMINAL L3 POSITIVE TERMINAL (B6) 0.3 VDC – 1.0 VDC

POSITIVE TERMINAL (B6) TERMINAL L1 OL

POSITIVE TERMINAL (B6) TERMINAL L2 OL

POSITIVE TERMINAL (B6) TERMINAL L3 OL

NEGATIVE TERMINAL (B5) TERMINAL L1 0.3 VDC – 1.0 VDC

NEGATIVE TERMINAL (B5) TERMINAL L2 0.3 VDC – 1.0 VDC

NEGATIVE TERMINAL (B5) TERMINAL L3 0.3 VDC – 1.0 VDC

TERMINAL L1 NEGATIVE TERMINAL (B5) OL

TERMINAL L2 NEGATIVE TERMINAL (B5) OL

TERMINAL L3 NEGATIVE TERMINAL (B5) OL

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Figure 1. Input rectifier and SCR (pre-charge) board locations

Input rectifier and SCR (pre-charge) board locations

0000178365_x.png

Figure 2. Input rectifier terminal and SCR (pre-charge) board plug J40
locations

Input rectifier terminal and SCR (pre-charge) board plug J40 locations

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0000178364_x.png

Figure 3. SCR (pre-charge) board plug J40 lead locations

SCR (pre-charge) board plug J40 lead locations

0000178383_x.png

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INVERTER CONTROL BOARD TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Inverter Control Board is functioning properly. The procedure will not check all
of the Inverter Control Board’s circuitry.

MATERIALS NEEDED
○ Volt/Ohmmeter
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the inverter control board. See Figure F.1. See Wiring Diagram.
5. Carefully apply the correct input power to the machine and turn ON the machine.
6. Visually inspect the LEDs according to Table F.1. See Figures F.2 and Figures F.3. See Wiring Diagram.
7. Using a volt/ohmmeter, perform the voltage tests outlined in Table F.2. See Figures F.2 and Figures F.3. See
Wiring Diagram.
8. If any of the tests fail, the inverter control board may be faulty.
9. If faulty, perform the Inverter Control Board Removal And Replacement Procedure.
10. Perform the Case Cover Replacement Procedure.

Inverter control board LED tests

DESCRIPTION LOCATION MEANING

LED 1 INVERTER +15 VDC SUPPLY ON

CONTROL
BOARD

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DESCRIPTION LOCATION MEANING

LED 2 INVERTER ARCLINK SUPPLY ON

CONTROL
BOARD

LED 1 DAUGHTER ARCLINK STATUS INDICATOR STEADY GREEN = SYSTEM OK BLINKING GREEN
BOARD = OCCURS DURING STARTUP. NORMAL FOR FIRST 1 TO 30 SECONDS AFTER
POWER IS APPLIED. ALTERNATING GREEN AND RED = READ THE ERROR
CODE BEFORE THE MACHINE IS POWERED OFF.

Inverter control board voltage tests

DESCRIPTION TEST POINT (POS) TEST POINT (POS) EXPECTED CONDITIONS

READING

CAN COMMUNICATION PLUG J5 PIN 2 PLUG J5 PIN 1 2 VDC MACHINE ON

(LEAD 53A) (LEAD 54A)

USER INTERFACE BOARD PLUG J5 PIN 4 PLUG J5 PIN 3 42 VDC MACHINE ON

INPUT POWER (LEAD 52A) (LEAD 51A)

FAN POWER PLUG J13 PIN 4 PLUG J13 PIN 3 42 VDC MACHINE ON
(LEAD RED) (LEAD BLACK)

FAN POWER PLUG J14 PIN 4 PLUG J14 PIN 3 42 VDC MACHINE ON
(LEAD RED) (LEAD BLACK)

PLUG J6 PIN 2 PLUG J6 PIN 1 2 VDC MACHINE ON

(LEAD 53) (LEAD 54)

PLUG J9 PIN 2 PLUG J9 PIN 1 60 VDC MACHINE ON

(LEAD 220D) (LEAD 221D)

PLUG J11 PIN 1 PLUG J11 PIN 2 60 VDC MACHINE ON

(LEAD 220A) (LEAD 221A)

LEM SUPPLY PLUG J11 PIN 4 PLUG J11 PIN 9 +15 VDC MACHINE ON
(LEAD 216A) (LEAD 218A)

LEM SUPPLY PLUG J11 PIN 5 PLUG J11 PIN 9 -15 VDC MACHINE ON
(LEAD 217A) (LEAD 218A)

PLUG J4 PIN 4 PLUG J4 PIN 1 3 VDC MACHINE ON

(LEAD 473) (LEAD B2D)

PLUG J3 PIN 16 PLUG J3 PIN 15 3 VDC MACHINE ON

(LEAD 466) (LEAD 465)

PLUG J6 PIN 3 PLUG J13 PIN 1 30 VDC MACHINE ON

(LEAD 463) (LEAD 464)

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Figure 1. Inverter control board location

Inverter control board location

0000178422_x.png

Figure 2. Inverter control board test points

Inverter control board test points

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0000178421_x.png

Figure 3. Inverter control board lead locations

Inverter control board lead locations

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0000178419_x.png

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LINE SWITCH TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Line Switch is functioning properly.

MATERIALS NEEDED
○ Offset Phillips Screwdriver
○ Volt/Ohmmeter
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the line switch on the rear of the front panel. See Figure F.1. See Wiring Diagram.
5. Carefully remove the cable tie, securing the plastic protective sleeve to the line switch. Move the plastic
protective sleeve flap to gain access to the rear of the line switch. See Wiring Diagram.
6. Using an offset Phillips screwdriver, remove the six screws securing leads L1, L2, L3 and the three input
(black, red and white) leads to the line switch. See Figure F.2. See Wiring Diagram. Label and disconnect leads
from the line switch.
7. Using a volt/ohmmeter, perform the resistance tests outlined in Table F.1. See Figure F.2. See Wiring
Diagram.
8. If any of the tests fail, the line switch may be faulty.
9. If faulty, perform the Line Switch Removal And Replacement Procedure.
10. Using an offset Phillips screwdriver, attach the six screws securing leads L1, L2, L3 and the three input (black,
red and white) leads to the line switch. See Wiring Diagram.
11. Carefully position the flap and secure the plastic protective sleeve with a new cable tie.
12. Perform the Case Cover Replacement Procedure.

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Table F.1 - Line switch resistance tests

TEST POINT (POS) TEST POINT (NEG) EXPECTED READING SWITCH

POSITION

L1 WHITE LEAD VERY LOW RESISTANCE (LESS THAN ONE OHM) “ON” POSITION

L2 RED LEAD VERY LOW RESISTANCE (LESS THAN ONE OHM) “ON” POSITION

L3 BLACK LEAD VERY LOW RESISTANCE (LESS THAN ONE OHM) “ON” POSITION

L1 WHITE LEAD HIGH RESISTANCE (GREATER THAN 500K “OFF” POSITION

OHMS)

L2 RED LEAD HIGH RESISTANCE (GREATER THAN 500K “OFF” POSITION

OHMS)

L3 BLACK LEAD HIGH RESISTANCE (GREATER THAN 500K “OFF” POSITION

OHMS)

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Figure 1. Line switch location

Line switch location

0000178373_x.png

Figure 2. Line switch lead location

Line switch lead location

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0000178372_x.png

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MAIN CAPACITOR BOARD TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Main Capacitor Board is functioning properly.

