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Lincoln Electric VRTEX 360, Service Manual

The Lincoln Electric VRTEX 360 is a cutting-edge virtual welding simulator that provides a realistic training experience. Ensure your machine stays in top condition with the free Service Manual available for download at manualshive.com. Get your manual today and keep your VRTEX 360 running smoothly.

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NOTES

F-62

F-62

VRTEX 

TM

360

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Summary of Contents for VRTEX 360

Page 1: ...operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be ca...

Page 2: ...All manuals and user guides at all guides com...

Page 3: ...ING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the...

Page 4: ...arts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to...

Page 5: ...a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutti...

Page 6: ...Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et...

Page 7: ...he VR SMAW device and VR GMAW FCAW gun with care When not in use these items should be placed in the appropriate holders These devices are customized and cannot be used on normal welding machines Hand...

Page 8: ...96 EC on Waste Electrical and Electronic Equipment WEEE and its imple mentation in accordance with national law electrical equipment that has reached the end of its life must be collected sep arately...

Page 9: ...ge Safety i vi Installation Section A Operation Section B Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagrams Section G Parts Manual P 638 RETU...

Page 10: ...3 Safety A 4 Location A 4 Environmental Area A 4 Stacking Tilting Lifting A 4 High Frequency Interference Protection A 4 General Description A 5 Design Features A 5 Hardware Uncrating Set up A 5 A 8...

Page 11: ...must be con sulted in all cases where this symbol is displayed Explosion Dangerous Voltage Shock Hazard GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL U1 I1 1 Shock Hazard Return to Se...

Page 12: ...WEIGHT 78 0 in 39 0 in 47 0 in 102 lbs 1981 mm 990 mm 1194 mm 46 kg PHYSICAL DIMENSIONS STAND OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 410 950 F 50 350 C 320 1490 F 00 650 C TEMPERATURE R...

Page 13: ...ine inside and dry at all times Do not place it on wet ground or in puddles Never place liq uids on top of the machine STACKING The VRTEXTM 360 cannot be stacked ELECTRIC SHOCK can kill Only qualified...

Page 14: ...ortion in the motion tracking For best results do not install VRTEXTM 360 machine in the welding lab Electrical interference from power lines though gen erally small can be present Therefore all elect...

Page 15: ...4 Carefully slide the crate assembly from the VRTEXTM 360 5 Slide towards the rear of the machine Be careful to avoid damaging the welding device holders located on each side of the machine 6 Careful...

Page 16: ...the post at the 6 location 6 From the top slide the table onto the post letting it rest on the collar pin inserted in previous step 7 Insert the second collar pin into the post at the 13 position 8 Ob...

Page 17: ...e connected using the audio jack located on the back of the machine TRACKING SYSTEM FUNDAMENTALS The magnetic tracking system is composed of the following Control Unit Inside VR Machine o Contains the...

Page 18: ...360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user gu...

Page 19: ...4 Welders View B 15 Instructors View B 15 LASER Live Action Student Evaluation Report B 16 Technique Parameters B 16 Position B 17 Work Travel Angle B 18 Pass Number B 19 Timing Direction Discontinuit...

Page 20: ...included in this manual If the equipment is used in a manner not specified by the manufacturer the protection provided to the equip ment and user may be impaired Access panels are not to be removed ex...

Page 21: ...er to input wire feed speed amperage 5 The voltage dial allows the user to input the weld ing voltage This dial also allows input of trim values when pulse process is in use 6 The white screen select...

Page 22: ...d should now be fixed in that position Do not change the rod angle while the rod is extending or retracting VR SMAW DEVICE VR GMAW FCAW GUN CAUTION VR GMAW FCAW GUN Properly Stored CAUTION Store gun a...

Page 23: ...uld be stored there To open the drawer press the top indent down and slide the drawer out Each coupon fits in its own area defined by the foam locator in the drawer Coupons The coupons represent the v...

Page 24: ...an be pulled out for coupons to be inserted or removed and pushed in for coupons to be secured The front of the swing arm can be rotated down at a 45 or 90 degree angle to allow 2G 5G and 6G pipe weld...

Page 25: ...ence Select Imperial or Metric Units Shutdown System Continue to the next Setup Screen 1 On Screen Keyboard The user enters their name by using the joystick and red select button on the VR weld machin...

Page 26: ...measurement system Use the joystick to highlight the desired unit of measurement Press the red select button to accept Press the blue again to exit the measurement unit menu Selecting Metric or Imper...

