Lincoln Electric PRECISION TIG 185 SVM169-A Service Manual page 99

G-3
SCHEMATIC - ENTIRE MACHINE - (G4588)
G4588 ENGINEERING CONTROLLED CHANGE DETAIL: RELEASED FROM X A.02
MANUFACTURER: No
OUTPUT CONTROL &
MODE SETTINGS ARE
MEMORIZED AT POWER
- DOWN AND RECALLED
AT POWER - UP
POWER-UP SEQUENCE
METER AND MODE DISPLAY THE PREVIOUS OUTPUT
CONTROL AND MODE SETTINGS. FAN RUNS FOR 5
SECONDS. IF MODE IS TIG, GAS FLOWS FOR A TIME
+15V
SET BY THE POSTFLOW KNOB. OUTPUT IS HOT IF
MODE IS STICK. IN TIG MODE OUTPUT IS COLD UNTIL
S1
TRIGGER IS CLOSED
MODE
TOGGLE BETWEEN TIG &
TYPICAL OCV STICK.
HI-FREQ, GAS, BALANCE
65V IN DC
CONTROL, PULSE
75V IN AC FREQUENCY, &
MICRO-START CIRCUIT
+5Vref
ARE DISABLED IN STICK
A
C
OUTPUT CONTROL B
METER, ENCODER, SWITCH, LEDs,
(ENCODER)
AND ALL POTENTIOMETERS ARE
5 - 185A IN DC A1
MOUNTED ON PC BOARD
7 - 185A IN AC
+5Vref
From Auto Loc/Rem
MAX. PENETRATION
CW CW
BALANCE CONTROL IS
BALANCE R1
DISABLED IN STICK AND
10K
DC TIG MAX. CLEANING
AUTO
+5Vref
20 HZ
CW CW
PULSE FREQUENCY IS PULSE FREQUENCY
R2
DISABLED IN STICK
0.1 HZ
10K
OFF
+5Vref
30 S
CW CW
POSTFLOW R3
10K
1 S
LED 1
STICK
(RED)
NEXT TO MODE SWITCH
LED 4
FREQUENCY
AUT0BALANCE
(GREEN)
(GREEN)
NEXT TO PULSE
NEXT TO BALANCE POT.
FREQUENCY POT.
OFF IN STICK AND DC TIG
OFF IN STICK, BLINKS AT
FREQUENCY RATE
TO MICRO
PROCESSSOR
AUTO
LOCAL/ +15V
REMOTE
CONTROL -15V
AUTO LOCAL/REMOTE
STICK MODE: ALWAYS LOCAL
TIG MODE: REMOTE IF PLUGGED
LOCAL IF UNPLUGGED
RF
RECEPTACLE
CHOKES
Left front
4 PIN (WHITE)
U A 1J5
PROGRAMMING
CONNECTOR
10K N B 3J5
J6
R C 2J5
B D 5J5
+5Vref
(GREEN)
W E 6J5
F
POSTFLOW
TOROID
TM
OPTIONAL AMPTROL REMOTE
CONTROL AND ARC START SWITCH
HI-FREQ BYPASS CONNECTION HI-FREQ BYPASS
FROM BOTTOM LEFT
CONNECTION
MOUNTING HOLE TO SHEET
METAL
DISPLAY PRESET AT IDLE +15V +5V +24V
5J2
ACTUAL AMP WHEN WELDING
6J2
NO HOLD FUNCTION
3J2
8J2
3 DIGIT FIRE_SCR
SCR
2J2
METER
GATING & SNUBBER
1J2
(DISP1)
4J2
+5V
7J2
+15V PHASE
METER
INTERFACE
BACKGROUND AC INPUT
11J3
MICRO-START
BACKGROUND ( - )
BG
10J3
CIRCUIT
BACKGROUND ( + )
+5Vref 9J3
BACKGROUND AC INPUT
(DISABLED IN STICK)
12J3
+15V -15V
TOROID
PHASE_FIRE
1J1
OUTPUT REGULATOR 2J1
Iarc
SETPOINT
+24V +5Vref
5J3
DET_REM Polling signal AC/DC
INTERFACE
REM_SENSE Hi = Local
6J3
REM_POT Remote control
2J3
THERMOSTAT
INTERFACE
1J3
+24V +5Vref
DATA 1J6
SCLK PROGRAMMING CONNECTOR
2J6
FOR SOFTWARE UPGRADE
XRES 3J6
4J6
+5Vref
+15V
PHASE
115V CIRCUIT
MICRO-
TRIAC & OPTO-TRIAC
PROCESSOR TRIGGER
DRIVER
+5V
LED INTERFACE
4J4
1J4
LED 3
TIG 3J4
(GREEN)
2J4
NEXT TO MODE SWITCH
TO MICRO PROCESSOR
AND SCR GATING
PHASE
LED 6
