Lincoln Electric BIG RED 500 Service Manual page 157

G-3
SCHEMATIC - BIG RED ® 500 CODE 11599 (G6822)
ENGINEERING CONTROLLED
MANUFACTURER:
High Temperature Ambient rating available, see IM Manual
Stick Rating: 65A - 500A, 90VDC, OCV Max (High RPM)
Tig Rating: 65A - 250A, 75VDC, OCV Max (High RPM)
Scratch start Tig Only.
WELD ROTOR
TIME DELAY RELAY
CR3
200A
200B
201
201A
ELECTRICAL DIAGRAMS
CHANGE DETAIL: New
No
SELECTOR SWITCH/COARSE CURRENT CONTROL
Tap 1: 65 - 115
Tap 2: 105 -220
Tap 3: 150 -330
Tap 4: 200 - Max
C2, B2, & A2 Leads are not used
Left side, front of fuel tank,
REACTOR
behind panel
Area front of fuel tank
(Buy Item)
C1
60 to 65VAC Phase to Phase
C2
C3
C4
THREE C5
TO PIN 8
C6 W3
HOT START PHASE
AMMETER
RECTIFIER
RELAY
(OPTIONAL) B1
B2
B3
B4
W4
212 B5 W4
ANALOG METER KIT OPTION
A1A
211 B6 W5
Top front
A1
BY-PASS FILTER
VOLTMETER ASSEMBLY A2
(OPTIONAL)
A3
100K
A4
R2
A5
A6
222A
221A
221 SELECTOR
SWITCH
A6A
222
221A Top left front case
SHUNT
50mV=800A
Connected only when
TO PIN 5 HOT
optional meters are
START RELAY (Buy Item)
connected.
HOT START CHOKES
On Output Stud
222
Lower center, left baffle area
(2 Chokes)
OUTPUT
STUDS
LEFT RIGHT
Middle Front Panel
RCD Option
3
115VAC CB4 3D 6J
3D 6J
15A
J10 L/+
5
240V/15A 120V/16A
3
1 PHASE 1 PHASE
(BLUE)
(YELLOW)
6E
115VAC
6
GND-D
NEUTRAL
6
W
B
AUXILIARY ROTOR MODULE
NEUTRAL
HOT START RELAY
CB1 CB6
6B 203B
204B
6A 203A R1
A6A 204C
235A 7D
235 6D
232T
5U CR4
CR1
232N
5Y
A1A
232T
SHUT DOWN RELAY
D2 D1
7
200A 204C
RELAY SOCKET
TOP OF
232E
201A 5H 232M
CAPACITOR
232P
232N
226
232P
234
D5 247
D3
5J
5U
203B 204
5Z 5N
5Y
204B
5P
5Z
5S
202A 202 602C
D1, D2, D3, D4, & D5 are T13637-5 (35A, 800V)
202A
CENTER PANEL DETAIL
Left side, forward
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
K2861-1 REMOTE CONTROL (Optional) 100 ft. Cable
G
PLUG FOR REMOTE
Y CONTROL POTENTIOMETER
X
G
B = BLACK
25
G = GREEN
B W
50W
W = WHITE
50 REMOTE CONTROL
POTENTIOMETER BOX
300W
RESISTORS CONNECT TO BASE
STICK/TIG
Shown in Stick mode
Front, below selector
WELD STATOR 7D
switch handle
(No Load)
Stator shrouds FINE CURRENT
50 , 300W
large blower CONTROL
REHOSTAT
Positive brush connected Top right of case
W2 paddles
W2 to slip ring nearest to front
required for
the lamination
cooling rotor &
W3
7A 6D
stator
See Detail for location CB1
200B 200A 15A
WELD
STATOR 163VDC
WINDINGS No D2
7 6B
Load 4200 F
LOCAL/REMOTE SWITCH
300VDC
201 201A Shown in Local position
W5
7C 6M
WELD See Detail for location
Max 5H
ROTOR at 25 v C
Closer to
engine
W6
Flashing from 115V when build up.
W6
W1
W1
204B
Positive brush connected to slip
15A
ring nearest to the lamination
203B
203A
CB6
204
First rotor in flashing.