Page 27: ...Short Arc Axial Spr ay Pulse STT E7018 E6010 Gas Shielded Self Shielded 1 4 6 1 8 3 1 4 6 3 8 10 1 4 6 3 8 10 1 8 3 1 4 6 3 8 10 3 8 10 3 8 10 3 8 10 3 8 10 2 XXS 50 6 Sch 40 150 2 XXS 50 6 Sch 40 15...

Page 28: ...in screen with the user s name removed Change Coupon Type Selecting Change Coupon Type goes back to the configuration selection screen Back Selecting Back takes the user to the previous screen Stand S...

Page 29: ...that appear next to the pin positions for the table and arm height into the stand setup screen The image on the right side of the stand setup screen moves to match the selections entered on the left I...

Page 30: ...REEN Menu Selecting Logout takes the user back to the login screen with the user s name removed Back Selecting Back takes the user to the previous screen STAND SET UP SCREEN OVERLAY Back Selecting Bac...

Page 31: ...yed on the monitor The Welder s view shows the helmets point of view The LASER screen displays a real time graph of the weld being made and gives a score when the user selects end pass The Instructor...

Page 32: ...r is within the tolerances set in the tolerances editor Generally these cues are color coded as well as symbolic When cues are red they indicate being out of tolerance Yellow cues indi cate close to t...

Page 33: ...ed to rotate through the LASER screen instructor s view and welder s view Welder s View screen Overview This screen shows the virtual view as seen by the user wearing the helmet Instructor s View scre...

Page 34: ...upon and the right side represents the right side of the coupon For vertical welds the graph is rotated so that it is vertical with the bottom representing the bot tom of the coupon and the top repres...

Page 35: ...p to work distance CTWD for VR GMAW and VR FCAW and arc length for VR SMAW are the dis tances from the tip of the VR GMAW FCAW gun or VR SMAW device to a plane going through the ideal position locatio...

Page 36: ...the user should be pushing or dragging If the user pushes when they should be drag ging they will not receive maximum points For pipe welding this is the angle between the electrode and the tan gent o...

Page 37: ...ce The user can choose between viewing the whole pipe or one of the four quadrants of the pipe Use the joystick to highlight the pipe section desired Travel Direction The travel direction is located o...

Page 38: ...ewing the WeldometerTM using the tolerance editor and setting other preferences In order to access instructor mode the user must first go back to the login screen This can be done on most screens by p...

Page 39: ...upons have been used and their cumulative weight Note that plate 3 8 includes groove joints as well as tee joints while plate 1 4 includes both tee joints and practice plates Gas tracks how much virtu...

Page 40: ...ps with Lincoln default welding parameters pre installed These default parameters can be modified by the instructor to reflect a specific welding application or technique The welding parame ters that...

Page 41: ...urrently shown The user can cancel out by pressing no or pressing the back button Pressing Rename brings the user to a keyboard screen where the name of the current file can be changed USB Edit This m...

Page 42: ...nue goes to the tolerance process selection screen Tolerances Process Selection Screen Overview The user selects which process to modify Menu Selecting Logout and then yes in the submenu brings the us...

Page 43: ...that range is accept able but will be scored lower the further it is from the ideal value As an example a work angle with an ideal of 45 degrees and a 1 of 10 degrees means that the user can use a wo...

Page 44: ...s in a mis placed weld Tolerances Welding Technique Parameters Screen Overview This screen allow for the modification of CTWD Arc Length Work Angle Travel Angle TOLERANCES WELDING TECHNIQUE PARAMETERS...

Page 45: ...le Time Travel Speed Tolerances Weave Screen Overview This screen allows for the modification of weaving welding technique including Width of Weave Weave Timing Weave Spacing WHIP TRAVEL SPEED SCREEN...

Page 46: ...STT 045 ER70S 6 SuperArc L 56 100C 15 35 5G Pipe down 130 to 150 NA GMAW Pulse 045 ER70S 6 SuperArc L 56 90A 10C 25 40 5G Pipe up 125 130 95 trim GMAW STT 045 ER70S 6 SuperArc L 56 100C 15 35 6G Pipe...

Page 47: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 48: ...ECTION D 1 D 1 VRTEX TM 360 Maintenance D 1 Cleaning and Maintenance D 2 Major Component Location D 3 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals an...

Page 49: ...ccasionally blow out dirt You may want to clean the inside of the helmet occa sionally Be sure to do so without exposing the FMD to any unacceptable materials as explained above The FMD should be kept...