MATERIALS NEEDED
○ Volt/Ohmmeter
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the main capacitor board. See Figure F.1. See Wiring Diagram.
5. Carefully apply the correct input power to the machine and turn ON the machine.
6. Visually verify that LED 1 and LED 2 are illuminated Green. This indicates that voltage is present. See Figure
F.2.
7. Using a volt/ohmmeter, measure the voltage at terminals B2 and B1 on the main capacitor board. See Figure
F.2. See Wiring Diagram. Normal voltage is approximately 860 VDC.
8. If any of the tests fail, the main capacitor board may be faulty.
9. If faulty, perform the Main Capacitor Board Removal And Replacement Procedure.
10. Perform the Case Cover Replacement Procedure.

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Figure 1. Main capacitor board location

Main capacitor board location

0000178391_x.png

Figure 2. Main capacitor board terminal and LED locations

Main capacitor board terminal and LED locations

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0000178390_x.png

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0000178428

MAIN TRANSFORMER TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Main Transformer is functioning properly. In order for this test to produce the
expected results the Main Transformer must be receiving the correct input voltage from the Switchboard.

MATERIALS NEEDED
○ Volt/Ohmmeter
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the main transformer. See Figure F.1. See Wiring Diagram.
5. Using a volt/ohmmeter, perform the voltage tests in Table F.1. See Figure F.2. See Wiring Diagram.
6. If any of the tests fail, the main transformer may be faulty.
7. If faulty, perform the Main Transformer Removal And Replacement Procedure.
8. Connect all previously removed leads.
9. Perform the Case Cover Replacement Procedure.

Table F.1 - Main transformer voltage tests

TEST POINT TEST POINT EXPECTED MACHINE

READING CONDITION

X12 (AT OUTPUT RECTIFIER X11 (AT OUTPUT RECTIFIER 120 VAC MACHINE ON.
BUSS BAR) BUSS BAR)

X21 (AT BOOST RECTIFIER) LEAD #110 (AT BOOST RELAY) 24 VAC MACHINE ON.

X11 (AT OUTPUT RECTIFIER X13 (AT NEGATIVE OUTPUT 24 VAC MACHINE ON.
BUSS BAR) TERMINAL)

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TEST POINT TEST POINT EXPECTED MACHINE

READING CONDITION

X12 (AT OUTPUT RECTIFIER X13 (AT NEGATIVE OUTPUT 40 VAC MACHINE ON.
BUSS BAR) TERMINAL)

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Figure 1. Main transformer location

Main transformer location

0000178430_x.png

Figure 2. Main transformer test point locations

Main transformer test point locations

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0000178429_x.png

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0000178453

MODE SELECT SWITCH TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Mode Select Switch is functioning properly.

MATERIALS NEEDED
○ Volt/Ohmmeter
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the mode select switch. See Figure F.1. See Wiring Diagram.
5. Label and disconnect plug J3 from the user interface board. See Figure F.2. See Wiring Diagram.
6. Using a volt/ohmmeter, perform the resistance tests outlined in Table F.1. See Figure F.3. See Wiring
Diagram.
7. If any of the tests fail, the mode select switch may be faulty.
8. If faulty, perform the Mode Select Switch Removal And Replacement Procedure.
9. Connect plug J3 to the user interface board. See Wiring Diagram.
10. Perform the Case Cover Replacement Procedure.

Table F.1 - Line switch resistance tests

SWITCH TEST POINT TEST POINT EXPECTED READING

POSITION

GTAW PLUG J3 PIN PLUG J3 PIN VERY LOW RESISTANCE (LESS THAN ONE OHM) IN SWITCH
2 (LEAD 301) 1 (LEAD 308) POSTION. HIGH RESISTANCE (GREATER THAN 50OK OHMS)
IN ALL OTHER POSITIONS.

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SWITCH TEST POINT TEST POINT EXPECTED READING

POSITION

SMAW PLUG J3 PIN PLUG J3 PIN VERY LOW RESISTANCE (LESS THAN ONE OHM) IN SWITCH
7 (LEAD 302) 1 (LEAD 308) POSTION. HIGH RESISTANCE (GREATER THAN 50OK OHMS)
IN ALL OTHER POSITIONS.

CV PLUG J3 PIN PLUG J3 PIN VERY LOW RESISTANCE (LESS THAN ONE OHM) IN SWITCH
6 (LEAD 303) 1 (LEAD 308) POSTION. HIGH RESISTANCE (GREATER THAN 50OK OHMS)
IN ALL OTHER POSITIONS.

CV- PLUG J3 PIN PLUG J3 PIN VERY LOW RESISTANCE (LESS THAN ONE OHM) IN SWITCH
INNERSHIELD 5 (LEAD 305) 1 (LEAD 308) POSTION. HIGH RESISTANCE (GREATER THAN 50OK OHMS)
IN ALL OTHER POSITIONS.

ARCLINK PLUG J3 PIN PLUG J3 PIN VERY LOW RESISTANCE (LESS THAN ONE OHM) IN SWITCH
8 (LEAD 306) 1 (LEAD 308) POSTION. HIGH RESISTANCE (GREATER THAN 50OK OHMS)
IN ALL OTHER POSITIONS.

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Figure 1. Mode select switch location

Mode select switch location

0000178436_x.png

Figure 2. User interface board plug J3 location

User interface board plug J3 location

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0000178435_x.png

Figure 3. User interface board plug J3 lead locations

User interface board plug J3 lead locations

0000178434_x.png

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OUTPUT RECTIFIER ASSEMBLY TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Output Rectifier Assembly is functioning properly.

MATERIALS NEEDED
○ 7/16" Nutdriver
○ 1/2" Nutdriver
○ Volt/Ohmmeter
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the output rectifier. See Figure F.1. See Wiring Diagram.
5. Using a 7/16” nutdriver, remove the bolt and associated washers securing the transformer leads (X11 and
X12) to the output rectifier. Label and disconnect the transformer leads (X11 and X12) from the output
rectifier assembly. See Figure F.2. See Wiring Diagram.
6. Using a 1/2” nutdriver, remove the bolt securing the positive boost lead to the output rectifier heatsink. See
Figure F.2. Label and disconnect positive boost lead.
7. Using a volt/ohmmeter (set for diode testing), perform the forward voltage drop test per Table F.1. See
Figure F.2. See Wiring Diagram.
8. If the tests determine that the diodes are shorted or open, the output rectifier assembly may be faulty.
9. When testing is complete connect any previously disconnected leads. See Wiring Diagram.
10. Perform the Case Cover Replacement Procedure.

Table F.1 - Output rectifier forward voltage drop tests

TEST POINT (POS) TEST POINT (NEG) EXPECTED READING

UPPER BUSS BAR OUTPUT RECTIFIER HEATSINK 0.2 VDC – 0.7 VDC

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TEST POINT (POS) TEST POINT (NEG) EXPECTED READING

LOWER BUSS BAR OUTPUT RECTIFIER HEATSINK 0.2 VDC – 0.7 VDC

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Figure 1. Output rectifier assembly location

Output rectifier assembly location

0000178404_x.png

Figure 2. Lead X11 and X12 connection point locations

Lead X11 and X12 connection point locations

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0000178404_x.png

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PFC BOOST BOARD TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the PCF Boost Board is functioning properly.

