Lincoln Electric 12596 - User Manual

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SERVICE MANUAL

Flextec

650x

SVM278 | Issue D ate 17-Aug

For use with machines having Code Numbers:

Flextec 650x: 12596

Main Page

Section A: Warnings3
Electric Shock Can Kill4
Table of Contents6
Flextec® 650X6
Service Manual6
Theory of Operation8
Input Section8
Switch Board and Main Transformer9
Output Section10
DC Bus Board, User Interface Board and Vrd (Voltage Reduction Device)11
Crosslinc™ Capability12
Thermal Protection12
Protective Circuits12
Under/Over Voltage Protection12
Insulated Gate Bipolar Transistor (Igbt) Operation13
Pulse Width Modulation14
Troubleshooting & Repair15
How to Use Troubleshooting Guide15
Pc Board Troubleshooting Procedures16
Troubleshooting Guide17
Using the Status Led to Troubleshoot System Problems21
Test Procedures23
Case Cover Removal and Replacement Procedure23
Materials Needed23
Capacitor Discharge Procedure25
Test Description25
Thermostat 3 (Auxiliary Transformer Thermostat) Test Procedure27
Thermal Protection Thermostat Test Procedure30
Output Rectifier Test Procedure32
User Interface Board Test Procedure35
Switch Board Test Procedure39
Operation41
Current Transducer (Lem) Test Procedure44
40Vdc Bus Board Test Procedure47
Main Transformer Test Procedure50
Input Rectifier Test Procedure53
Auxiliary Transformer (T2) Test Procedure55
Fan and F.a.n. Circuit Test Procedure58
Auxiliary Rectifier (D3) Test Procedure61
Choke Test Procedure63
Input Switch Test Procedure65
Removal and Replacement Procedures68
Thermostat 2 Removal and Replacement Procedure68
Output Rectifier Removal and Replacement Procedure70
User Interface Board Removal and Replacement Procedure73
Switch Board Removal and Replacement Procedure75
Current Transducer (Lem) Removal and Replacement Procedure78
40Vdc Bus Board Removal and Replacement Procedure81
Main Transformer Removal and Replacement Procedure83
Input Rectifier Removal and Replacement Procedure86
Auxiliary Transformer Removal and Replacement Procedure88
Auxiliary Rectifier Removal and Replacement Procedure90
Choke Removal and Replacement Procedure92
Retest after Repair96
Voltage Calibration97

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Lincoln Electric 12596 Specifications

General

Brand	Lincoln Electric
Model	12596
Category	Welding System
Language	English

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Lincoln Electric 12596 - User Manual

Table of Contents

Lincoln Electric 12596 Specifications

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