Page 50: ...tand Assembly Accessories 6 Cart Assembly 7 Covers FIGURE D 1 MAJOR COMPONENT LOCATION 1 1 3 3 4 4 7 7 6 6 2 2 5 5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section T...

Page 51: ...to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user guides at all...

Page 52: ...AL USB VIDEO RECEPTACLE MONITOR VGA SPLITTER 12 VDC GREEN LED 12 VDC SUPPLY GREEN LED 5 VDC SUPPLY 5 VDC CPU COMPUTER ASSEMBLY U S B S I G N A L U S B POLHEMUS INTERFACE MODULE FROM CPU VGA 1 INTERFAC...

Page 53: ...INAL STRIP ON SWITCH INTERLOCK RELAY 5 VDC USB SIGNAL AUDIO 1 AUDIO RECEPTACLE DISPLAY LED PC BOARD INTERFACE MODULE DIGITAL USB VIDEO RECEPTACLE MONITOR VGA SPLITTER 12 VDC GREEN LED 12 VDC SUPPLY GR...

Page 54: ...rd 115 240 VAC 50 60 HERTZ SINGLE PHASE INPUT TERMINAL STRIP ON SWITCH INTERLOCK RELAY 5 VDC USB SIGNAL AUDIO 1 AUDIO RECEPTACLE DISPLAY LED PC BOARD INTERFACE MODULE DIGITAL USB VIDEO RECEPTACLE MONI...

Page 55: ...itor and the Video and Audio Receptacles FIGURE E 4 COMPUTER ASSEMBLY CPU FUNCTIONS USER CONTROLS INDICATORS VIDEO AUDIO COMPONENTS 115 240 VAC 50 60 HERTZ SINGLE PHASE INPUT TERMINAL STRIP ON SWITCH...

Page 56: ...feedback information to the CPU When the Stick Electrode Device is selected the Motor Control PC Board is commanded by the Interface Digital I O Module to retract the magnetic electrode to simulate t...

Page 57: ...360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user gu...

Page 58: ...FMD Controller and Helmet Removal and Replacement F 51 Relay PC Board Removal and Replacement F 55 5 Volt Supply Removal and Replacement F 59 12 15 Volt Supply Removal and Replacement F 63 ON Button R...

Page 59: ...possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer...

Page 60: ...m the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immedia...

Page 61: ...AC Terminal Block See the wiring diagram If the correct volt is not present check the continuity of leads 101 and 102 If the correct volt is present at the Upper AC Terminal Block leads 101 to 102 che...

Page 62: ...eing applied to the VRTEXTM 360 115 230VAC single phase With the ON Switch activated 5VDC should be present at the Input Relay Coil Terminal A1 Red Lead to Terminal A2 Black Lead See the wiring diagra...

Page 63: ...green light via a USB cable Verify that the green LEDs on the 5VDC Power Supply and the 12VDC Power Supply are on If they are not then perform the 5VDC Power Supply Test and the 12VDC Power Supply Te...

Page 64: ...nd the Video Monitor Check for loose or faulty connections between the VGA Splitter and the CPU Computer Assembly See the wiring diagram Check for the presence of 12VDC at the VGA Splitter See the wir...

Page 65: ...ring diagram The Wire Feed Speed and Output Controls are encoders and are connected to the User Interface Digital IO Module See the wiring diagram Make sure the devices in question are not damaged and...

Page 66: ...ce Module and the CPU for loose or faulty connections Check the USB connections between the Polhemus Interface Module and the CPU for loose or faulty connections Make sure the FMD Control Unit is are...

Page 67: ...nections between the Motor Control PC Board and the VR SMAW Device See the wiring diagram Check for loose or faulty connections between the Motor Control PC Board and the Relay PC Board See the wiring...

Page 68: ...erform the Interface Digital Module IO Test The Relay PC Board may be faulty The VR GMAW Device may be faulty There is jitter or shaking in the Helmet display and Monitor Make sure there is not any TI...

Page 69: ...check settings are activated the incorrect settings appear Check the settings in the Instructor Mode Make sure all of the settings are correct for the process and parameters being used Check for the...

Page 70: ...data will only be available for the first pass Again End Pass must be pressed before a new pass is started Use the joystick to go to pass number and change which pass data you are looking for Note tha...

Page 71: ...to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user guides at all...

Page 72: ...form the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid...