MATERIALS NEEDED
○ Volt/Ohmmeter
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the PFC boost board. See Figure F.1. See Wiring Diagram.
5. Using a volt/ohmmeter, perform the diode drop and resistance tests outlined in Table F.1. See Figure F.2. See
Wiring Diagram.
6. If any of the tests fail, label and disconnect leads from the terminals and retest. See Wiring Diagram.
7. If any of the tests still fail, the PFC boost board may be faulty.
8. If faulty, perform the PFC Boost Board Removal And Replacement Procedure.
9. Perform the Case Cover Replacement Procedure.

Table F.1 - PFC boost board diode drop and resistance tests

TEST POINT TEST POINT EXPECTED READING

TERMINAL B1 TERMINAL B7 0.3 VDC – 1.0 VDC

TERMINAL B5 TERMINAL B7 0.3 VDC – 1.0 VDC

TERMINAL B1 TERMINAL B7 GREATER THAN 100K OHMS

TERMINAL B5 TERMINAL B7 GREATER THAN 100K OHMS

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TEST POINT TEST POINT EXPECTED READING

TERMINAL B7 TERMINAL B2 0.3 VDC – 1.0 VDC

TERMINAL B7 TERMINAL B2 GREATER THAN 100K OHMS

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Figure 1. PFC boost board location

PFC boost board location

0000178384_x.png

Figure 2. PFC boost board terminal locations

PFC boost board terminal locations

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0000178403_x.png

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RETEST AFTER REPAIR

Retest a machine:

• If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s
electrical characteristics.

• If you repair or replace any electrical components.

TEST PROCEDURE

RATED OUTPUT TESTS

PROCESS DUTY CYCLE PHASES VOLTS (AT RATED AMPS) AMPS

GMAW (CV) 60% 3 31.5 350

GMAW (CV) 100% 3 29 300

GTAW (CC) 60% 3 24 350

GTAW (CC) 100% 3 22 300

SMAW (CC) 60% 3 34 350

SMAW (CC) 100% 3 32 300

FCAW-GS (CV) 60% 3 31.5 350

FCAW-GS (CV) 100% 3 29 300

FCAW-SS (CV) 60% 3 31.5 350

FCAW-SS (CV) 100% 3 29 300

GMAW (CV) 60% 1 29 300

GMAW (CV) 100% 1 27.5 270

GTAW (CC) 60% 1 22 300

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PROCESS DUTY CYCLE PHASES VOLTS (AT RATED AMPS) AMPS

GTAW (CC) 100% 1 20.8 270

SMAW (CC) 60% 1 32 300

SMAW (CC) 100% 1 30.8 270

FCAW-GS (CV) 60% 1 29 300

FCAW-GS (CV) 100% 1 27.5 270

FCAW-SS (CV) 60% 1 29 300

FCAW-SS (CV) 100% 1 27.5 270

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SPECIAL TESTING MODES

TEST DESCRIPTION
These modes can be used for calibration or to verify correct voltage and current calibration.

MATERIALS NEEDED
○ Grid Load Bank
○ Wiring Diagram
○ Certified Voltmeter And Ammeter

CONSTANT VOLTAGE GRID LOAD TESTING

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15. Carefully apply the correct input power to the machine and turn the machine ON. Allow at least thirty seconds
after power on before running this test to allow for the ArcLink system to be mapped.
16. The left display will read “VOL “ and the right display will show the preset voltage.
17. Adjust the output control knob or the 12-pin remote potentiometer to set the preset voltage desired for
testing.
18. Switch the weld terminals switch to the ON position (with the machine properly loaded by a grid load) and the
machine will show the actual voltage and current on the displays.
19. When the output control potentiometer is changed quickly while operating, the output may “drop out” during
a transition to a new voltage. This is normal for the special voltage grid load test mode. The meter reading on
the machine must match the readings on the certified meters.
20. Switch the weld terminals switch to the Remote position and the output will turn off.
21. Carefully remove the input power from the machine.
22. Place the #4 DIP switch in the OFF position.
23. Perform the Case Cover Replacement Procedure.

Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the DIP switch on the user interface board. See Figure F.1.
5. Place the #4 DIP switch in the ON position. See Figure F.1. All other DIP switches should be in the OFF
position.
6. Place the weld terminals on/remote switch into the remote position. See Figure F.2.
7. Place the weld process selection switch into the GTAW position. See Figure F.2.
8. The local/remote switch selects whether the local output control potentiometer or the remote 12-pin
connector potentiometer will be used. Place the local/remote switch in the appropriate position for the
testing situation. See Figure F.2.
9. The output control potentiometer controls current set (2 to 815 amps) when the local/remote switch is in the
Local position.
10. Turn the arc control potentiometer fully counter-clockwise (-10). See Figure F.2.
11. Turn the hot start knob to the “0” position. See Figure F.2.
12. If necessary, disconnect the 14-pin feeder connector. See Figure F.2.
13. The 12-pin remote connector controls current set (2 to 815 amps) when local/remote switch is in the remote
position.
14. Connect a load bank and the certified meters to the machine.
15. Carefully apply the correct input power to the machine and turn the machine ON. Allow at least thirty seconds
after power on before running this test to allow for the ArcLink system to be mapped.
16. The right display will read “Cur“ and the left display will show the preset for the current set.
17. Adjust the output control knob to set the preset current desired for testing.
18. Switch the weld terminals switch to the ON position (with the machine properly loaded by a grid load) and the
machine will show the actual voltage and current on the displays. The meter reading on the machine must
match the readings on the certified meters.
19. Switch the weld terminals switch to the remote position and the output will turn off.

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20. Carefully remove the input power from the machine.

21. Place the #4 DIP switch in the OFF position.
22. Perform the Case Cover Replacement Procedure.

Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the DIP switch on the user interface board. See Figure F.3.
5. Place the #8 DIP switch in the ON position. See Figure F.3. All other DIP switches should be in the OFF
position.
6. Place the weld terminals on/remote switch into the remote position. See Figure F.2.
7. Place the weld process selection switch into the GTAW position. See Figure F.2.
8. Place the local/remote switch in the local position. See Figure F.2.
9. Turn the output control potentiometer fully counter-clockwise (minimum). See Figure F.2.
10. Turn the arc control potentiometer fully counter-clockwise (-10) (minimum). See Figure F.2.
11. Turn the hot start knob to the “0” position (minimum). See Figure F.2.
12. Carefully apply the correct input power to the machine and turn the machine ON.
13. The displays will show “---” “---”.
14. The local/remote switch will be used to step through the test steps and the error log.
15. The left display will show the test step number.
16. Turn the local/remote switch to remote, then back to local in order to enter Step 1. The left display will show
the step number and the right display will show the value of the panel control or the remote control under
test. To advance from one step to the next, operate the local/remote switch in the same manner used to enter
step 1.
17. Step 1 - Arc Control Potentiometer, all models

ARC CONTROL SETTING LEFT DISPLAY RIGHT DISPLAY

AT MIN. POSITION 1 0

TURNING UP 1 INCREASING

AT MAX. POSITION 1 100

18. Step 2 – 14-pin Wire Feeder Remote Potentiometer, CONSTRUCTION and FX350 models:

14-PIN REMOTE SETTING LEFT DISPLAY RIGHT DISPLAY

UNCONNECTED 2 0

19. Step 2 – 14-pin Wire Feeder Remote Potentiometer, STANDARD model:

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14-PIN REMOTE SETTING LEFT DISPLAY RIGHT DISPLAY

AT MIN. POSITION 2 0

TURNING UP 2 INCREASING

AT MAX. POSITION 2 100

20. Step 3 – Machine Output Control, all models:

OUTPUT CONTROL SETTING LEFT DISPLAY RIGHT DISPLAY

AT MIN. POSITION 3 0

TURNING UP 3 INCREASING

AT MAX. POSITION 3 100

21. Step 4 – 12-pin Remote Potentiometer for STANDARD and CONSTRUCTION models, 3-pin Remote
Potentiometer for FX350 models:

3-PIN AND 12-PIN REMOTE SETTING LEFT DISPLAY RIGHT DISPLAY

AT MIN. POSITION 4 0

TURNING UP 4 INCREASING

AT MAX. POSITION 4 100

22. Step 5 – Hot Start Potentiometer, all models:

HOT START SETTING LEFT DISPLAY RIGHT DISPLAY

AT MIN. POSITION 5 0

TURNING UP 5 INCREASING

AT MAX. POSITION 5 100

23. Step 6 – Toggle Switches, FX350 model:

TOGGLE SWITCH SETTING LEFT DISPLAY RIGHT DISPLAY

AT INITIAL POSITIONS 6 1

24. Step 6 – Toggle Switches, CONSTRUCTION model:

TOGGLE SWITCH SETTING LEFT DISPLAY RIGHT DISPLAY

AT INITIAL POSITIONS 6 3

REMOTE TRIGGER (S2): ON 6 2

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TOGGLE SWITCH SETTING LEFT DISPLAY RIGHT DISPLAY

REMOTE TRIGGER (S2): OFF 6 3

25. Step 6 – Toggle Switches, STANDARD model:

TOGGLE SWITCH SETTING LEFT DISPLAY RIGHT DISPLAY

AT INITIAL POSITIONS 6 1

FEEDER TRIGGER (S3): ON 6 0

FEEDER TRIGGER (S3): OFF 6 1

REMOTE TRIGGER (S2): ON 6 0

REMOTE TRIGGER (S2): OFF 6 1

WELD TERMINALS (S5): ON 6 3

WELD TERMINALS (S5): OFF 6 1

26. Step 7 – Mode Switch, all models:

MODE SWITCH SETTING LEFT DISPLAY RIGHT DISPLAY

GTAW 7 0

SMAW 7 1

CV 7 2

CV-INNERSHIELD 7 3

ARCLINK (STANDARD MODELS) 7 4

27. Carefully remove the input power from the machine.

28. Place the #8 DIP switch in the OFF position.
29. Perform the Case Cover Replacement Procedure.

10. Turn the arc control potentiometer fully counter-clockwise (-10). See Figure F.2.
11. Turn the hot start knob to the “0” position. See Figure F.2.
12. Carefully apply the correct input power to the machine and turn the machine ON.
13. The displays will show “---” “---”.
14. The local/remote switch will be used to step through the test steps and the error log.
15. The left display will show the test step number.
16. Cycle the weld terminals switch until the left display shows “20”. The right display will show “---”.
17. Rotate the output control potentiometer clockwise.
18. The left display will show numbers between 1 and 25.
19. The right display will show the 25 most recent weld sequencer errors.
20. Return the output control potentiometer to zero.
21. Cycle the weld terminals switch again. The left display will show “21”. The right display will show “---”.
22. Rotate the output control potentiometer clockwise.
23. The left display will show numbers between 1 and 25.
24. The right display will show the 25 most recent weld controller errors.
25. Return the output control potentiometer to zero.
26. Cycle the weld terminals switch again. The left display will show “22”. The right display will show “---”.
27. Rotate the output control potentiometer clockwise.
28. The left display will show numbers between 1 and 25.
29. The right display will show the 25 most recent user interface errors.
30. Return the output control potentiometer to zero.
31. Carefully remove the input power from the machine.
32. Place the #8 DIP switch in the OFF position.
33. Perform the Case Cover Replacement Procedure.

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13. Cycle the weld terminals switch until the left display shows “ 9”. The right display will show the last three digits
of the switchboard software number (Example: S30146-07 is software, then the right display shows “607”).
14. Cycle the weld terminals switch until the left display shows “ 10”. The right display will show the last three
digits of the switchboard boot code version.
15. Cycle the weld terminals switch until the left display shows “ 11”. The right display will show the last three
digits of the switchboard main code version.
16. Cycle the weld terminals switch until the left display shows “ 12”. The right display will show the last three
digits of the switchboard parameter file version.
17. Cycle the weld terminals switch until the left display shows “ 13”. The right display will show the last three
digits of the switchboard weld set.
18. Cycle the weld terminals switch until the left display shows “ 14”. The right display will show the last three
digits of the user interface boot code version.
19. Cycle the weld terminals switch until the left display shows “ 15”. The right display will show the last three
digits of the user interface main code version.
20. Cycle the weld terminals switch until the left display shows “ 16”. The right display will show the last three
digits of the user interface parameter version.
21. At this point, all software has been verified.
22. Carefully remove the input power from the machine.
23. Place the #8 DIP switch in the OFF position.
24. Perform the Case Cover Replacement Procedure.

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Figure 1. User interface board DIP switch location and position

User interface board DIP switch location and position

0000178480_x.png

Figure 2. User controls locations

User controls locations

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0000178479_x.png

Figure 3. User interface board DIP switch location and position

User interface board DIP switch location and position

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0000178478_x.png

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SWITCHBOARD TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Switchboard is functioning properly. In order for this test to produce the
expected results the Switchboard must be receiving the correct input voltage from the Main Capacitor Board and
the proper gate drive signals from the Inverter Control Board.

MATERIALS NEEDED
○ Volt/Ohmmeter
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the switchboard. See Figure F.1. See Wiring Diagram.
5. Locate the inverter control board. See Figure F.2. See Wiring Diagram.
6. Using a volt/ohmmeter, perform the resistance and diode drop tests outlined in Table F.1. See Figures F.3,
F.4 and F.5. See Wiring Diagram.
7. If any of the resistance test results are not as expected, label and disconnect the leads attached to the
terminals and retest.
8. Carefully apply the correct input power to the machine and turn ON the machine.
9. Visually check the LEDs per Table F.2. See Figure F.3 for LED locations. See Wiring Diagram.
10. Using a volt/ohmmeter, measure the voltage between terminals B2 and B1. See Figure F.3. See Wiring
Diagram. Normal voltage is approximately 860 VDC.
11. If any of the tests fail, the switchboard may be faulty.
12. If faulty, perform the Switchboard Removal And Replacement Procedure.
13. Perform the Case Cover Replacement Procedure.