LED 5 LED 2
THERMAL THERMAL
(YELLOW) (YELLOW)
NEXT TO METER
NEXT TO METER
TWO THERMAL LEDs TO
LIGHT THROUGH
PHASE
BACK-LIT THERMAL
DETECTOR
SYMBOL
+5V
+5V
DO NOT REVERSE LEADS
+24V
209 & 210, USED FOR SCR
PHASE TIMING
+15V
7J3
TRIGGER TRIGGER +5V
POWER SUPPLY CONTROL BOARD SUPPLY
INTERFACE +5Vref
TO MICRO
8J3
PROCESSOR -15V
4J3
J1 2 PIN
J2
3J3
8 PIN
+15V
AUX. WINDINGS OF
(GREEN)
MAIN TRANSFORMER T1
MICRO-PROCESSOR
X1
MODE
J3
+5V
OUTPUT CONTROL
SOFTWARE (GREEN)
VERSION LABEL
12 PIN
J4
FREQUENCY BALANCE
J5 4 PIN
6 PIN
CONTROL PCB MAIN COMPONENT & DIANOSTIC LED LAYOUT
(VIEWED FROM COMPONENT SIDE) CONTROL PC BOARD
Front Panel Top
SCHEMATIC G4550-
ASSEMBLY G4551-
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS
SCR1 GATE 216
G1
SCR2 GATE G2 G4 4
SCR3 GATE G3
G3 3
SCR4 GATE G4
Rear of machine attached to
G2 2
SCR3,SCR2 CATHODE 218
base, below fan
SCR1 CATHODE 217 220
220A
SCR4 CATHODE 216 R4
SCR1,SCR4 ANODE 220
12/100 EACH
G1 1
R5
217
BACKGROUND RESISTORS
218
218A
216A
IN-LINE CONNECTOR J7
245
Inside sleeving at top left side of
244
Main Rectifier
240
DC
SHUNT (+)
W 221
TWISTED PAIRS
SHUNT (-)
R 222
CURRENT FEEDBACK
On top of Main
Transformer
DETERMINE IF HI-FREQ IS Lower left side of
CONTINUOUS OR START Polarity Switch
ONLY, MIN. CURRENT, AND
BALANCE CONTROL
311
MICRO SWITCH INPUT
312
314
THERMOSTAT INPUT
313 MICRO SWITCH CLOSED IN DC
DISABLE OUTPUT & HI-FREQ
IF THERMOSTAT OPEN
CHOKE TSTAT
(NORMALLY CLOSED
OPEN AT 135C TYP.)
In Front of main Inside hi-freq box on
transformer, right side of machine
Attached to Base near front
Left side of Machine
near front
HIGH VOLTAGE ARC STARTER ASSEMBLY
TRANSFORMER
T2
200/100
238
HI-FREQ (115VAC)
236 R3 L2
GAS (115VAC) 237
235
236B
115VAC IN
232 S 12.5 OHM TYP.
C4
FAN (115VAC) 15/250
260 5.5 OHMS
SPARK
14.5 KOHMS
TYP.
TYP. GAP .020
12.5 OHM TYP.
115V
5000V
L3
F
HI-FREQ CIRCUIT
239
GAS
Rear Panel
SOLENOID
Right Side
(115VAC)
235 SV1 231
209 232
X5
18VAC
210 X6 435 OHMS TYP.
T1
115VAC
12 OHMS TYP.
X3
201
18VAC FAN
TRIGGER CIRCUIT
X4
204 260
Between SCR Bridge halves
Right front side of
Main Transformer
COMPONENT LOCATION DESCRIPTIONS ARE AS VIEWED
FROM FRONT OF MACHINE UNLESS STATED
OTHERWISE
Top rear
216A Center of machine
SEE CONNECTION DETAIL
G4
MAIN
15 - 20 OHM
G3
SCR4 SCR3 TRANSFORMER
GATE-CATHODE
T1
G2 RESISTANCE TYP.
MAIN SCR + H3
- HIGH
RECTIFIER
D1
FREE WHEELING DIODE
SCR1
H2 LOW
SCR2 X2
G1
80 VAC
H1
X1
R 222(-) SHUNT
Right Side of SCR Bridge
W 221(+)
400A/200mV
Rectifier. Top of Machine
RECONNECT IS DONE AT
behind Choke.
AC
POWER SWITCH
Right side of Machine
OUTPUT
above Choke Coil.