Page 73: ...is lit See Figure F 2 If so con tinue to step 10 NOTE This indicates that the machine is receiv ing the correct input power If the green LED is not lit continue to step 8 ELECTRIC SHOCK can kill Have...

Page 74: ...ct all associated leads 50 to 81 from the 5 Volt Supply terminals 12 Re check for the presence of 5VDC at the supply terminals 13 If 5VDC is not present and the correct input voltage is being applied...

Page 75: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 76: ...pairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid the technician i...

Page 77: ...indicates that the machine is receiv ing the correct input power If the green LED is not lit continue to step 8 TROUBLESHOOTING AND REPAIR F 20 F 20 VRTEX TM 360 12 15 VOLT SUPPLY ELECTRIC SHOCK can k...

Page 78: ...l and disconnect all associated leads 72 to 71 from the 12 Volt Supply terminals 12 Re check for the presence of 12VDC at the supply terminals 13 If 12VDC is not present and the correct input voltage...

Page 79: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 80: ...form the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid...

Page 81: ...wer switch is in the ON position Not all units have an ON switch 8 Verify that the FMD Control Unit is receiving 5 VDC from the 5 volt power supply If not check for loose or faulty connections between...

Page 82: ...roper connections are intact the FMD may be faulty Replace Perform the FMD Control Unit Removal and Replacement Procedure 11 Perform the Case Cover Replacement Procedure 12 Perform the Monitor and Ped...

Page 83: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 84: ...m the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid the...

Page 85: ...dure 4 Connect the input power 5 Power up the machine 6 Locate the Interface Digital Module I O See Figure F 7 ELECTRIC SHOCK can kill Have a qualified individual install and service this equip ment T...

Page 86: ...properly between the Interface Digital Module I O and the CPU Try connecting a new USB cable to a different available port on the CPU NOTE Make sure that there are no shorts between the ribbon cables...

Page 87: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 88: ...o perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will...

Page 89: ...4 Connect the input power 5 Power up the machine 6 Locate the USB Interface Module See Figure F 9 ELECTRIC SHOCK can kill Have a qualified individual install and service this equip ment Turn the inpu...

Page 90: ...n LED is not lit check the USB con nection between the CPU and the USB Interface Module Try connecting a new USB cable to a different available port on the CPU See wiring diagram 11 If the LED is not...

Page 91: ...to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user guides at all...

Page 92: ...form the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid...

Page 93: ...input power 5 Power up the machine 6 Locate the Polhemus Interface Module See Figure F 11 ELECTRIC SHOCK can kill Have a qualified individual install and service this equip ment Turn the input supply...

Page 94: ...eck for loose or faulty con nections between the FMD control unit and the following Welding Stand CPU FMD Control Unit Relay PC Board Note See wiring diagram 11 If the LED is not lit check for the pre...

Page 95: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 96: ...pairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid the technician i...

Page 97: ...pletely remove the top two phillips screws unless a new monitor is required 5 The monitor can now be removed Note It is not necessary to remove the pedestal if just the monitor is to be replaced 6 Usi...

Page 98: ...the new monitor 3 Slide monitor onto pedestal and install bottom two screws previously removed 4 Tighten all four phillips screws securing monitor 5 Connect power supply cord and VGA cable pre viousl...

Page 99: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 100: ...ble to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure...

Page 101: ...st be depressed See Figure F 16 3 Pull drawer out and away from machine 4 Using a 3 8 wrench remove the seven screws securing the coupon drawer mounting frame to the case sides and back 5 Carefully re...

Page 102: ...tracks on bot tom of drawer with tracks on frame and push to close 5 Carefully negotiate monitor leads through hole in case roof while setting in place 6 Replace black plastic grommet previously remo...

Page 103: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 104: ...test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid the tech...

Page 105: ...am 6 Remove the five associated cables connected to the Polhemus Module Note and label the locations before disconnecting See Figure F 18 7 Carefully remove Polhemus Module from hori zontal mounting s...

Page 106: ...at the rear of the Polhemus Module is in the ON position Also make sure that the five pins on the dip switch are in the OFF position down 3 Perform Case Cover Replacement Procedure 4 Perform the Moni...

Page 107: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 108: ...ncoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid the technician in the removal and replaceme...

Page 109: ...crews securing the FMD Controller access plate exposing the access hole See Figure F 20 8 Disconnect sensor 2 plug from the polhemus module See Figure F 18 See wiring diagram 9 Remove any necessary ca...