150V
STICK / TIG 136VDC
D3
No 203B 602C
206A 206
Load
220
202
65VAC
AUXILIARY See Detail
202A
D4
207 for location
ROTOR
Close to front
AUXILIARY
221 v
STATOR 40.5-42.5 at 25 C
D5
0.204 Max
at 25 v C
5Z
CB3
6E
20A
6A B
CB2
6L
15A
5W
Middle Front Panel 6K
6L
B
J12
L/+
J11
Auxiliary welding can be done, but with
SILVER
5W
GND-E derating of output. See IM Manual
GND-G
Lower Front Panel
W
GND-E
GND-G
GND-D
W
B GND-M
Upper Front Panel
GFCI
Power Light
Goes out when tripped
20A
or no power to module
W2/W3
AUXILIARYPOWER
C4
C5
C3 C6
SELECTOR SWITCH CONNECTION DETAIL
INPUT SIGNAL
8V
4.5V
ON
OFF
OUTPUT RELAY (K1)
LOGIC DIAGRAM FOR
HOT START RELAY
HOT START RELAY
See Detail for location
6D
4 7
7D
REACTOR REACTOR
8 INPUT 5
VOLTAGE A1A A6A VOLTAGE
SIGNAL
SIGNAL
SIGNAL
B A
CR4
12VDC
STARTER
238A
5Y 212T SOLENOID
Stud on front
tank support
231 238B
6A
START
238
BUTTON
MOTOR
RUN/STOP
See Detail for location FLASHING
- +
CIRCUIT ALTERNATOR
5F 238 232H
D+
10
BATTERY LIGHT
25W
239 232D
D1
R1 204C Amber
232A
TIMER DELAY RELAY
232E
60 sec.
232N
5U - CR3
+
232T
OIL PRESSURE
AUXILIARY
STATOR SWITCH
ENGINE SHUTDOWN
RELAY
235A
Internal
OIL TEMP SWITCH 85 86
234 CR1 232E
Internal
ENGINE PROTECTION LIGHT 30
87
5T 232P
Amber
Part of Shutdown
Fuel Solenoid
HOLD COIL
87A
3 2
5S 226
FUEL GAUGE/HOUR METER
2 3
5K 232K
Top left of fuel tank Middle of Case Front
FUEL LEVEL J51
SENSOR
1
5J 229
230 EMPTY OIL PRESSURE GAUGE
Part of Oil Pressure Switch
30 FULL
1 3
5M 232B
Middle of Case Front
OIL PRESSURE
J53
SENSOR
2
228
OIL TEMP GAUGE
1 3
Grounded device 5L
232C
Middle of Case Front
OIL TEMP J52
SENSOR
5N
2
241
No Output Choke is required in this unit.
Idle Control: Unit stays at High Idle all of the time.
W1/W6
B4 A6/A6A
B5
ENGINE PROTECTION & MONITOR
B6 A3 A5
B3
A4
W4/W5 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PRO PRIETARY & C ONFIDENTIAL:
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUF ACTURING TO LERANCE PER E2056
CLEVEL AND SCALE:
UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: EQUIPM ENT TYPE:
Top View
ON 2 PLACE DECIMALS I S ± .02 in. ( ± 0.5 mm) NONE
ON 3 PLACE DECIMALS IS ± .002 in. ( ± 0.05 mm) DRAWN BY: Maglietta
IF PRINTED SUBJECT:
ON A LL AN GL ES IS ± .5 OF A DEGREE
@ A1 SIZE
MATERIAL TOLERANCE (" ") TO AGREE t ENGINEER: Farah
WITH PUBLISHED STANDARDS. UNITS:
MATERIAL
NA
DO NOT SCALE THIS DRAWING APPROVED: Farah INCH DISPOSITION:
G-3
+
12V BATTERY
Lower left side of welder, rear area
-
238B
CB5
236B
20A
Left side of engine support
236A
Start engine within 60 seconds or protection light will light
PRESSURE SWITCH OPERATION
Closes at 0.4 bar/6 psi +0.2 bar/3 psi
Normally Cloced
TEMPERATURE SWITCH OPERATION
v
Closes at 138 C
Normally Open
PRESSURE SENDER OPERATION
1 bar/14.5 psi 48
2 bars/29 psi 82
3 bars/43.5 psi 116
5.5 bars/80 psi 187
TEMPERATURE SENDER OPERATION
20 v C 1140
90 v C 80
v
130 C 27.9
No Idle control provided
Engine Specifications:
Deutz 2011L03i Diesel, 125 cu. in.
3 cylinder, 32 HP @ 1800 RPM
Idle - 1890 RPM Loaded - 1800 RPM
20 gal. Fuel tank
6.3 qt of Oil
Baffle required around stator
A square type oil cooling baffle is required. (Top of Machine)
Replacement fiters & belt; Information available in IM Manual
Fuel consumption: 40% Duty Cycle, approximately .97 gal/hr (See IM Manual)
BIG RE D 500 1 1
PAGE ___ OF ___
DOCUMENT DOCUMENT
MAC HI N E SC HEMATIC
NUMBER: REVISION:
G6822
REFERENCE: A
APPROVAL PROJECT
1/15/2010 CRM38354-A
G6791
DATE: NUMBER:
BIG RED ® 500/600