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Table F.1 - Switchboard resistance and diode drop tests

DESCRIPTION TEST POINT (POS) TEST POINT (NEG) EXPECTED READING

CHECKING SWITCHBOARD TERMINAL B4 SWITCHBOARD TERMINAL B2 0.3 TO 1.0 VDC

“HIGH-SIDE”
IGBTs

CHECKING SWITCHBOARD TERMINAL B3 SWITCHBOARD TERMINAL B2 0.3 TO 1.0 VDC

“HIGH-SIDE”
IGBTs

CHECKING SWITCHBOARD TERMINAL B2 SWITCHBOARD TERMINAL B4 100K OHMS

“HIGH-SIDE”
IGBTs

CHECKING SWITCHBOARD TERMINAL B2 SWITCHBOARD TERMINAL B3 100K OHMS

“HIGH-SIDE”
IGBTs

CHECKING “LOW- SWITCHBOARD TERMINAL B1 SWITCHBOARD TERMINAL B3 0.3 TO 1.0 VDC

SIDE” IGBTs

CHECKING “LOW- SWITCHBOARD TERMINAL B1 SWITCHBOARD TERMINAL B4 0.3 TO 1.0 VDC

SIDE” IGBTs

CHECKING “LOW- SWITCHBOARD TERMINAL B1 SWITCHBOARD TERMINAL B3 100K OHMS

SIDE” IGBTs

CHECKING “LOW- SWITCHBOARD TERMINAL B1 SWITCHBOARD TERMINAL B4 100K OHMS

SIDE” IGBTs

THERMISTOR PLUG J12 PIN 1 (LEAD 431) ON PLUG J12 PIN 2 (LEAD 433) ON 10K – 40K OHMS
TEST INVERTER CONTROL BOARD INVERTER CONTROL BOARD (TEMPERATURE
(WITH PLUG J12 (WITH PLUG J12 DEPENDANT)
DISCONNECTED) DISCONNECTED)

THERMISTOR PLUG J12 PIN 1 (LEAD 431) ON SWITCHBOARD TERMINAL B2 5K – 20K OHMS
TEST INVERTER CONTROL BOARD (TEMPERATURE
(WITH PLUG J12 DEPENDANT)
DISCONNECTED)

THERMISTOR PLUG J12 PIN 2 (LEAD 433) ON SWITCHBOARD TERMINAL B2 5K – 20K OHMS
TEST INVERTER CONTROL BOARD (TEMPERATURE
(WITH PLUG J12 DEPENDANT)
DISCONNECTED)

Table F.2 - Switchboard LEDs

LED LED LED FUNCTION

NUMBER COLOR

1 GREEN INDICATES SWITCHBOARD IS RECEIVING PRIMARY VOLTAGE FROM THE MAIN

CAPACITOR BOARD.

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LED LED LED FUNCTION

NUMBER COLOR

2 GREEN INDICATES SWITCHBOARD IS RECEIVING GATE DRIVE SIGNALS FROM THE

INVERTER CONTROL BOARD.

3 GREEN INDICATES SWITCHBOARD IS RECEIVING GATE DRIVE SIGNALS FROM THE

INVERTER CONTROL BOARD.

4 GREEN INDICATES SWITCHBOARD IS RECEIVING GATE DRIVE SIGNALS FROM THE

INVERTER CONTROL BOARD.

5 GREEN INDICATES SWITCHBOARD IS RECEIVING GATE DRIVE SIGNALS FROM THE

INVERTER CONTROL BOARD.

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Figure 1. Switchboard location

Switchboard location

0000178398_x.png

Figure 2. Inverter control board location

Inverter control board location

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0000178397_x.png

Figure 3. Switchboard terminal and LED locations

Switchboard terminal and LED locations

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0000178396_x.png

Figure 4. Inverter control board plug J12 location

Inverter control board plug J12 location

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0000178395_x.png

Figure 5. Inverter control board plug J12 lead locations

Inverter control board plug J12 lead locations

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0000178394_x.png

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THERMOSTAT #1 AND #2 CIRCUIT TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the Thermostat Circuit is functioning properly.

MATERIALS NEEDED
○ Volt/Ohmmeter
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate thermostat #1 on the output rectifier heatsink. See Figure F.1. See Wiring Diagram.
5. Label and disconnect leads #224 and #225 from thermostat #1. See Wiring Diagram.
6. Using a volt/ohmmeter, test the resistance from one thermostat terminal to the other. The resistance should
be very low (less than one ohm).
7. If the resistance is greater than one ohm, the thermostat may be faulty.
8. Thermostat #2 is located inside the output choke coil. See Wiring Diagram.
9. Label and disconnect the two in-line connections attached to leads #226 and #224 on thermostat #2 in the
output choke. See Wiring Diagram.
10. Using a volt/ohmmeter, check the resistance of thermostat #2 from lead #226 to #224. The resistance should
be very low (less than one ohm). See Wiring Diagram.
11. If the resistance is greater than one ohm, thermostat #2 may be faulty. If faulty, perform the Choke Removal
And Replacement Procedure.
12. Connect all previously removed leads. See Wiring Diagram.
13. Locate the inverter control board. See Figure F.2. See Wiring Diagram.
14. To check the thermostat circuit, locate plug J3 on the inverter control board. See Figure F.3. See Wiring
Diagram.
15. Label and disconnect plug J3 from the inverter control board. See Figure F.3. See Wiring Diagram.

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16. Using a volt/ohmmeter, check the resistance from plug J3 pin 5 (lead #225) to pin 13 (lead #226). See Figure
F.4. Resistance should be less than one ohm. If the resistance is greater than one ohm, there is an open or
high resistance connection in the thermostat circuit. See Wiring Diagram.
17. Connect any previously remove plugs and leads. See Wiring Diagram.
18. Perform the Case Cover Replacement Procedure.

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Figure 1. Thermostat #1 location

Thermostat #1 location

0000178452_x.png

Figure 2. Inverter control board location

Inverter control board location

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0000178451_x.png

Figure 3. Inverter control board plug J3 location

Inverter control board plug J3 location

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0000178450_x.png

Figure 4. Inverter control board plug J3 lead locations

Inverter control board plug J3 lead locations

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0000178449_x.png

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USER INTERFACE BOARD TEST PROCEDURE

TEST DESCRIPTION
This test will help determine if the User Interface Board is functioning properly.

MATERIALS NEEDED
○ Volt/Ohmmeter
○ Wiring Diagram

TEST PROCEDURE
Procedure Steps:
1. Turn off the Flextec 350X Power Connect machine.
2. Perform the Case Cover Removal Procedure.
3. Perform the Capacitor Discharge Procedure.
4. Locate the user interface board. See Figure F.1. See Wiring Diagram.
5. Using a volt/ohmmeter, perform the resistance tests outlined in Table F.1 with all plugs connected to the
board. See Figure F.2 and Figure F.3. See Wiring Diagram.
6. Carefully apply the correct input power to the machine and turn ON the machine.
7. Observe and make sure the status LEDs on the front and rear of the user interface board are indicating a
properly functioning user interface board. See Tables F.2 and F.3. See Figure F.2.
8. Using a volt/ohmmeter, perform the voltage tests outlined in Table F.4. See Figures F.2 and Figures F.3. See
Wiring Diagram.
9. If any of the tests fail, the user interface board may be faulty.
10. If faulty, perform the User Interface Board Removal And Replacement Procedure.
11. Perform the Case Cover Replacement Procedure.

Table F.1 - User interface board resistance tests

TEST POINT TEST POINT EXPECTED READING

PLUG J1 PIN 6 (LEAD PLUG J1 PIN 1 (LEAD 0 – 3.24 K OHMS DEPENDENT ON ARC CONTROL POT
281) 282) POSITION.

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TEST POINT TEST POINT EXPECTED READING

PLUG J1 PIN 5 (LEAD PLUG J1 PIN 3 (LEAD 0 – 3.24 K OHMS DEPENDENT ON OUTPUT CONTROL KNOB
252) 253) POSITION.

PLUG J1 PIN 4 (LEAD PLUG J1 PIN 2 (LEAD 0 – 3.24 K OHMS DEPENDENT ON HOT START KNOB
317) 316) POSITION.