Page 110: ...viously removed cable ties 5 Secure previously leads using the previously removed strain relief devices 6 Secure the access plate 7 Close door on front of machine 8 Perform the Case Cover Replacement...

Page 111: ...to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user guides at all...

Page 112: ...o perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will...

Page 113: ...ure F 21 5 Label and remove the three cables J2 J3 J4 from the relay board See Figure F 22 6 Remove the 8 pin molex plug J1 See Figure F 22 7 Carefully remove the relay board from the four mounting st...

Page 114: ...ed 8 pin molex plug J1 4 Connect the three cables J2 J3 J4 previ ously removed 5 Perform the Case Cover Replacement Procedure 6 Perform the Monitor and Pedestal Replacement Procedure 7 See Retest Afte...

Page 115: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 116: ...st repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid the technic...

Page 117: ...rewdriver remove leads 102A white 103B pink red and the green ground lead from the bottom of the Supply Module See Figure F 24 6 Label and remove the positive and negative leads 81 81 50 50 from the t...

Page 118: ...Supply Module to the DIN rail 3 Connect all previously removed leads to their proper locations on the Supply Module 4 Perform the Case Cover Replacement Procedure 5 Perform the Monitor and Pedestal Re...

Page 119: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 120: ...st repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid the technic...

Page 121: ...r remove leads 102B white 103C pink red and the green ground lead from the bottom of the 12 15VDC Supply Module See Figure F 26 6 Label and remove the positive and negative leads 71 71 72 72 from the...

Page 122: ...e 2 Secure the new Supply Module to the DIN rail 3 Connect all previously removed leads to their proper locations on the Supply Module 4 Perform the Case Cover Replacement Procedure 5 Perform the Moni...

Page 123: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 124: ...re unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This pro...

Page 125: ...associated leads 101B 103A 90 91 from the ON Button See wiring diagram 6 Remove switch from push button by pushing in and turning a turn counter clockwise 7 If necessary remove the nut and push butto...

Page 126: ...the ON Button 4 Perform the Case Cover Replacement Procedure 5 Perform the Monitor and Pedestal Replacement Procedure 6 See Retest After Repair TROUBLESHOOTING AND REPAIR F 69 F 69 VRTEX TM 360 Retur...

Page 127: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 128: ...the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid the technician in the removal and rep...

Page 129: ...erface Module Digital I O NOTE The interface module digital USB is secured to the Interface Module Digital I O with Hook Loop mounting pads 6 Disconnect the large ribbon cable See Figure F 30 7 Label...

Page 130: ...Shortcut to Start up Sim See Figure F 31 7 Click x to close screen and cancel loading At this point a basic computer screen desktop will appear 8 Computer may show a found new hardware screen Click n...

Page 131: ...wn the VRTEXTM 360 via a normal CPU shutdown Click Start Turn off computer Turn off 15 Remove input power after CPU has complete ly shut down 16 Disconnect the USB keyboard and mouse 17 Perform Case C...

Page 132: ...rs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid the technician in t...

Page 133: ...onnect the USB cable See Figure F 34 6 Unplug the 16 pin terminal strip from the Interface Module USB See Figure F 34 7 Carefully remove the Interface Module USB from the top of the interface module d...

Page 134: ...r to the machine 6 Wait for Shortcut to Start up Sim See Figure F 35 7 Press x to cancel loading At this point a basic computer screen desktop will appear 8 Computer may show a found new hardware scre...

Page 135: ...Interfaces click USB Devices click USB 0 14 In the box labeled Visa Alias on my system type these letters LECSPI in CAPS 15 Save and close out screen 16 Shut down the VRTEXTM 360 via a normal CPU shu...

Page 136: ...ontinued TROUBLESHOOTING AND REPAIR F 79 F 79 VRTEX TM 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to M...

Page 137: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 138: ...to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure wil...

Page 139: ...arefully lower the control panel 4 Locate the Display Board See Figure F 37 5 Remove plug J37 from the display board See Figure F 38 6 Carefully remove the Display Board from the three mounting stand...

Page 140: ...d from the Display Board 3 Close the control panel 4 Install the two 3 8 screws previously removed from the top of the control panel 5 Turn on input power 6 See the Retest After Repair TROUBLESHOOTING...

Page 141: ...to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user guides at all...

Page 142: ...he test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid the te...

Page 143: ...om terminal strip See Figure F 40 See the Wiring Diagram 7 Using the small flathead screwdriver remove the three leads 50W 20 18 from the top ter minal strip on the Motor Control Board See Figure F 40...