L1
VOLTAGE RECONNECTION
INDUCTOR
Gang D
SEE RATING PLATE FOR SPECIFIC VOLTAGES
Gang C
Gang B
Gang G
230 or 400-415 or 575 VOLT CONNECTION
240
DC + +
DC
(AS SHOWN & AS SHIPPED FROM FACTORY)
AC AC
DC - DC -
Gang A
CBW
CBW CBW
CBW = CONNECTED
BY SWITC H
Gang H THESE CONNECTIONS
AC
ARE MASE BY POLARITY
AC
- + - + SWITCH, THEY ARE NOT
DC DC DC 208 or 380 or 460 VOLT CONNECTION
DC
PHYSICAL LEADS
CBW CBW
311
CLOSED Gang E Gang F
S2
IN DC N.C.
POLARITY SWITCH
C1 AND C2 MUST ALWAYS BE CONNECTED
Front Panel Center
312
SEE CONNECTION DETAIL
ACROSS TRANSFORMER PRIMARIES
OPEN IN AC 285
284
Inside hi-freq box on
right side of machine
near front
BYPASS/STABILIZER
PCB
(SCHEMATIC S22530)
(PCB AS'BLY L10121-1)
284A
285A
100/100
R2
284B
HOLDING RESISTORS
SCR
285B
HEATSINK
R1
100/100
Right side of machine,
FARTHEST LEFT
HI-FREQ OFF IN STICK front of gas solenoid,
SCR (VIEWED
START ONLY IN DC TIG
attached to Base
CONTINUOUS IN AC TIG FROM FRONT)
Mounted to front side
C3
of hi-freq box on
right side of machine
near front.
.0015/12KV
HIGH FREQ.
T3
TRANSFORMER
240
Center front
WORK
ELECTRODE
Right front
232
T1
X7
FAN RUNS FOR 5 S AT POWER-UP
115VAC
STOPS AT IDLE 8 MINUTES
X8
AFTER WELDING.
SCR BRIDGE AND POLARITY SWITCH CONNECTION DETAIL
TYP. RPM:
1600 RPM 60Hz
Right rear side of Main
1340 RPM 50Hz Transformer
behind choke.
PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
DESIGN INFORMATION REFERENCE:
THE INFORMATION ON THIS EQUIPMENT TYPE:
PRINT IS FOR REFERENCE
DRAWN BY: Jbarto Reference
ONLY. COMPONENTS AND SUBJECT: MACHINE SCHEMATIC
ENGINEER: TNguyen SCALE:
CIRCUITRY MAY BE DIFFERENT
MATERIAL APPROVAL
FROM AN ACTUAL MACHINE. NONE UF
APPROVED: Approve 02/20/2004
DISPOSITION: DATE:
G-3
Attached to Power Switch
BYPASS ASSEMBLY
C1
.0047/
250VAC
POWER SWITCH
C2
L1
W
S1
B L2
G
Front Panel Left side
H1 and H3 (HIGH) TO POWER SWITCH.
H2 NOT CONNECTED; INSULATE.
H1 and H2 (LOW) TO POWER SWITCH.
H3 NOT CONNECTED; INSULATE.
TO0 COPPER BAR
W 222
R 222 R 222
ALUMINUM BAR
FARTHEST RIGHT SCR
(VIEWED FROM
BOTTOM
FRONT)
COPPER 7 GA. FLEX LEAD
BAR
6 GA. FLEX LEADS
DC
Gang A
Gang D
OUTPUT INDUCTOR
285
Gang F
Rear gang H
UNUSED TERMINAL
Rear gang G
311
Gang E
MICRO SWITCH
X1
312
Gang C gang B
GANG LOCATIONS ARE
VIEWED FROM REAR OF
SWITCH
MOUNTING HOLE
POLARITY SWITCH MICRO SWITCH
OPEN
AC A-C, D-E, B-F
CLOSED
DC+ B-D, C-E, A-F, G-H
CLOSED
DC- B-D, A-E, C-F, G-H
LEAD COLOR CODE: COMPONENT VALUE UNITS:
B-BLACK OR GRAY CAPACITOR: MFD/VOLTS
G-GREEN
RESISTOR: OHMS/WATTS
O-ORANGE
R-RED OR PINK
CONNECTOR PIN NUMBERS:
U-BLUE
W-WHITE EX. 12 PIN CONNECTOR
Y-YELLOW
1 2
6
LABELS:
COMMON
7 12
FRAME GROUND
LATCH
EARTH GROUND
VIEW OF CONNECTOR ON PC BOARD
Precision Tig 185 1 1
PAGE ___ OF ___
DOCUMENT DOCUMENT
NUMBER: REVISION:
G4588
PROJECT A
CRM36191
NUMBER:
PRECISION TIG 185