Table F.2 - User interface board LEDs

LED NUMBER LED COLOR FUNCTION

1 AMBER THERMAL LED

2 GREEN VRD LED VOLTAGE REDUCED

3 RED VRD LED VOLTAGE NOT REDUCED

4 GREEN STATUS “OK”

4 RED/GREEN STATUS “ERROR” (CHECK CODE FOR SPECIFIC ERROR) (BI-COLOR)

5 GREEN +15 VDC POWER SUPPLY “OK”

Table F.3 - User interface board LED indication

LIGHT MEANING
CONDITION

STEADY GREEN SYSTEM “OK”

ALTERNATING A SYSTEM FAULT HAS OCCURRED. IF THE USER INTERFACE BOARD STATUS LED IS
GREEN AND RED FLASHING ANY COMBINATION OF RED AND GREEN, ERRORS ARE PRESENT. INDIVIDUAL
CODE DIGITS ARE FLASHED IN RED WITH A LONG PAUSE BETWEEN DIGITS. IF MORE THAN
ONE CODE IS PRESENT, THE CODES WILL BE SEPARATED BY A GREEN LIGHT. SEE FAULT
CODES.

Table F.4 - User interface board voltage tests

DESCRIPTION TEST POINT TEST POINT EXPECTED CONDITIONS

(POS) (NEG) READING

INPUT FROM AUXILIARY PLUG J4 PIN 4 PLUG J4 PIN 3 42 VDC MACHINE ON.
POWER BOARD (LEAD 52C) (LEAD 51C)

CAN COMMUNICATION PLUG J4 PIN 2 PLUG J4 PIN 1 2 VDC MACHINE ON.

(LEAD #54A) (LEAD #53A)

+15 VDC SUPPLY PLUG J3 PIN 3 PLUG J1 PIN 1 15 VDC MACHINE ON.
(LEAD #290) (LEAD #282)

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DESCRIPTION TEST POINT TEST POINT EXPECTED CONDITIONS

(POS) (NEG) READING

+10 VDC PLUG J1 PIN 7 PLUG J1 PIN 1 10 VDC MACHINE ON.

(LEAD #280) (LEAD #282)

WELD TERMINALS SWITCH PLUG J3 PIN 9 PLUG J3 PIN 4 0 VDC WELD TERMINALS SWITCH
(LEAD #212) (LEAD #210) ON.

WELD TERMINALS SWITCH PLUG J3 PIN 9 PLUG J3 PIN 4 15 VDC WELD TERMINALS SWITCH
(LEAD #212) (LEAD #210) OFF.

LOCAL/REMOTE SWITCH PLUG J3 PIN 10 PLUG J3 PIN 3 15 VDC LOCAL/REMOTE SWITCH IN

(LEAD #289) (LEAD #290) REMOTE POSITION.

LOCAL/REMOTE SWITCH PLUG J3 PIN 10 PLUG J3 PIN 3 0 VDC LOCAL/REMOTE SWITCH IN

(LEAD #289) (LEAD #290) LOCAL POSITION.

REMOTE TRIGGER PLUG J2 PIN 9 PLUG J1 PIN 1 15 VDC MACHINE ON.

(LEAD #4) (LEAD 282)

ARC CONTROL SUPPLY PLUG J1 PIN 7 PLUG J1 PIN 1 10 VDC MACHINE ON.
(LEAD #280) (LEAD #282)

OUTPUT CONTROL SUPPLY PLUG J1 PIN 8 PLUG J1 PIN 1 10 VDC MACHINE ON.
(LEAD #251) (LEAD #282)

MODE SWITCH PLUG J3 PIN 1 PLUG J1 PIN 1 15 VDC MODE SWITCH IN GTAW
(LEAD #308) (LEAD 282) POSITION.

MODE SWITCH PLUG J3 PIN 1 PLUG J1 PIN 1 12.5 VDC MODE SWITCH IN SMAW
(LEAD #308) (LEAD 282) POSITION

MODE SWITCH PLUG J3 PIN 1 PLUG J1 PIN 1 10 VDC MODE SWITCH IN CV-GAS
(LEAD #308) (LEAD 282) POSITION.

MODE SWITCH PLUG J3 PIN 1 PLUG J4 PIN 3 7.5 VDC MODE SWITCH IN CV-
(LEAD #308) (LEAD #51C) INNERSHIELD POSITION.

3(5)
162
0000178405

Figure 1. User interface board location

User interface board location

0000178408_x.png

Figure 2. User interface board plug and LED locations

User interface board plug and LED locations

4(5)
163
0000178405

0000178407_x.png

Figure 3. User interface board lead locations

User interface board lead locations

0000178406_x.png

5(5)
164
0000178342

General Description

Figure 1. Block diagram

Block diagram

0000178343_x.png

The Flextec 350X Power Connect™ is an inverter based welding power source that features integrated digital
control and power conversion electronics. It will automatically connect to any AC input (single or three phase)
voltages from 200 to 575 Volts. It communicates both internally and externally via ArcLink. It also has CrossLinc
capabilities that communicates with compatible wire feeders. Using CrossLink the operator can adjust the open
circuit voltage on the Flextec 350X Power Connect™ from the compatible wire feeder. This is accomplished by
sending a 1000 Hz pulse through the welding cables.
Note: Unshaded areas of Block Logic Diagram are the subject of discussion

1(1)
165
0000178340

Input Section

Figure 1. Input section

Input section

0000178341_x.png

When a single or three phase input voltage is applied through the line switch to the input / precharge SCR bridge
board the AC input voltage is rectified and controlled. This rectified voltage is applied, via the PFC boost board, to
the auxiliary power board. The auxiliary board is then powered up. The auxiliary power board creates the 42 VDC
and also sends 18 VDC to power the PFC boost board. The 42 VDC is applied to the UI board, the inverter control
board and the remote receptacles. After the PFC boost board is powered it sends a closure signal to the pre-
charge relay, located on the input / precharge SCR bridge board. The capacitor board is then charged to
approximately 860 VDC.
Note: Unshaded areas of Block Logic Diagram are the subject of discussion

1(1)
166
0000178335

Insulated Gate Bipolar Transistor (IGBT) Operation

Figure 1. Insulated gate bipolar transistor (IGBT) operation

Insulated gate bipolar transistor (IGBT) operation

0000178336_x.png

An IGBT is a type of transistor. IGBT are semiconductors well suited for high frequency switching and high current
applications.

Example A in Figure E.8 shows an IGBT in passive mode. There is no gate signal, zero volts relative to the source
and therefore, no current flow. The drain terminal of the IGBT may be connected to a voltage supply; but since
there is no conduction, the circuit will not supply current to components connected to the source. The circuit is
turned OFF like a light switch.

Example B shows the IGBT in an active mode. When the gate signals a positive DC voltage relative to the source,
is applied to the gate terminal of the IGBT, it is capable of conducting current. A voltage supply connected to the
drain terminal will allow the IGBT to conduct and supply current to the circuit components coupled to the source.
Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is
present. This is similar to turning ON a light switch.

1(1)
167
0000178334

Inverter Control Board And Switchboard

Figure 1. Inverter control board and switchboard

Inverter control board and switchboard

0000178339_x.png

The inverter control board is powered up by the 42 VDC from the auxiliary power board. From the 42 VDC the
inverter control board creates several DC supplies for the internal electronics and a +5 VDC supply for Arclink
communications. It also receives the 860 VDC capacitor voltage from the PFC boost board. The welding software is
housed on the inverter control board and it is the master of the ArcLink system and controls the CAN
communication. The welding voltage and current feedback are received by the inverter control board and also
user commands from the UI board via Arclink communication protocol. It then sends the appropriate IGBT gate
firing signals to the switchboard. The inverter control board also controls the cooling fans speed. The inverter
control board also monitors the thermostat and thermistor circuits. In addition, it monitors the Crosslinc circuit
and turns on the green LED when the Flextec 350X Power Connect™ is connected to a compatible crosslinc
wirefeeder.