Page 144: ...leads to their proper terminals See wiring diagram 3 Perform Case Cover Replacement Procedure 4 Perform the Monitor and Pedestal Replacement Procedure 5 See the Retest After Repair TROUBLESHOOTING AND...

Page 145: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 146: ...rm the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid th...

Page 147: ...from the relay board See Figure F 22 6 Using the 3 8 wrench remove the two screws holding the sheet metal strain relief to the front panel See Figure F 42 7 Locate and disconnect the 16 pin molex styl...

Page 148: ...ard 3 Reconnect the 16 pin molex cable splice 4 Turn on input power 5 Perform Case Cover Replacement Procedure 6 Perform the Monitor and Pedestal Replacement Procedure 7 See the Retest After Repair TR...

Page 149: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 150: ...erform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will ai...

Page 151: ...screws holding the sheet metal strain relief to the front panel See Figure F 44 6 Locate the VGA cable splice audio style con nector and disconnect See wiring diagram 7 Disconnect VGA cable splice Y...

Page 152: ...usly removed VGA cables Y adapter and audio style connector 3 Perform Case Cover Replacement Procedure 4 Perform the Monitor and Pedestal Replacement Procedure 5 See the Retest After Repair TROUBLESHO...

Page 153: ...M 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user g...

Page 154: ...the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure will aid the t...

Page 155: ...and move the FMD controller aside 6 Label and remove the four cables connected to the VGA Splitter See Figure F 46 7 Remove the VGA Splitter Module from the hor izontal mounting shelf NOTE The VGA Spl...

Page 156: ...VGA Splitter using Hook Loop mounting pads 4 Perform Case Cover Replacement Procedure 5 Perform the Monitor and Pedestal Replacement Procedure 6 Turn on input power 7 See the Retest After Repair TROUB...

Page 157: ...TM 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user...

Page 158: ...le to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This procedure...

Page 159: ...in relief from the Table Swing Arm cable at the rear of the machine See Figure F 48 7 Remove any cable ties 8 Carefully slide the Table Swing Arm off of the top of the table mounting post 9 Remove the...

Page 160: ...able ties 6 Install the strain relief from the Table Swing Arm cable previously removed from the rear of the machine 7 Connect the previously removed cable labeled SOURCE to the polhemus module 8 Perf...

Page 161: ...n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC All manuals and user guides at al...

Page 162: ...e unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3878 TEST DESCRIPTION This proc...

Page 163: ...reful not to stretch or break any leads or connections 9 Label and remove the five USB cables from the rear of the CPU See Figure F 52 See wiring diagram 10 Label and remove the three VGA cables from...

Page 164: ...proper location and secure using the three screws previously removed 8 Connect the previously removed external audio jack into the CPU 9 Install the strain relief securing the welding stand cable 10...

Page 165: ...ING AND REPAIR F 108 F 108 VRTEX TM 360 STRAIN RELIEF 3 8 SCREWS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Retur...

Page 166: ...SHOOTING AND REPAIR F 109 F 109 VRTEX TM 360 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retu...

Page 167: ...tton and then using the joystick select Change Process Select Yes 13 Navigate through the following See the Operation Section of this manual a Select coupon must match actual coupon in arm b Select 3...

Page 168: ...Diagrams G 1 Schematic Entire Machine G3244 565 G 2 Schematic Relay PC Board M22295 1D0 G 3 PC Board Assembly Relay PC BD M22296 1 G 4 Return to Master TOC Return to Master TOC Return to Master TOC R...

Page 169: ...ENCODER 1 CH A WFS ENCODER 1 CH B SET RELAY RST RELAY 50V 26 28 30 32 36 38 40 42 44 46 48 48 38 40 42 44 46 36 32 30 28 26 7 5 3 31 WFS ENCODER 1 V ENCODER 2 1 2 3 1 2 3 47 50N 45 43 41 50P 50N 50P...

Page 170: ...r reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to M...

Page 171: ...2 19 2010 BSB MBRANT OBS DRAWN BY ENGINEER CLEVELAND APPROVED CONTROL M22296 1 VR WELDER M22296 1 D11 D16 D7 D6 D13 D14 D5 D3 D12 D4 C1 C2 D9 J4 J3 J2 CR9 CR11 CR10 D15 D10 D2 D8 D1 CR1 CR8 CR2 CR3 CR...

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