The main function of the switchboard is to receive and process the rectified and filtered primary power received
from the input / precharge SCR bridge board and capacitor board. There are two quadrants of IGBTs housed on
the switchboard that operate at 25 kHz and provide pulse width modulated power to the primary windings of the
main transformer. The switchboard receives the IGBT gate firing signals from the inverter control board. See
Pulse Width Modulation and Insulated Gate Bipolar Transistor (IGBT) Operation. The switchboard has 5 LEDs
that indicate the current status of the board. LED 1 indicates that the board is receiving rectified and filtered
primary voltage from the capacitor board. LEDs 2 thru 5 indicate that the switchboard is receiving IGBT gate drive
signals from the inverter control board. The Pulse Width Modulated output of the switchboard is applied through
coupling capacitors to the primary of the main transformer.
Note: Unshaded areas of Block Logic Diagram are the subject of discussion

1(1)
168
0000178350

Main Transformer

Figure 1. Main transformer

Main transformer

0000178351_x.png

The main transformer is a step-down transformer. The primary windings receive the high voltage pulse width
modulated power from the switch board. The 25 KHz AC output that is created on the center tapped weld
secondary winding is applied to the output rectifiers. The boost winding output is applied to the boost relay via
the boost reactor. When welding output current is drawn the boost relay receives a 15 VDC control signal from
the inverter control board and the AC boost voltage is applied to the boost rectifier. The resultant elevated DC
voltage is applied through the output choke to the positive output terminal. The boost circuit is active only in the
SMAW mode.
Note: Unshaded areas of Block Logic Diagram are the subject of discussion

1(1)
169
0000178348

Output Rectifier And Choke

Figure 1. Output rectifier, choke and current transducer

Output rectifier, choke and current transducer

0000178349_x.png

There are two output diode modules mounted to a heatsink. The AC output of the center tapped weld secondary
winding, of the main transformer, is full wave rectified by the output rectifier. The resultant DC output has a 50
KHz ripple content. This output power is applied through the output choke to the positive output terminal.

The output choke is an inductor that helps with arc stabilization at low welding output currents. The inductance
allows for smoother arc and accurate waveform response.

Current Transducer (LEM)

The LEM converts welding current to a low voltage that is applied to the inverter control board for digital arc
control.
Note: Unshaded areas of Block Logic Diagram are the subject of discussion

1(1)
170
0000178337

Pulse Width Modulation

Figure 1. Typical IGBT outputs

Typical IGBT outputs

0000178338_x.png

The term Pulse Width Modulation is used to describe how much time is devoted to conduction in the positive and
negative portions of the cycle. Changing the pulse width is known as modulation. Pulse Width Modulation (PWM)
is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine.

1(2)
171
0000178337
Minimum Output

By controlling the duration of the gate signal, the IGBT is turned on and off for different durations during the
cycle. The top drawing in Figure E.7 shows the minimum output signal possible over a 40-microsecond time
period.

The positive portion of the signal represents one IGBT group1 conducting for one microsecond. The negative
portion is the other IGBT group1. The dwell time (off time) is 19 microseconds (both IGBT groups off). Since only
two microseconds of the 40-microsecond time period are devoted to conducting, the output power is minimized.

Maximum Output

By holding the gate signal on for 19-microseconds each and allowing only two microseconds of dwell time (off
time) during the 40-microsecond cycle, the output is maximized. The darkened area under the top curve can be
compared to the area under the curve indicates that more power is present.

1 An IGBT group consists of two IGBT modules feeding one transformer primary winding.

2(2)
172
0000178347

Thermal Protection
There are two separate thermal protection circuits in the Flextec 350X Power Connect™. Two normally closed
thermostats protect the output choke and the output rectifier bridge from over temperature. They are wired in
series and are connected to the inverter control board. These protect the machine against reduced airflow or
overload. If excessive operating temperatures should occur, the thermostats will open and the fans will turn on,
the thermal symbol will illuminate, the output will be disabled and error 36 will be logged and displayed.

Two thermistors, located on the top and bottom switch board heatsinks, protect the IGBT` quadrants in the
switch board. The resistance of these thermistors are read by the inverter control board and converted to
temperatures. If excessive operating temperatures should occur the fans will turn on, the thermal symbol will
illuminate, the output will be disabled and error 36 will be logged and displayed.

These devices are self-resetting once the machine cools down sufficiently or any overload is removed. If the
thermal shutdown was caused by excessive output or duty cycle and the fans were operating normally, the power
switch may be left ON and the reset should occur within a 15-minute timeframe. If the fans are not functioning
normally or the air intake louvers are obstructed, then the power must be removed from the machine and the fan
problem or air obstruction corrected.

If the machine was being operated in the “Remote” mode when the thermal fault occurred the remote trigger will
needed to be opened and closed when the thermal fault has cleared to re-established output.

The PFC boost board and auxiliary power board are also thermally protected. If the current draw on the auxiliary
power board exceeds four amps (for any reason) the fans will turn on. The welding output will NOT be disabled
and the thermal symbol will NOT be illuminated. If the PFC boost board exceeds its normal operating temperature
the fans will turn on. If the temperature continues to rise and exceeds a set limit then the welding output will be
disabled and the thermal symbol will illuminate.

Protective Circuits
Protective circuits are designed into the Flextec 350X Power Connect™ to sense trouble and shut down the
machine before damage occurs to the machine’s internal components.

1(1)
173
0000178352

User Interface (UI) Board

Figure 1. User interface (UI) board

User interface (UI) board

0000178353_x.png

The UI board is powered by the 42 VDC received from the auxiliary power board. LED 5 indicates that the on-
board power supply if functioning. Led 4 is the Arclink status indicator. The user controls, switches, and
connectors allow the operator to communicate to the UI board the desired processes and welding requirements.
The UI board then sends the desired parameters to the inverter control board via Arclink CAN communication.
The UI board displays to the user the preset settings (voltage and current). During welding the UI board will
display the actual voltage and current. The UI board also reads the input from the various receptacles used for
connections to external equipment such as wirefeeders and remote controls. There are two Voltage Reduction
Devices (VRD) lights on the board. When shipped the VRD function is disabled. VRD is enabled by setting the
dipswitch on the UI board. When the VRD is enabled the open circuit is reduced to about 15 VDC in the GTAW and
SMAW weld modes.
Note: Unshaded areas of Block Logic Diagram are the subject of discussion

1(1)
174
0000178346

1(1)
175
0000178481

TROUBLESHOOTING GUIDE
Observe Safety Guidelines detailed in the beginning of this manual.

FUNCTION PROBLEMS

PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF

ACTION

Major mechanical or
1. Contact your local Lincoln Authorized 1. Contact the Lincoln Electric
electrical damage is
Field Service Facility. Service Department at
evident.
1-888-935-3877.

The machine is “dead”.

1. Make sure the line switch is in the ON 1. Check the input switch for
No lights, no output, the
position. proper operation. Also check
machine appears to have
the associated leads for
no input power. 2. Check to make sure the correct input
loose or faulty connections.
power is present at the machine.
See Wiring Diagram.
2. Perform the Line Switch
Test Procedure.
3. Perform the Input Rectifier
And SCR (Pre-Charge)
Board Test Procedure.
4. Perform the Auxiliary
Power Board Test
Procedure.
5. Perform the Main Capacitor
Board Test Procedure.

There is no welding
1. Make sure the S5 weld terminals switch 1. Perform the PFC Boost
output from the Flextec
is in the “ON” position (standard models Board Test Procedure.
350X Power Connect
only).
machine. NOTE: This 2. Perform the Main Capacitor
problem may be 2. Make certain the correct input power is Board Test Procedure.
accompanied by an error being applied to the machine. The input
3. Perform the Switchboard
code. may be too high or too low. In this case
Test Procedure.
error 713 or 714 will be displayed.
4. Perform the User Interface
3. There may be a thermal shutdown.
Board Test Procedure.
Check the thermal LED.
5. Perform the Output
Rectifier Assembly Test
Procedure.
6. Perform the Inverter
Control Board Test
Procedure.
7. Perform the Main
Transformer Test
Procedure.
8. Perform the Choke Test
Procedure.

1(3)
176
0000178481

PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF

ACTION

9. Perform the Mode Select

Switch Test Procedure.

The thermal LED is “ON”.

1. The welding application may be 1. Perform the Thermostat #1
The machine regularly
exceeding the duty cycle and/or limits of and #2 Circuit Test
overheats.
the machine. Procedure.
2. Dirt or dust may have clogged the 2. Perform the Fan and F.A.N.
cooling channels inside the machine. Circuit Test Procedure.
3. Air intake and exhaust louvers may be
blocked due to inadequate clearance.
4. Make sure the fans are functioning
correctly. The unit is equipped with
F.A.N. (fan as needed) circuitry. The fans
run whenever the output current is
established and will continue running for
approximately five minutes after the
output current is disabled.

The machine turns on but

1. Turn the machine off and back on to re- 1. Perform the User Interface
the display is not visible,
boot. Board Test Procedure.
flickers or has missing
digits. 2. Check for loose or faulty connections at 2. Perform the Auxiliary
the user interface board. See Wiring Power Board Test
Diagram. Procedure.

The fan is running at all

1. Make sure there is no load on the output 1. Perform the Fan And F.A.N.
times.
terminals. Circuit Test Procedure.
2. Perform the Inverter
Control Board Test
Procedure.

Machine will not respond

1. Make sure the machine is in “Local” 1. Perform the User Interface
to the user controls and
control. Board Test Procedure.
switches.

The CrossLinc™ function

1. Make sure a compatible wire feeder 1. Check the cables between
does not work.
(LN-25X) is connected to the Flextec 350X the power source and the
Power Connect. feeder. The voltage drop
must be less than 10 VDC.
2. The weld voltage can only be adjusted
from the LN-25X when the Flextec 350X
Power Connect is in an OCV condition,
not welding.
3. The green CrossLinc™ LEDs on both
machines must be illuminated.

2(3)
177
0000178481

WELDING PROBLEMS

PROBLEMS POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION

(SYMPTOMS)

There is a general
1. Make sure the correct input power is 1. Perform the Choke Test
degradation of the
being applied to the machine. Procedure.
welding performance.
2. Make sure the machine’s controls are 2. Perform the Current Transducer
set correctly for the welding process (LEM) Test Procedure.
being used.
3. Perform the Output Rectifier
3. Check for poor connections or “loops” Assembly Test Procedure.
in the welding cables.
4. If using a wire feeder check for the
correct and consistent wire feed
speed at the wire feeder.

The machine looses

1. A secondary over-current may have 1. Perform the Output Rectifier
output during a weld.
occurred. The welding application Assembly Test Procedure.
may have exceeded the current
2. If in SMAW mode, perform the
limitations of the machine.
Boost Relay Test Procedure.
2. Make sure the correct input power is
3. Perform the Boost Rectifier Test
being applied to the machine.
Procedure.

Wire feeder won’t

1. Check the control cable connectors on 1. Make sure the wire feeder is
work. Apparently no
the case front of the machine to make connected correctly to the power
power to wire feeder.
sure it is properly connected. source. See Wiring Diagram and
Operators manual.
2. Check the control cable between the
power source and the wire feeder for
continuity.

3(3)
178
0000178409

USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS

Observe Safety Guidelines detailed in the beginning of this manual.

Errors are displayed on the user interface. In addition, there are status lights on the User Interface board and the
Switchboard that contain error sequences.

Included in this section is information about the status lights and some basic troubleshooting charts for both
machine and weld performance.

The status lights on the User Interface board, Crosslinc™, Input board, Inverter Control board and the
Switchboard are dual-color LED’s or green LEDs. Normal operation for each is described on the wiring diagram.

Error conditions are indicated in the following chart.

FAULT CODES

ERROR DESCRIPTION POSSIBLE CAUSE CORRECTIVE ACTION

CODE
NUMBER

6
1. Device that controls 1. Communication from the 1. Weld Terminals Remote: Re-
sequence of the Power Source failed before trigger to recover from error.
welding operation mapping was complete.
2. Weld Terminals Local: Toggle
halted due to an
Remote / Local Switch to
error.
recover from error.

18
1. ArcLink Auto- 1. The machine could not 1. Refer to the Operator’s
Mapping Failed. properly configure the Manual for proper
devices that are attached to configuration. Verify all
it. This configuration devices in the system are
problem could be caused by properly powered.
the type of devices that are
connected to the machine
or a required device that is
not connected.

21
1. Device that controls 1. A component of the system 1. Weld Terminals Remote: Re-
sequence of the encountered an error trigger to recover from error.
welding operation during the welding
2. Weld Terminals Local: Toggle
halted due to an sequence and caused
Remote / Local Switch to
error. system to stop. The
recover from error.
component with the error
could be a wire drive, a user
interface or some other
part of the system.

31
1. Primary Overcurrent. 1. Peak current through the 1. Check the input power
transformer primary has (voltage and frequency). Verify
exceeded its threshold. that the PC boards and input
rectifier are in working
condition and proper input
power and welding output

1(2)
179
0000178409

ERROR DESCRIPTION POSSIBLE CAUSE CORRECTIVE ACTION

CODE
NUMBER
cable connections. Verify
proper connections of main
internal power components.
Power must be cycled to the
machine to reset the error.

36
1. Thermal Fault. 1. Machine shut off output 1. Check for material blocking
due to elevated internal intake or exhaust louvers. •
temperatures. Blow air in the rear louvers to
clear dirt from the fan. NOTE:
The Fan As Needed circuitry
automatically shuts off the fan
5 minutes after welding has
stopped.
2. Welding output ratings may
have been exceeded. Allow
the machine to cool down and
reset.
3. Measure the thermostats at
the Switchboard and replace if
defective.

45
1. Output Voltage 1. During OCV, the voltage at 1. If VRD is enabled, the stud
Limit Exceeded. the studs exceeded the voltage exceeded 35 volts
allowable levels. peak. In standard operation,
the stud voltage exceeded 113
volts peak. Verify the voltage
feedback leads are properly
connected inside the machine.
Verify the input voltage is
within ¬± 10% of the nominal
value.

213
1. Communication 1. CAN communication 1. Power must be cycled to the
Fault. between the User Interface machine to reset the error.
board and the Switchboard Visually inspect the CAN
has been interrupted. harness to ensure connections
and condition. Verify power
supply to the User Interface
and Switchboard. Replace
defective assemblies as
required.

711
1. DC Link Capacitor 1. The voltage on the main DC 1. Verify all phases of the AC
Over/Under Voltage. link capacitors housed on input are connected.
the switchboard has either
gone too high or too low.

2(2)
180

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